2005 Hourly Lead Emission Inventory for the Doe 

Run Company's Herculaneum, Missouri Smelter 

Prepared For : 

The Doe Run Company 

Prepared By: 

Shell Engineering & Associates, Inc. 

2403 West Ash 

Columbia MO, 65203 

February l, 2007 
Table of Contents 

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i 

List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii . . List of Figures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii 1.0 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i 1 .1 Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 1 .2 Facility Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 2.0 Unloading Department . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 3.0 Sinter Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 4.0 Blast Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 5.0 Drossing Plant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 6.0 Refinerv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 7.0 ROD _Rolling Mil1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 8.0 Fugitive Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 8 .1 Storage Piles-Material Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 8 .2 Storage Piles-Wind Erosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 8 .3 Haul Roads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 
List of Tables 

Table 1-1 . Source Summarv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 

Table 8-1. Material /Storage Pile Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 

Table 8-2. Street Sample Summarv . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 

List of Figures 

Figure 1-1. 

Figure 1-2. 

Ficgure 1-3. 

Figure 2-1. 

Figure 2-2. 

Figure 2-3. 

Figure 3-1. 

Figure 3-2. 

Figure 4-1 . 

Figure 5-1 . 

Figure 6-1 . 

Figure 6-2. 

Figure 7-1 . 

Figure 7-2. 

Figure 8-1 . 

Figure 8-2. 

Figure 8-3. 

Fiqure 8-4. 

2005 Annual Emissions by Department . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 

General Facilitv_Location . . . . . . . . . . . . . . . . . . . . . . . . . . : . . . . . . . . . . . . . . . . . . . . . . . . .12 

General__Facilitv Lavout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 

Hourly Traffic Scalars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 

Daily Concentrate Deliverv. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 

Dailv_Unloadinq Department Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 

Dailv Sinter Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 

Daily Sinter Plant Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 

Dailv Blast Furnace Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 

Dailv Dross Plant Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 

Daily Refined Lead Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 

Daily Refinery Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 

Daily Lead Strip Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 

Daily Strip Rollinq Mill Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 

Haul Roads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79 

Haul Roads (Continuedj . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 

Haul Roads (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . ., . . . . . . . . . . . . . . . . . . . . . . . . . .81 

Dailv_Fuqitive Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 
1.0 Introduction 

Z,1 Project Description _ 

The Doe Run Company operates a primary lead smelter in Herculaneum, 

Missouri, located approximately 25 . miles south of St. Louis, Missouri, adjacent to 

the Mississippi River. The city of Herculaneum was designated as nonattainment for lead in 1991 . The Missouri Department of Natural Resources 

submitted a revised SIP in 1994, which failed to meet the quarterly lead National 

Ambient Air Quality Standard (NAAQS) . An additional SIP revision was submitted 

in 2001, which established an attainment date of August 14, 2002. Following the 

August 2002 attainment date, lead monitoring in Herculaneum indicated that the 

lead NAAQS was met for ten consecutive quarters. However, measured lead 

concentrations at the Broad Street monitor site exceeded the lead standard for 

the first three quarters of 2005 . Violations have also occurred in the 1St and 3rd 

quarters during 2006. Based on these violations of the lead NAAQS, ~the Missouri 

lead SIP must be revised so the Herculaneum area will be in attainment of the 

lead standard . 

An integral part of developing the revision to the lead SIP is the development of 

the hourly lead emission inventory that will be used as input into the atmospheric 

dispersion model . The purpose of this report is to discuss in detail the 

methodology that has been used in the development of the emission inventory. 

In accordance with the recommendations of the Missouri Department of Natural 

Resources (MDNR) and Region 7 EPA, the year of 2005 was used as the study 

period for the analysis. 

The remainder of the report has broken out into seven sections, one for each 

department at the facility : 

Section 2 - Unloading Department 

Section 3 - Sinter Plant 
Section 4 - Blast Furnace (Includes the Main Stack) 

Section 5 - Drossing Plant 

Section 6 - Refinery 

Section 7 - Strip Rolling Mill 

Section 8 - Fugitive Emissions (Storage Piles and Haul Roads) 

The emission points at the smelter and changes since the 2000 SIP study have 

been summarized in Table 1-1 . The annual lead emissions for each department 

have been summarized in Figure 1-1 . 

Z,2 Facility Description 

As previously mentioned, the smelter is located in Herculaneum, Missouri . A 

map showing the general location of the facility has been provided as Figure 1-2 

and the general facility layout has been depicted in Figure 1-3. 

Lead concentrate, which contains approximately 75% lead by weight, is delivered 

to the facility by truck. The trucks currently come down main street and enter 

on the south end of the plant north of the strip rolling mill . The trucks dump the 

concentrate into a hopper and the material is then conveyed to a storage pile . 

The concentrate is then picked up using a front end loader and dumped into a 

railcar . The railcar transports the concentrate to the rotary dumper where it is 

unloaded and transferred to the mixing bins. The concentrate, secondary feed 

constituents, and return sinter are then crushed and mixed before being sent to 

the sinter machine. The material coming off of the sinter machine is screened . 

The overs (sinter) are crushed using a smooth roll crusher (in the sinter plant) 

and are then ready to be fed to the blast furnace. The fines (material that needs 

additional contact time on the sinter machine) are cooled and crushed before 

returning to the sinter machine for additional processing. The fines drop from 

the screen to a conveyor that feeds the sinter cooler. The cooled sinter then 

drops onto the CV-30 belt that fills the 130 ton return fines bin. The CV-37A belt 
transports the fines from the bin to the smooth roll crusher which feeds the CV37B belt. Material on the CV-37B belt puts the material back to the sinter 

machine feed line . 

The sintered material, which contains approximately 50% lead, is mixed with 

coke and fed to the blast furnace. Molten lead exits the bottom of the blast 

furnace and is transferred to the drossing plant in pots using overhead cranes. 

Slag is also tapped off of the blast furnace. The slag is granulated and then is 

either used as a feedstock to the sinter machine or is hauled to storage. 

In the drossing department, the molten lead is cooled and impurities are 

skimmed from the surface . The lead is approximately 97% pure when it exits 

the drossing plant for the refinery. In the refinery, the remaining trace amounts 

of impurities are removed producing a refined lead that is greater than 99.999% 

pure. The lead is then sent to either the casting machine or the strip rolling mill 

to put it into its final form . 
Table 1-1. Source Summary 

Change from 2005 Annual 

Source ID Source 

Description 

Department the 2000 SIP Pb Emissions 

Study (Ib/yr) 

When the 2000 

SIP study was 

developed 

concentrate was 

Dump- Unloading delivered by rail . 

10001A1 Concentrate- Department Concentrate is 370 

Hopper now delivered to 

the facility by 

truck and 

unloaded at the 

hopper. 

_ , When the 2000 

SIP study was 

developed 

concentrate was 

Dump- Unloading delivered by rail . 

10001A2 Concentrate- Department Concentrate is 370 

Storage now delivered to 

the facility by 

truck and 

unloaded at the 

hopper. 

Load-Conc .- Unloading j 10001B1 Railcar (Front Department No Change 382 

End Loader 

Concentrate is 

Dump-Conc. And now loaded with 

10001132 Sec.-Unloader . Unloading secondaries on the south end 459 (80% Conc, 20% Department and mix is Sec) dumped at the 

unloader. 

Fume is now 

dumped with 

concentrate at 

10001C Dump-Fume- Unloading the unloader. --- 

Unloader Department Source Removed . 

Emissions 

accounted for in 

10001132 . 

Load-Sinter20001A,13 Railcar/Dump- Sinter Plant No Change 0.219 

Sinter-Unloader 

Load-Sinter20002,3 Truck/Dump- Sinter Plant No Change 0.18 

Sinter-Storage 
Source ID Source 

Description Department 

Change from 

the 2000 SIP 

Study 

2005 Annual 

Pb Emissions 

(Ib/yr) 

When the 2000 

SIP study was 

developed dry 

fume was loaded 

to railcar and 

then transferred 

to the unloader 

and dumped. 

Load-Fume- Fume is now 

20004 Railcar Sinter Plant loaded to railcar 3 

wet (>8% 

moisture, 30% 

typical) and 

stored on the 

south end. It is 

then loaded with 

concentrate and 

dumped at the 

unloader 

When the 2000 

SIP study was 

developed dry 

fume was loaded 

. to railcar and 

then transferred 

to the unloader 

and dumped . 

Railcar Fume Fume is now 

20004B Unloading (At Sinter Plant loaded to railcar 3 

Storage) wet (>8% 

moisture, 30% 

typical) and 

stored on the 

south end . It is 

then loaded with 

concentrate and 

dumped at the 

unloader 
Change from 2005 Annual 

Source ID Source 

Description Department the 2000 SIP Pb Emissions 

Study (Ib/yr) 

When the 2000 

SIP study was 

developed dry 

fume was loaded 

to railcar and 

then transferred 

to the unloader 

and dumped. 

Railcar Fume Fume is now 

20004C (South, Front Sinter Plant loaded to railcar 2 

End Loader) ' wet (>8% 

moisture, 30% 

typical) and 

stored on the 

south end. It is 

then loaded with 

concentrate and 

dumped at the 

unloader 

The 2000 SIP 

study included 

Sinter Plant Mix sinter handling in 

20005A-F Room Fugitives- Sinter Plant the mix room . 461 Concentrate and Sinter is not 

Fume Handling handled in the 

mix room and 

was removed . 

As part of the 

model 

reconciliation 

work and 

comparison to 

, 

" 

the CMB data 

and meassured 

20006 Sinter Plant Sinter Plant lead values, the 1408 Building Fugitives sinter plant 

fugitives were 

scaled up by a 

factor of 4 from 

the emissions 

used in the 2000 

SIP study. 

20007 Baghouse No. 3 Sinter Plant No Change 14 Fugitives 

Revised emission 

30001 Main Stack Blast Furnace factor from 

12/9/2004 Stack 50007 

Test 
Source Change from 2005 Annual 

Source ID Description Department the 2000 SIP Pb Emissions 

Study (Ib/yr) 

As part of the 

2000 SIP control 

strategy the blast 

furnace building 

30002 Blast Furnace Blast Furnace openings were 1744 I Fugitves enclosed (30002) 

and the charge 

belt roof vent 

was enclosed 

- (30003-5) . 

30011-13 Baghouse No. 5 Blast Furnace No Change 22 Vents 

40004,5 Dross Kettle Heat 

Stacks Dross Plant No Change 83 

As part of the 

2000 SIP control 

strategy the 

dross aerovents 

were removed 

40006 Dross Plant Dross Plant (40001-3). A 1047 Fugitives baghouse was 

added to 

ventilate the 

dross plant 

(40007, 

Ba house No. 7) . 

This is a new 

baghouse added 

40007 Baghouse No. 7 Dross Plant as part of the 4032 

2000 SIP control 

strategy. 

As part of the 

2000 SIP control 

strategy the 

refinery roof 

monitors (50001- 

` 2) and aerovents 

Refinery Plant (50004-5) were 

50006 Fugitives Refinery removed . Two 1055 

baghouses were 

added to 

ventilate the 

refinery (50007, 

Baghouse 8 and 

50008, Baghouse 

9 . 
Change from 2005 Annual 

Source ID Source 

Description Department the 2000 SIP Pb Emissions 

Study (Ib/yr) 

This is a new 

baghouse added 

50007 Baghouse No. 8 Refinery as part of the 1964 

2000 SIP control 

strategy. 

This is a new 

baghouse added 

50008 Baghouse No. 9 Refinery as part of the 13301 

2000 SIP control 

strategy. 

50011-18 Kettle Setting 

Heat Stacks Refinery No Change 880 

60001 2 Strip Mill Heat , Strip Mill No Change 1 Stacks 

60003 Strip Mill 

Ba house Strip Mill No Change 

0.04 

60004 Low Alpha 

Baghouse Strip Mill No Change 5 

60005-8 Strip Mill Roof Strip Mill No Change 24 Vents 

70001 Fugitive Dross 

Handling Fugitives No Change 11 

70007 Fugitive Slag Fugitives No Change 

0.15 Handling 

Fugitive 

70009 Secondaries Fugitives No Change 1 

Handling 

Dross Storage 

70002 Fugitive Wind Fugitives No Change 0 

Erosion 

Conc. Storage 

70004 Fugitive Wind Fugitives No Change 0 

Erosion 

Sinter Storage 

70006 Fugitive Wind Fugitives No Change 0 

Erosion 

Slag Storage 

70008A,B Fugitive Wind Fugitives No Change 80 

Erosion 

Sec Storage 

70010 Fugitive Wind Fugitives No Change 0 

Erosion 
Source Change from 2005 Annual 

Source ID Description Department the 2000 SIP Pb Emissions 

Study (Ib/yr) 

New Source. In 

Hwy 55 to plant and outside 

70100-122 Joachim Bridge Fugitives plant haul road 97 

Exit (Segment A- emissions 

B) completely 

updated. 

New Source. In 

Joachim Bridge plant and outside 

70150-213 Exit to Plant Fugitives plant haul road 955 Entrance emissions 

(Segment B-C) completely 

updated . 

New Source. In 

Plant Entrance to plant and outside 

70250-252 NW Corner of Fugitives plant haul road 63 Strip Mill Building emissions 

(Segment C-D) completely 

updated. 

NW Corner of New Source. In 

Strip Mill Building plant and outside 

70300 to.Concentrate Fugitives plant haul road 11 

Hopper emissions 

(Segment D-E) completely 

updated. 

Concetrate New Source. In 

Hopper to SW plant and outside 

70350-358 Corner of Strip Fugitives plant haul road 14 

Mill Building emissions 

(Segment E-F) completely 

updated. 

NW Corner of New Source. In 

Strip Mill Building plant and outside 

70400-406 to SW Corner of Fugitives plant haul road 39 

Strip Mill Building emissions 

(Segment D-F) completely 

updated. 

SW Corner of New Source. In 

Strip Mill Building plant and outside 

70450-454 to North End of Fugitives plant haul road 24 

Slag Haul Road ` J emissions 

(Segment F-G) completely 

updated. 
Change from 2005 Annual 

Source ID Source 

Description Department the 2000 SIP Pb Emissions 

Study (Ib/yr) 

, New Source. In 

North End of plant and outside 

70500-513 Slag Haul Road Fugitives plant haul road 157 

to Refinery Dock emissions 

(Segment G-H) completely 

updated. 

New Source . In 

South Slag Haul plant and outside 

70550-553 Road (Paved) Fugitives plant haul road 21 

(Segment G-K) emissions 

completely 

updated . 

North End of New Source. In 

plant and outside Main Building to plant haul road 70600-612 Refinery Dock Fugitives emissions 2801 

(Unpaved) completely (Segment H-L) updated. 

New Source. In 

Sinter Plant to 

plant and outside 

70650-669 Sinter Storage Fugitives plant haul road 17 

(Segment I-J) 

, 

emissions 

completely 

updated. 

New Source. In 

South Slag Haul plant and outside 

70700-703 Road (Unpaved) Fugitives plant haul road 29$ 

(Segment K-M) emissions 

completely 

updated. 

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2.0 Unloading Department 

10001A1 

Dump-Concentrate-Hopper 

Emission Factor 

Pb Emission Factor = 1 .63E-03 Ib-Pb/Tons-Concentrate-Handled 

Test at the trestle operation (73.75 g-Pb/100ton-Concentrate-Dumped) 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 1, Source 10001 . 

When the 2000 SIP was developed concentrate was delivered by rail . 

Production Data ° 

2005 Average Daily Production Rate = 621 Tons-Concentrate-Handled/day 

Given 

Daily Lead Emissions 

The average daily Pb emissions were then calculated for each production day 

(6am to 6am of the following day). A sample calculation using the average daily 

production rate has been provided below : 

2005 Average Daily Pb Emissions = 

621 (Tons-Concentrate-Handled/day) * 1 .63E-03 (Ib-Pb/Tons-ConcentrateHandled) * 1 Sources = 

1 .0129 Ib-Pb/day 

Annual Lead Emissions 

The annual lead emissions can be calculated from the average daily lead 

emissions : 

2005 Annual Pb Emissions = 

1 .0129 (Ib-Pb/day) * 365 (day/yr) _ 

370 Ib-Pb/yr 

Hourly Lead Emissions 

Daily emissions apportioned to each hour using the traffic scalars. Refer to TRC 

Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", March 

2000, Section 7 . Refer to Figure 2-1 . 
10001A2 

Dump-Concentrate-Storage 

Emission Factor 

Pb Emission Factor = 1 .63E-03 Ib-Pb/Tons-Concentrate-Handled 

Test at the trestle operation (73.75 g-Pb/100ton-Concentrate-Dumped) 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 1, Source 10001 . 

When the 2000 SIP was developed concentrate was delivered by rail . 

Production Data 

2005 Average Daily Production Rate = 621 Tons-Concentrate-Handled/day 

Given 

Daily Lead Emissions 

The average daily Pb emissions were then calculated for each production day 

(6am to 6am of the following day). A sample calculation using the average daily 

production rate has been provided below : 

2005 Average Daily Pb Emissions = 

621 (Tons-Concentrate-Handled/day) * 1 .63E-03 (Ib-Pb/Tons-ConcentrateHandled) * 1 Sources = 

1 .0129 Ib-Pb/day 

Annual Lead Emissions 

The annual lead emissions can be calculated from the average daily lead 

emissions : 

2005 Annual Pb Emissions = 

1 .0129 (Ib-Pb/day) * 365 (day/yr) _ 

370 Ib-Pb/yr 

Hourly Lead Emissions 

Daily emissions apportioned to each hour using the traffic scalars . Refer to TRC 

Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", March 

2000, Section 7 . Refer to Figure 2-1 . 
10001131 

Load-Conc .-Railcar (Front End Loader) 

Emission Factor 

Pb Emission Factor = 1 .63E-03 Ib-Pb/Tons-Concentrate-Handled 

Test at the trestle operation (73 .75 g-Pb/100ton-Concentrate-Dumped) 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 1, Source 10001. 

Production Data 

2005 Average Daily Production Rate = 642 Tons-Concentrate-Handled/day 

Given 

Daily Lead Emissions 

The average daily Pb emissions were then calculated for each production day 

(6am to 6am of the following day). A sample calculation using the average daily 

production rate has been provided below : 

2005 Average Daily Pb Emissions = 

642 (Tons-Concentrate-Handled/day) * 1 .63E-03 (Ib-Pb/Tons-ConcentrateHandled) * 1 Sources = 

1 .0471 Ib-Pb/day 

Annual Lead Emissions 

The annual lead emissions can be calculated from the average daily lead 

emissions : 

2005 Annual Pb Emissions = 

1 .0471 (Ib-Pb/day) * 365 (day/yr) _ 

382 Ib-Pb/yr 

Hourly Lead Emissions 

Daily Emissions prorated over the 6 hours between 6a and 12a . 
10001B2 

Dump-Conc. And Sec.-Unloader (80% Conc, 20% Sec) 

Emission Factor 

Pb Emission Factor = 1.63E-03 Ib-Pb/Tons-Concentrate-Handled 

Test at the trestle operation (73 .75 g-Pb/100ton-Concentrate-Dumped) 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 1, Source 10001. 

Secondaries and fume are now mixed w/ the concentrate on the south end 

(80/20 split) before being dumped at the unloader. 

Production Data 

2005 Average Daily Production Rate = 771 Tons-Concentrate-Handled/day 

(Conc. Feed to Sinter Plant) * 1 .2 ` ` 

80 tons of concentrate is loaded into each railcar . The railcars are then topped 

off (additional 20 tons) with secondaries (ie cleanup). 

Daily Lead Emissions 

The average daily Pb emissions were then calculated for each production day 

(6am to 6am of the following day). A sample calculation using the average daily 

production rate has been provided below: 

2005 Average Daily Pb Emissions = 

771 (Tons-Concentrate-Handled/day) * 1 .63E-03 (Ib-Pb/Tons-ConcentrateHandled) * 1 Sources = 

1 .2565 Ib-Pb/day 

Annual Lead Emissions 

The annual lead emissions can be calculated from the average daily lead 

emissions : 

2005 Annual Pb Emissions = 

1 .2565 (Ib-Pb/day) * 365 (day/yr) _ 

459 Ib-Pb/yr 

Hourly Lead Emissions 

Daily Emissions prorated over the 6 hours between 6a and 12a. 
c~r 

rLa 

N 

0 

.-i 

N 

u 

N 

O 0 

O 

00 
a 

0 
C 

O 17 

W 

C 

a 

_ 10 

ra 0 

M 

1 

N 

~ _1 

0 

n 

N ri 

O 

N 

O 

O 

W 

ON 

O 

O 

N N 

R 

0 

0 

M 

0 

0 

N 

N 

0 

o ,.~_, 
3.0 Sinter Plant 

20001A,B 

Load-Sinter-Railcar/Dump-Sinter-Unloader 

Emission Factor 

Pb Emission Factor = 1 .15E-05 Ib-Pb/Tons-Sinter-Handied 

Test at the trestle operation 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 2, Source 20001 . 

Production Data 

2005 Average Daily Production Rate = 26 Tons-Sinter-Handled/day 

Given 

Daily Lead Emissions 

The average daily Pb emissions were then calculated for each production day 

(6am to 6am of the following day). A sample calculation using the average daily 

production rate has been provided below : 

2005 Average Daily Pb Emissions = 

26 (Tons-Sinter-Handled/day) * 1 .15E-05 (Ib-Pb/Tons-Sinter-Handled) * 2 

Sources = 

0.0006 Ib-Pb/day 

Annual Lead Emissions 

The annual lead emissions can be calculated from the average daily lead 

emissions : 

2005 Annual Pb Emissions = 

0.0006 (Ib-Pb/day) * 365 (day/yr) _ 

0.219 Ib-Pb/yr 

Hourly Lead Emissions 

Daily Emissions prorated over the 6 hours between 6a and 12a . 
20002,3 

Load-Sinter-Truck/Dump-Sinter-Storage 

Emission Factor 

Pb Emission Factor = 1 .15E-05 Ib-Pb/Tons-Sinter-Handled 

Test at the trestle operation 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 2, Source 20002 and 20003 . 

Production Data 

2005 Average Daily Production Rate = 23 Tons-Sinter-Handled/day 

(Sinter Produced) * 0 .02 

2005 Blast Furnace-Sinter Feed-From Storage = 9613 tpy. 2005 Sinter Produced 

= 415212 tpy. 9613/415212 = 0.02 . 

Daily Lead Emissions 

The average daily Pb emissions were then calculated for each production day 

(6am to 6am of the following day). A sample calculation using the average daily 

production rate has been provided below: 

2005 Average Daily Pb Emissions = 

23 (Tons-Sinter-Handied/day) * 1 .15E-05 (Ib-Pb/Tons-Sinter-Handied) * 2 

Sources = 

0 .0005 Ib-Pb/day 

Annual Lead Emissions 

The annual lead emissions can be calculated from the average daily lead 

emissions : 

2005 Annual Pb Emissions = 

0.0005 (Ib-Pb/day) * 365 (day/yr) _ 

0.18 Ib-Pb/yr 

Hourly Lead Emissions _ , 

Daily emissions prorated over the day (typically operates 24 hr/dy). The 

production data utilized in the anlaysis is referenced to the "production day" 6a 

of day i to 6a of day (i+1) . 
20004 

Load-Fume-Railcar 

Emission Factor 

Pb Emission Factor = 7.06E-03 Ib-Pb/Tons-Fume-Handled 

Test at the trestle operation (3202.22 g-Pb/100ton-Fume-Dumped) . This testing 

was done when the fume was dumped dry. The fume is now sent to storage at 

approximately 30% moisture. The emissions were estimated at 1/10 of the 

tested level . 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 2, Source 20004. 

Production Data 

2005 Average Daily Production Rate = 1 Tons-Fume-Handled/day 

(Sinter Produced) * 0 .001 . 

Fume Unloaded (10/1/98-4/30/99) = 350 tons . Sinter Produced (10/1/98-

4/30/99) = 406023 tons. 350/460023=0 .001 . 

Daily Lead Emissions 

The average daily Pb emissions were then calculated for each production day 

(6am to 6am of the following day). A sample calculation using the average daily 

production rate has been provided below: 

2005 Average Daily Pb Emissions = 

1 (Tons-Fume-Handled/day) * 7.06E-Q3-~Ib-Pb/Tons-Fume-Handled) * 1 Sources 

0.0069 Ib-Pb/day 

Annual Lead Emissions 

The annual lead emissions can be calculated from the average daily lead 

emissions : 

2005 Annual Pb Emissions = 

0.0069 (Ib-Pb/day) * 365 (day/yr) _ 

3 Ib-Pb/yr 

Hourly Lead Emissions 

Daily Emissions prorated over the 6 hours between 6a and 12a. 
20004B 

Railcar Fume Unloading (At Storage) 

Emission Factor 

Pb Emission Factor = 7.06E-03 Ib-Pb/Tons-Fume-Handled 

Test at the trestle operation (3202.22 g-Pb/100ton-Fume-Dumped) . This testing 

was done when the fume was dumped dry. The fume is now sent to storage at 

approximately 30% moisture. The emissions were estimated at 1/10 of the 

tested level . 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 2, Source 20004. 

When the 2000 SIP was developed fume was stored in railcars and then dumped 

by itself at the unloader. Fume is now taken by rail to the south end and put to 

storage (wet, >8% moisture) . The fume is then added to the concentrate cars 

and dumped. 

Production Data 

2005 Average Daily Production Rate = 1 Tons-Fume-Handled/day 

(Sinter Produced) * 0.001 

Fume Unloaded (10/1/98-4/30/99) = 350 tons . Sinter Produced (10/1/98-

4/30/99) = 406023 tons. 350/460023=0.001 . 

Daily Lead Emissions 

The average daily Pb emissions were then calculated for each production day 

(6am to 6am of the following day) . A sample calculation using the average daily 

production rate has been provided below: 

2005 Average Daily Pb Emissions = 

1 (Tons-Fume-Handled/day) * 7 .06E-03 (Ib-Pb/Tons-Fume-Handled) * 1 Sources 

0.0069 Ib-Pb/day 

Annual Lead Emissions 

The annual lead emissions can be calculated from the average daily lead 

emissions : 

2005 Annual Pb Emissions = 

0.0069 (Ib-Pb/day) * 365 (day/yr) _ 

3 Ib-Pb/yr 

Hourly Lead Emissions 

Daily Emissions prorated over the 6 hours between 6a and 12a. 

24 
20004C 

Railcar Fume (South, Front End Loader) 

Emission Factor 

Pb Emission Factor = 7.06E-03 Ib-Pb/Tons-Fume-Handled 

Test at the trestle operation (3202.22 g-Pb/100ton-Fume-Dumped) . This testing 

was done when the fume was dumped dry. The fume is now sent to storage at 

approximately 30% moisture. The emissions were estimated at 1/10 of the 

tested level . 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 2, Source 20004. 

When the 2000 SIP was developed fume was stored in railcars and then dumped 

by itself at the unloader. Fume is now taken by rail to the south end and put to 

storage (wet, >8% moisture) . The fume is then added to the concentrate cars 

and dumped. 

Production Data 

2005 Average Daily Production Rate = 1 Tons-Fume-Handled/day 

(Conc. Used) * 0 .0151 

Fume Produced (2005) = 356 tons. Conc. Used (2005) = 235148 tons . 

356/235148 = 0.00151 . 

Daily Lead Emissions 

The average daily Pb emissions were then calculated for each production day 

(6am to 6am of the following day) . A sample calculation using the average daily 

production rate has been provided below : 

2005 Average Daily Pb Emissions = 

1 (Tons-Fume-Handied/day) * 7 .06E-03 (Ib-Pb/Tons-Fume-Handied) * 1 Sources 

0.0068 Ib-Pb/day 

Annual Lead Emissions 

The annual lead emissions can be calculated from the average daily lead 

emissions : 

2005 Annual Pb Emissions = 

0.0068 (Ib-Pb/day) * 365 (day/yr) _ 

2 Ib-Pb/yr 

Hourly Lead Emissions 

Daily Emissions prorated over the 6 hours between 6a and 12a. 

25 
20005A-F 

Sinter Plant Mix Room Fugitives-Concentrate Handling 

Emission Factor 

Pb Emission Factor = 1 .63E-03 Ib-Pb/Tons-Concentrate-Handled 

Test at the trestle operation (73 .75 g-Pb/100ton-Concentrate-Dumped) 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 2, Source 20005. , , 

Production Data 

2005 Average Daily Production Rate = 775 Tons-Concentrate-Handled/day 

Given 

Daily Lead Emissions 

The average daily Pb emissions were then calculated for each production day 

(6am to 6am of the following day) . A sample calculation using the average daily 

production rate has been provided below: 

2005 Average Daily Pb Emissions = 

771 (Tons-Concentrate-Handled/day) * 1 .63E-03 (Ib-Pb/Tons-ConcentrateHandled) * 1 Sources = 

1 .2567 Ib-Pb/day 

Annual Lead Emissions 

The annual lead emissions can be calculated from the average daily lead 

emissions : 

2005 Annual Pb Emissions = 

1 .2567 (Ib-Pb/day) * 365 (day/yr) _ 

458 .7 Ib-Pb/yr 

Hourly Lead Emissions 

Daily Emissions prorated over the 6 hours between 6a and 12a . 
20005A-F 

Sinter Plant Mix Room Fugitives-Fume Handling 

Emission Factor 

Pb Emission Factor = 7.06E-03 Ib-Pb/Tons-Fume-Handled 

Test at the trestle operation (3202.22 g-Pb/100ton-Fume-Dumped) . This testing 

was done when the fume was dumped dry. The fume is now sent to storage at 

approximately 30% moisture. The emissions were estimated at 1/10 of the 

tested level . 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 2, Source 20005. 

Production Data 

2005 Average Daily Production Rate = 1 Tons-Fume-Handled/day 

(Sinter Produced) * 0 .001 

Fume Unloaded (10/1/98-4/30/99) = 350 tons. Sinter Produced (10/1/98-

4/30/99) = 406023 tons. 350/460023=0 .001 . 

Daily Lead Emissions 

The average daily Pb emissions were then calculated for each production day 

(6am to 6am of the following day). A sample calculation using the average daily 

production rate has been provided below : 

2005 Average Daily Pb Emissions = 

1 (Tons-Fume-Handled/day) * 7.06E-03 (Ib-Pb/Tons-Fume-Handled) * 1 Sources 

= 0.0071 Ib-Pb/day 

Annual Lead Emissions 

The annual lead emissions can be calculated from the average daily lead 

emissions : 

2005 Annual Pb Emissions = 

0.0071 (Ib-Pb/day) * 365 (day/yr) _ 

2 .6 Ib-Pb/yr 

Hourly Lead Emissions 

Daily Emissions prorated over the 6 hours between 6a and 12p . 
20006 

Sinter Plant Building Fugitives 

Emission Factor 

Pb Emission Factor = 3 .40E-03 Ib-Pb/Tons-Sinter-Produced 

Personnel Sampling (2000 SIP value times 4 per model reconcilliation work) (0 .00085*4=0.0034 Ib/ton) 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 2, Source 20006 . 

Production Data 

2005 Average Daily Production Rate = 1135 Tons-Sinter-Produced/day 

Given 

Daily Lead Emissions 

The average daily Pb emissions were then calculated for each production day (6am to 6am of the following day). A sample calculation using the average daily 

production rate has been provided below : 

2005 Average Daily Pb Emissions = 

1135 (Tons-Sinter-Produced/day) * 3 .4aE-03 (Ib-Pb/Tons-Sinter-Produced) * 1 

Sources = 

3 .8578 Ib-Pb/day 

Annual Lead Emissions 

The annual lead emissions can be calculated from the average daily lead 

emissions : 

2005 Annual Pb Emissions = 

3 .8578 (Ib-Pb/day) * 365 (day/yr) _ 

1408 Ib-Pb/yr 

Hourly Lead Emissions 

Daily emissions prorated over the day (typically operates 24 hr/dy). The 

production data utilized in the anlaysis is referenced to the "production day" 6a 

of day i to 6a of day (i+1). 
20007 

Baghouse No. 3 Fugitives 

Emission Factor 

Pb Emission Factor = 3 .28E-05 Ib-Pb/Tons-Sinter-Produced 

In-house testing for the No. 5 Baghouse Vents (1981) 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 2, Source 20007. 

Production Data 

2005 Average Daily Production Rate = 1135 Tons-Sinter-Produced/day 

Given 

Daily Lead Emissions 

The average daily Pb emissions were then calculated for each production day 

(6am to 6am of the following day) . A sample calculation using the average daily 

production rate has been provided below: 

2005 Average Daily Pb Emissions = 

1135 (Tons-Sinter-Produced/day) * 3 .28E-05 (Ib-Pb/Tons-Sinter-Produced) * 1 

Sources = 

0.0372 Ib-Pb/day 

Annual Lead Emissions 

The annual lead emissions can be calculated from the average daily lead 

emissions : 

2005 Annual Pb Emissions = 

0.0372 (Ib-Pb/day) * 365 (day/yr) _ 

14 Ib-Pb/yr 

Hourly Lead Emissions 

Daily emissions prorated over the day (typically operates 24 hr/dy) . The 

production data utilized in the anlaysis is referenced to the "production day" 6a 

of day i to 6a of day (i+l) . 
_ 

L 

a 

L 

_ 

R 

0 

L t~n 

_ 

O 

0 

N 

0 

N 

O 

n 

N 

O 

O 

n 

O 

H 

O 

O 

M 

O 

O 

r-i 

O 

O\1 

N 

d-0 

M 

0 ~ N 

Ln 

l0 
0 

N 

H 

O 

N 

O 

M 

C 

O . 

. 

W 

C 

fp 

L 

0 

N 

i 

M 

L 

O1 (AP/4D suo!ss!w3 qd Al!pa 

o 

a 

0 

C ,; 

0 
4.0 Blast Furnace 

30001 

Main Stack 

Emission Factor 

Pb Emission Factor = 5 .70E-02 Ib-Pb/(Tons-Sinter-Produced)+(Tons-Lead 

Bearing Material-Charged to the Blast Furnace) 

12/9/2004 Stack Test 

7.1/124 .58 = 5 .7e-2 Ib/ton 

Production Data 

2005 Average Daily Production Rate = 2-404 (Tons-Si nter-Produced)+(Tons-Lead 

Bearing Material-Charged to the Blast Furnace)/day 

Given 

Daily Lead Emissions 

The average daily Pb emissions were then calculated for each production day 

(6am to 6am of the following day). A sample calculation using the average daily 

production rate has been provided below: 

2005 Average Daily Pb Emissions = 

2404 ((Tons-Sinter-Produced)+(Tons-Lead~ Bearing Material-Charged to the Blast 

Furnace)/day) * 5.70E-02 (Ib-Pb/(Tons-Sinter-Produced)+(Tons-Lead Bearing 

Material-Charged to the Blast Furnace)) * 1 Sources = 

137.0065 Ib-Pb/day 

Annual Lead Emissions 

The annual lead emissions can be calculated from the average daily lead 

emissions : _ 

2005 Annual Pb Emissions = 

137 .0065 (Ib-Pb/day) * 365 (day/yr) _ 

50007 Ib-Pb/yr 

Hourly Lead Emissions 

Daily emissions prorated over the day (typically operates 24 hr/dy). The 

production data utilized in the anlaysis is referenced to the "production day" 6a 

of day i to 6a of day (i+1). 

32 
30002 

Blast Furnace Fugitves 

Emission Factor 

Pb Emission Factor = 4.10E-03 Ib-Pb/Tons-Sinter-Charged to the Blast Furnace 

30002-5 2000 SIP pre-control emission factor (8.2E-02 Ib/ton) with a 95% 

capture efficiency 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 3, Source 30002 . . ~- 

As part of the 2000 SIP control strategy the blast furnace building openings were 

enclosed (30002) and the charge belt roof vent was enclosed (30003-5). 

Production Data 

2005 Average Daily Production Rate = 1166 Tons-Sinter-Charged to the Blast 

Furnace/day 

Given 

Dailv Lead Emissions 

The average daily Pb emissions were then calculated for each production day 

(6am to 6am of the following day) . A sample calculation using the average daily 

production rate has been provided below: 

2005 Average Daily Pb Emissions = 

1166 (Tons-Sinter-Charged to the Blast Furnace/day) * 4.10E-03 (Ib-Pb/TonsSinter-Charged to the Blast Furnace) * 1 Sources = 

4.77881b-Pb/day 

Annual Lead Emissions 

The annual lead emissions can be calculated from the average daily lead 

emissions : 

2005 Annual Pb Emissions = 

4 .7788 (Ib-Pb/day) * 365 (day/yr) _ 

1744 Ib-Pb/yr 

Hourly Lead Emissions 

Daily emissions prorated over the day (typically operates 24 hr/dy). The 

production data utilized in the anlaysis is referenced to the "production day" 6a 

of day i to 6a of day (i+i). 
30011-13 

Baghouse No . 5 Vents 

Emission Factor 

Pb Emission Factor = 1 .70E-05 Ib-Pb/Tons-Sinter-Charged to the Blast Furnace 

In-house testing for the No. 5 Baghouse Vents (1981) . 5.ie-5/3=1 .7e-5 . 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 3, Source 30011-13 . 

Production Data 

2005 Average Daily Production Rate = 1166 Tons-Sinter-Charged to the Blast 

Furnace/day 

Given 

Daily Lead Emissions 

The average daily Pb emissions were then calculated for each production day 

(6am to 6am of the following day) . A sample calculation using the average daily 

production rate has been provided below: 

2005 Average Daily Pb Emissions = 

1166 (Tons-Sinter-Charged to the Blast Furnace/day) * 1 .70E-05 (Ib-Pb/TonsSinter-Charged to the Blast Furnace) * 3 Sources = 

0 .0594 Ib-Pb/day 

Annual Lead Emissions 

The annual lead emissions can be calculated from the average daily lead 

emissions : 

2005 Annual Pb Emissions = 

0 .0594 (Ib-Pb/day) * 365 (day/yr) _ 

22 Ib-Pb/yr 

Hourly Lead Emissions 

Daily emissions prorated over the day (typically operates 24 hr/dy) . The 

production data utilized in the anlaysis is referenced to the "production day" 6a 

of day i to 6a of day (i+1) . 
0 

H 

W 

V 

f0 

G 

L 

O 

N 

41 

R 

O 

m 

O 

0 ,-y 

IQ 
5.0 Drossing Plant 

40004,5 

Dross Kettle Heat Stacks 

Emission Factor 

Pb Emission Factor = 5.19E-04 Ib-Pb/Tons-Rough Lead-Produced 

Stack test of No. 4 kettle heat stack (1999) 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 4, Source 40004-5. 

Production Data 

2005 Average Daily Production Rate = 438 Tons-Rough Lead-Produced/day 

(Refined Lead Produced) / 0.97 

Refined Lead Produced (10/1/98-4/30/99) = 151470 tons. Rough Lead 

Produced (10/1/98-4/30/99) = 156450 tons. 151470/156450=0.97. 

Daily Lead Emissions 

The average daily Pb emissions were then calculated for each production day 

(6am to 6am of the following day). A sample calculation using the average daily 

production rate has been provided below: 

2005 Average Daily Pb Emissions = I ° 

438 (Tons-Rough Lead-Produced/day) * 5.19E-04 (Ib-Pb/Tons-Rough LeadProduced) * 1 Sources = 

0.2273 Ib-Pb/day 

Annual Lead Emissions 

The annual lead emissions can be calculated from the average daily lead 

emissions : 

2005 Annual Pb Emissions = 

0.2273 (Ib-Pb/day) * 365 (day/yr) _ 

83 Ib-Pb/yr 

Hourly Lead Emissions 

Daily emissions prorated over the day (typically operates 24 hr/dy). The 

production data utilized in the anlaysis is referenced to the "production day" 6a 

of day i to 6a of day (i+1). 

36 
40006 

Dross Plant Fugitives 

Emission Factor 

Pb Emission Factor = 6.55E-03 Ib-Pb/Tons-Rough Lead-Produced 

40001-3 2000 SIP pre-control emission factor (1 .31E-01 Ib/ton) with a .95% 

capture efficiency 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 4, Source 40001-3 . 

As part of the 2000 SIP control strategy the dross aerovents were removed 

(40001-3) . A baghouse was, added to ventilate the dross plant (40007, 

Baghouse No . 7). 

Production Data 

2005 Average Daily Production Rate = 438 Tons-Rough Lead-Produced/day 

(Refined Lead Produced) / 0.97 

Refined Lead Produced (10/1/98-4/30/9g) = 151470 tons. Rough Lead 

Produced (10/1/98-4/30/99) = 156450 tons. 151470/156450=0.97 . 

Daily Lead Emissions 

The average daily Pb emissions were then calculated for each production day 

(6am to 6am of the following day). A sample calculation using the average daily 

production rate has been provided below : 

2005 Average Daily Pb Emissions = 

438 (Tons-Rough Lead-Produced/day) * 6 .55E-03 (Ib-Pb/Tons-Rough LeadProduced) * 1 Sources = 

2.8692 Ib-Pb/day 

Annual Lead Emissions 

The annual lead emissions can be calculated from the average daily lead 

emissions : 

2005 Annual Pb Emissions = 

2.8692 (Ib-Pb/day) * 365 (day/yr) _ 

1047 Ib-Pb/yr 

Hourly Lead Emissions 

Daily emissions prorated over the day (typically operates 24 hr/dy) . The 

production data utilized in the anlaysis is referenced to the "production day" 6a 

of day i to 6a of day (i+1) . 

37 
40007 

Baghouse No. 7 

Emission Factor - ° 

Pb Emission Factor = 9 .48E-03 Ib-Pb/Tons-Sinter-Charged to the Blast Furnace 

12/3/2002 Stack Test 

0.5/52 .75=9.48e-3 Ib/ton 

This is a new baghouse added as part of the 2000 SIP control strategy. 

Production Data 

2005 Average Daily Production Rate = 1166 Tons-Sinter-Charged to the Blast 

Furnace/day 

Given 

Daily Lead Emissions 

The average daily Pb emissions were then calculated for each production day 

(6am to 6am of the following day). A sample calculation using the average daily 

production rate has been provided below : 

2005 Average Daily Pb Emissions = _ 

1166 (Tons-Sinter-Charged to the Blast Furnace/day) * 9.48E-03 (Ib-Pb/TonsSinter-Charged to the Blast Furnace) * 1 Sources = 

11 .0479 Ib-Pb/day 

Annual Lead Emissions 

The annual lead emissions can be calculated from the average daily lead 

emissions : 

2005 Annual Pb Emissions = 

11 .0479 (Ib-Pb/day) * 365 (day/yr) _ 

4032 Ib-Pb/yr 

Hourly Lead Emissions 

Daily emissions prorated over the day (typically operates 24 hr/dy). The 

production data utilized in the anlaysis is referenced to the "production day" 6a 

of day i to 6a of day (i+l) . 
0 

N 

O 

W 

N 

O 

O 

O 

O 

N 

n 

a 

G 

f. 

.~ 

0 

.E 

W 

C 

fC 

a 

0 L 

1 

L 

_ 

0 

M 

O 

O a 

N 

N 

O 

O , ; 
6.0 Refinery 

50006 

Refinery Plant Fugitives 

Emission Factor 

Pb Emission Factor = 6 .80E-03 Ib-Pb/Tons-Refined Lead-Produced 

50001-2,4-5 2000 SIP pre-control emission factor (1 .36E-01 Ib/ton) with a 95% 

capture efficiency 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 5. 

As part of the 2000 SIP control strategy the refinery roof monitors (50001-2) and 

aerovents (50004-5) were removed . Two baghouses were added to ventilate the 

refinery (50007, Baghouse 8 and 50008, Baghouse 9) . 

Production Data 

2005 Average Daily Production Rate = 425 Tons-Refined Lead-Produced/day 

Given 

Daily Lead Emissions 

The average daily Pb emissions were then calculated for each production day 

(6am to 6am of the following day). A sample calculation using the average daily 

production rate has been provided below : 

2005 Average Daily Pb Emissions = 

425 (Tons-Refined Lead-Produced/day) * 6 .80E-03 (Ib-Pb/Tons-Refined LeadProduced) * 1 Sources = 

2 .8893 Ib-Pb/day 

Annual Lead Emissions 

The annual lead emissions can be calculated from the average daily lead 

emissions : 

2005 Annual Pb Emissions = 

2 .8893 (Ib-Pb/day) * 365 (day/yr) _ 

1055 Ib-Pb/yr 

Hourly Lead Emissions 
Daily emissions prorated over the day (typically operates 24 hr/dy). The 

production data utilized in the anlaysis is referenced to the "production day" 6a 

of day i to 6a of day (i+i). 
50007 

Baghouse No. 8 

Emission Factor 

Pb Emission Factor = 1 .27E-02 Ib-Pb/Tons-Refined Lead-Produced 

12/5/2002 Stack Test 

0.21/16.58=1 .27e-2 Ib/ton 

This is a new baghouse added as part of the 2000 SIP control strategy. 

Production Data 

2005 Average Daily Production Rate = 425 Tons-Refined Lead-Produced/day 

Given 

Daily Lead Emissions 

The average daily Pb emissions were then calculated for each production day 

(6am to 6am of the following day) . A sample calculation using the average daily 

production rate has been provided below: 

2005 Average Daily Pb Emissions = 

425 (Tons-Refined Lead-Produced/day) * 1 .27E-02 (Ib-Pb/Tons-Refined LeadProduced) * 1 Sources = 

5 .3817 Ib-Pb/day 

Annual Lead Emissions 

The annual lead emissions can be calculated from the average daily lead 

emissions : 

2005 Annual Pb Emissions = 

5.3817 (Ib-Pb/day) * 365 (day/yr) _ 

1964 Ib-Pb/yr 

Hourly Lead Emissions 

Daily emissions prorated over the day (typically operates 24 hr/dy) . The 

production data utilized in the anlaysis is referenced to the "production day" 6a 

of day i to 6a of day (i+1). 
50008 

Baghouse No. 9 

Emission Factor 

Pb Emission Factor = 8.58E-02 Ib-Pb/Tons-Refined Lead-Produced 

12/4/2002 Stack Test 

1.44/16 .79=8.58e-2 Ib/ton 

This is a new baghouse added as part of the 2000 SIP control strategy. 

Production Data 

2005 Average Daily Production Rate =`425 Tons-Refined Lead-Produced/day 

Given 

Daily Lead Emissions 

The average daily Pb emissions were then calculated for each production day 

(6am to 6am of the following day). A sample calculation using the average daily 

production rate has been provided below : 

2005 Average Daily Pb Emissions = 

425 (Tons-Refined Lead-Produced/day) * 8.58E-02 (Ib-Pb/Tons-Refined LeadProduced) * 1 Sources = 

36.4416 Ib-Pb/day 

Annual Lead Emissions 

The annual lead emissions can be calculated from the average daily lead 

emissions : 

2005 Annual Pb Emissions = 

36.4416 (Ib-Pb/day) * 365 (day/yr) _ 

13301 Ib-Pb/yr 

Hourly Lead Emissions 

Daily emissions prorated over the day (typically operates 24 hr/dy) . The 

production data utilized in the anlaysis is referenced to the "production day" 6a 

of day i to 6a of day (i+i) . 
50011-18 

Kettle Setting Heat Stacks 

Emission Factor 

Pb Emission Factor = 7.09E-04 Ib-Pb/Tons-Refined Lead-Produced 

Stack test of No. 3 kettle heat stack (1999) 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 5, Sources 50011-18. 

Production Data 

2005 Average Daily Production Rate = 425 Tons-Refined Lead-Produced/day 

Given 

Daily Lead Emissions 

The average daily Pb emissions were then calculated for each production day 

(6am to 6am of the following day). A sample calculation using the average daily 

production rate has been provided below : 

2005 Average Daily Pb Emissions = 

425 (Tons-Refined Lead-Produced/day) * 7.09E-04 (Ib-Pb/Tons-Refined LeadProduced) * 8 Sources = 

2.4100 1b-Pb/day 

Annual Lead Emissions 

The annual lead emissions can be calculated from the average daily lead 

emissions : 

2005 Annual Pb Emissions = 

2.4100 (Ib-Pb/day) * 365 (day/yr) _ 

880 Ib-Pb/yr 

Hourly Lead Emissions 

Daily emissions prorated over the day (typically operates 24 hr/dy) . The 

production data utilized in the anlaysis is referenced to the "production day" 6a 

of day i to 6a of day (i+1) . 
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7.0 Strip Rolling Mill 

60001,2 

Strip Mill Heat Stacks 

Emission Factor 

Pb Emission Factor = 2.13E-04 Ib-Pb/Tons-Lead Strip-Produced 

Stack test of No. 3 kettle heat stack (1999) proportioned down to the size of the 

unit (30% of the refinery unit) . 0 .000709 Ib/ton * 0.3 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 6, Sources 60001-2 . 

Production Data 

2005 Average Daily Production Rate = 8 Tons-Lead Strip-Produced/day 

Given 

Daily Lead Emissions 

The average daily Pb emissions were then calculated for each production day 

(6am to 6am of the following day) . A sample calculation using the average daily 

production rate has been provided below: 

2005 Average Daily Pb Emissions = 

8 (Tons-Lead Strip-Produced/day) * 2.13E-04 (Ib-Pb/Tons-Lead Strip-Produced) 

* 2 Sources = 

0 .0032 Ib-Pb/day 

Annual Lead Emissions 

The annual lead emissions can be calculated from the average daily lead 

emissions : 

2005 Annual Pb Emissions = 

0.0032 (Ib-Pb/day) * 365 (day/yr) _ 

1 Ib-Pb/yr 

Hourly Lead Emissions 

Daily emissions prorated over the day (typically operates 24 hr/dy). The 

production data utilized in the anlaysis is referenced to the "production day" 6a 

of day i to 6a of day (i+1). 

47 
60003 

Strip Mill Baghouse 

Emission Factor 

Pb Emission Factor = 1 .12E-05 Ib-Pb/Tons-Lead Strip-Produced 

Uncontrolled emission factor from AP-42, Table 2.3-2 (0.0007 Ib/ton) . A 98 .4% 

control efficiency for the fabric filter was then utilized (AP-42, Table 2 .3-5) . 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 6, Source 60003. 

Production Data 

2005 Average Daily Production Rate = 8 Tons-Lead Strip-Produced/day 

Given 

Daily Lead Emissions 

The average daily Pb emissions were then calculated for each production day 

(6am to 6am of the following day). A sample calculation using the average daily 

production rate has been provided below :, 

2005 Average Daily Pb Emissions = 

8 (Tons-Lead Strip-Produced/day) * 1 .12E-05 (Ib-Pb/Tons-Lead Strip-Produced) 

* 1 Sources = 

0 .0001 Ib-Pb/day 

Annual Lead Emissions 

The annual lead emissions can be calculated from the average daily lead 

emissions : 

2005 Annual Pb Emissions = 

0 .0001 (Ib-Pb/day) * 365 (day/yr) _ 

0.04 Ib-Pb/yr 

Hourly Lead Emissions 

Daily emissions prorated over the day (typically operates 24 hr/dy) . The 

production data utilized in the anlaysis is referenced to the "production day" 6a 

of day i to 6a of day (i+i) . 
60004 

Low Alpha Baghouse 

Emission Factor 

Pb Emission Factor = 3.58E-01 Ib-Pb/Tohs-Lead Bearing Material-Charged to the 

Low Alpha Furnace 

Stack Testing (1999) . Note that the emission factor used in the 2000 SIP was 

based on Ib-Pb per Ib-charge. This was updated to a Ib/ton basis for consistency 

with other sources . 1 .79e-4*2000=0 .358 Ib/ton . 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 6, Source 60004. 

Production Data 

2005 Average Daily Production Rate = 0.04 Tons-Lead Bearing Material-Charged 

to the Low Alpha Furnace/day 

(Refined Lead Produced) * 9e-5 

Low Alpha Charge (10/1/98-4/30/99) = 14 tons. Refined Lead Produced 

(10/1/98-4/30/99) = 151470 tons. 14/151470 = 9e-5. 

Daily Lead Emissions 

The average daily Pb emissions were then calculated for each production day 

(6am to 6am of the following day). A sample calculation using the average daily 

production rate has been provided below : 

2005 Average Daily Pb Emissions = 

0.04 (Tons-Lead Bearing Material-Charged to the Low Alpha Furnace/day) * 

3 .58E-01 (Ib-Pb/Tons-Lead Bearing Material-Charged to the Low Alpha Furnace) 

* 1 Sources = 

0.0137 Ib-Pb/day 

Annual Lead Emissions 

The annual lead emissions can be calculated from the average daily lead 

emissions : 

2005 Annual Pb Emissions = 

0.0137 (Ib-Pb/day) * 365 (day/yr) _ 

5 Ib-Pb/yr 

Hourly. Lead Emissions 

Daily Emissions prorated over the 6 hou~_s between 6a and 12a . 

49 
60005-8 

Strip Mill Roof Vents 

Emission Factor 

Pb Emission Factor = 2 .21E-03 Ib-Pb/Tons-Lead Strip-Produced 

Personnel Sampling . Emission factor is for each vent. 8.84e-3/4=2.21e-3 Ib/ton. 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 6, Source 60005. 

Production Data 

2005 Average Daily Production Rate = 8 Tons-Lead Strip-Produced/day 

Given 

Daily Lead Emissions - ° 

The average daily Pb emissions were then calculated for each production day 

(6am to 6am of the following day) . A sample calculation using the average daily 

production rate has been provided below: 

2005 Average Daily Pb Emissions = 

8 (Tons-Lead Strip-Produced/day) * 2 .21E-03 (Ib-Pb/Tons-Lead Strip-Produced) 

* 4 Sources = 

0.0670 Ib-Pb/day 

Annual Lead Emissions 

The annual lead emissions can be calculated from the average daily lead 

emissions : 

2005 Annual Pb Emissions = 

0 .0670 (Ib-Pb/day) * 365 (day/yr) _ 

24 Ib-Pb/yr 

Hourly Lead Emissions 

Daily emissions prorated over the day (typically operates 24 hr/dy). The 

production data utilized in the anlaysis is referenced to the "production day" 6a 

of day i to 6a of day (i+1). 
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0 

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8.0 Fugitive Emissions 

8,1 Storage Piles-Material Handling 

Production for the fugitive handling sources was assumed proportional to the 

refined lead produced. 

Dross - Refined lead produced times 0.046 

Slag - Refined lead produced times 0.032 

Secondaries - Refined lead produced times 0 .058 

Material is handled at the storage piles approximately 12 hours per day from 6a 

to 6p. 

The fugitive particulate handling emissions were calculated using the 

methodology presented in AP42, Section 13.2.4 (Aggregate Handling and 

Storage Piles) . The equation has been presented below: 

E = 0 .74 * 0.0032 * (U/5)1~3 / (M/2)1~4 * (Pb/100) 

E = Lead emission factor (Ib/ton) 

U = Average wind speed (mph) 

M = Material moisture content (%) 

Pb = Material lead content (%) 

The lead and moisture contents have been provided in Table 8-1 . Refer to TRC 

Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", March 

2000, Section 7. 
70001 

Fugitive Dross Handling 

Emission Factor 

Pb Emission Factor = Varies Ib-Pb/Tons-~Material-Handled 

AP42, Section 13 .2 .4 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 7, Material Handling . 

Hourly emissions vary by avg . hourly wind speed and material throughput. 

Emissions are also dependent upon the material moisture content and lead 

fraction . 

Production Data 

2005 Average Daily Production Rate = 20 Tons-Material-Handled/day 

(Refined Lead Produced) * 0 .046 

Dross to Storage (10/1/98-4/30/99) = 6916 tons . Refined Lead Produced 

(10/1/98-4/30/99) = 151470 tons. 6916/151470 = 0.046. 

Daily Lead Emissions 

The average daily Pb emissions were then calculated for each production day 

(6am to 6am of the following day) . A sample calculation using the average daily 

production rate has been provided below:, 

2005 Average Daily Pb Emissions = 

20 (Tons-Material-Handled/day) * Varies (Ib-Pb/Tons-Material-Handled) * 1 

Sources = 

0.0290 Ib-Pb/day 

Annual Lead Emissions 

The annual lead emissions can be calculated from the average daily lead 

emissions : 

2005 Annual Pb Emissions = 

0.0290 (Ib-Pb/day) * 365 (day/yr) _ 

11 Ib-Pb/yr 

Hourly Lead Emissions 

Daily Emissions prorated over the 12 hours between 6a and 6p. 
70007 

Fugitive Slag Handling 

Emission Factor 

Pb Emission Factor = Varies Ib-Pb/Tons-Material-Handled 

AP42, Section 13.2.4 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 7, Material Handling. 

Hourly emissions vary by avg . hourly wind speed and material throughput. 

Emissions are also dependent upon the material moisture content and lead 

fraction. 

Production Data 

2005 Average Daily Production Rate = 14 Tons-Material-Handled/day 

(Refined Lead Produced) * 0 .032 

Slag to Storage (10/1/98-4/30/99) = 4739 tons. Refined Lead Produced 

(10/1/98-4/30/99) = 151470 tons. 4739/151470 = 0.032. 

Daily Lead Emissions 

The average daily Pb emissions were then calculated for each production day 

(6am to 6am of the following day) . A sample calculation using the average daily 

production rate has been provided below: 

2005 Average Daily Pb Emissions = 

14 (Tons-Material-Handled/day) * Varies (Ib-Pb/Tons-Material-Handled) * 1 

Sources = 

0.0004 Ib-Pb/day 

Annual Lead Emissions 

The annual lead emissions can be calculated from the average daily lead 

emissions : 

2005 Annual Pb Emissions = 

0.0004 (Ib-Pb/day) * 365 (day/yr) _ 

0.15 Ib-Pb/yr 

Hourly Lead Emissions 

Daily Emissions prorated over the 12 hours between 6a and 6p . 
70009 

Fugitive Secondaries Handling 

Emission Factor _ 

Pb Emission Factor = Varies Ib-Pb/Tons-Material-Handled 

AP42, Section 13 .2 .4 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 7, Material Handling . 

Hourly emissions vary by avg . hourly wind speed and material throughput. 

Emissions are also dependent upon the material moisture content and lead 

fraction. 

Production Data 

2005 Average Daily Production Rate = 25 Tons-Material-Handled/day 

(Refined Lead Produced) * 0 .058 

Plant and Sump Cleanings to Storage (10/1/98-4/30/99) = 8763 tons . Refined 

Lead Produced (10/1/98-4/30/99) = 151470 tons. 8763/151470 = 0.058 . 

Daily Lead Emissions 

The average daily Pb emissions were then calculated for each production day 

(6am to 6am of the following day) . A sample calculation using the average daily 

production rate has been provided below: ~ 

2005 Average Daily Pb Emissions = 

25 (Tons-Material-Handled/day) * Varies (Ib-Pb/Tons-Material-Handled) * 1 

Sources = 

0.0037 Ib-Pb/day 

Annual Lead Emissions 

The annual lead emissions can be calculated from the average daily lead 

emissions : 

2005 Annual Pb Emissions = 

0 .0037 (Ib-Pb/day) * 365 (day/yr) _ 

1 Ib-Pb/yr 

Hourly Lead Emissions 

Daily Emissions prorated over the 12 hours between 6a and 6p. 
8,2 Storage Piles- Wind Erosion 

The fugitive wind erosion emissions were calculated using the methodology 

presented in AP42, Section 13.2.5 (Industrial Wind Erosion) . The equation has 

been presented below for friction velocities exceeding the threshold friction 

velocity: 

P = (58 * (u* - ut*)z + 25 * (u*-ut*)) * (Pb/100) 

P = Lead Erosion (g/m2) 

u* = Friction velocity (m/s) 

ut* = Threshold friction velocity (m/s) 

Pb = Material lead content (%) 

If the friction velocity is less than the threshold friction velocity, the erosion is 

assumed equal to zero. 

The friction velocity is calculated by multiplying the maximum hourly 5-minute 

average wind speed in mph by 0 .0053. The 5-minute average wind speed 

corresponds well with the typical time of an erosion event. 

The lead content, storage pile area, and threshold friction velocity for each 

storage pile have been provided in Table 8-1 . 
70002 

Dross Storage Fugitive Wind Erosion 

Emission Factor 

Pb Emission Factor = Varies Ib-Pb/m2-hr 

AP42, Section 13 .2.5 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 7, Wind Erosion . 

A potential emission rate was calculated for each hour using the referenced 

equation and the material lead content. The friction velocity was calculated by 

multiplying the 5-min . maximum wind speed by 0.053. If the friction velocity 

was geater than the 

Production Data 

2005 Average Daily Production Rate = Emissions are referenced to storage area 

not throughput. 

465 square meters 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 7, Pb and Moisture of Materials Stored Outside (Table) . 

100*50* .3048^2 = 465 

Annual Lead Emissions 

2005 Annual Pb Emissions = 0 Ib-Pb/yr 

There were no wind events during 2005 that exceeded the threshold friction 

velocity of the storage pile . 
70004 

Conc. Storage Fugitive Wind Erosion 

Emission Factor 

' Pb Emission Factor = Varies Ib-Pb/m2-hr 

AP42, Section 13 .2 .5 . 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 7, Wind Erosion . 

A potential emission rate was calculated for each hour using the referenced 

equation and the material lead content. The friction velocity was calculated by 

multiplying the 5-min. maximum wind speed by 0.053 . If the friction velocity 

was geater than the 

Production Data 

2005 Average Daily Production Rate = Emissions are referenced to storage area 

not throughput. 

1161 square meters 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 7, Pb and Moisture of Materials Stored Outside (Table) . 

250*50* .3048^2 = 1161 

Annual Lead Emissions 

2005 Annual Pb Emissions = 0 Ib-Pb/yr v 

There were no wind events during 2005 that exceeded the threshold friction 

velocity of the storage pile . 
70006 

Sinter Storage Fugitive Wind Erosion 

Emission Factor 

Pb Emission Factor = Varies Ib-Pb/m2-hr 

AP42, Section 13.2.5 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 7, Wind Erosion . 

A potential emission rate was calculated for each hour using the referenced 

equation and the material lead content. The friction velocity was calculated by 

multiplying the 5-min. maximum wind speed by 0.053 . If the friction velocity 

was geater than the 

Production Data - ° 

2005 Average Daily Production Rate = Emissions are referenced to storage area 

not throughput. 

1742 square meters 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 7, Pb and Moisture of Materials Stored Outside (Table) . 

375*50* .3048^2 = 1742 

Annual Lead Emissions 

2005 Annual Pb Emissions = 0 Ib-Pb/yr 

There were no wind events during 2005 that exceeded the threshold friction 

velocity of the storage pile . 
70008A,B 

Slag Storage Fugitive Wind Erosion 

Emission _Factor 

Pb Emission Factor = Varies Ib-Pb/m2-hr 

AP42, Section 13 .2 .5 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 7, Wind Erosion . 

A potential emission rate was calculated for each hour using the referenced 

equation and the material lead content. ~The friction velocity was calculated by 

multiplying the 5-min . maximum wind speed by 0.053. If the friction velocity 

was geater than the 

Production Data 

2005 Average Daily Production Rate = Emissions are referenced to storage area 

not throughput. 

72565 square meters 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 7, Pb and Moisture of Materials Stored Outside (Table) . 

Annual Lead Emissions 

2005 Annual Pb Emissions = 80 Ib-Pb/yr 
70010 

Sec Storage Fugitive Wind Erosion 

Emission Factor 

Pb Emission Factor = Varies Ib-Pb/m2-hr 

AP42, Section 13 .2 .5 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 7, Wind Erosion . 

A potential emission rate was calculated for each hour using the referenced 

equation and the material lead content. c,The friction velocity was calculated by 

multiplying the 5-min . maximum wind speed by 0 .053. If the friction velocity 

was geater than the 

Production Data 

2005 Average Daily Production Rate = Emissions are referenced to storage area 

not throughput. 

465 square meters 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 7, Pb and Moisture, of Materials Stored Outside (Table) . 

100*50*.3048^2 = 465 

Annual Lead Emissions 

2005 Annual Pb Emissions = 0 Ib-Pb/yr 

There were no wind events during 2005 that exceeded the threshold friction 

velocity of the storage pile . 
8.3 Haul Roads 

The haul roads at the facility were broken out into twelve segments: 

A-B Hwy 55 to Joachim Bridge Exit 

B-C Joachim Bridge Exit to Plant Entrance 

C-D Plant Entrance to NW Corner of Strip Mill Building 

D-E NW Corner of Strip Mill Building to Concentrate Hopper 

E-F Concetrate Hopper to SW Corner of Strip Mill Building 

D-F NW Corner of Strip Mill Building to SW Corner of Strip Mill Building 

F-G SW Corner of Strip Mill Building to North End of Slag Haul Road 

G-H North End of Slag Haul Road to Refinery Dock 

G-K South Slag Haul Road (Paved) 

H-L North End of Main Building to Refinery Dock -

1-J Sinter Plant to Sinter Storage 

K-M South Slag Haul Road (Unpaved) 

The results from the sampling of the streets in and around the facility have been 

summarized in Table 8-2. 

Maps showing the locations of each road segment have been provided as Figures 

8-1, 8-2, and 8-3 . 

The emissions from the paved haul roads were calculated using AP42, Section 

13 .2 .1, Equation 1 and the lead content: 

E = 0.082 * (sL/2)0.ss * (W/3)l.s * (Pb/100) 

E = Lead Emission Factor (Ib/VMT) 

sL = Surface Silt Loading (g/m2) 

W = Average Vehicle Weight (tons) 

Pb = Material Lead Content (%) , 

The emissions from the unpaved haul roads were calculated using AP42, Section 

13.2.2, Equation 1a. 

E = 4 .9 * (s/12)0.7 * (W/3)0.45 * (Pb/100) 

E = Lead Emission Factor (Ib/VMT) 

sL = Surface Silt Content (%) 

W = Average Vehicle Weight (tons) 

63 
Pb = Material Lead Content (%) 

The daily lead emissions were calculated based on the daily amount of material 

hauled. The hourly emissions were apportioned using the traffic scalars. The 

traffic scalars were developed, and approved for use in the 2000 SIP study 

(Refer to TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum 

Smelter", March 2000, Section 7 and Figure 2-1) . 

The vehicle miles traveled for each segment were calculated based on the 

amount of material hauled (each day), the average payload for each material 

hauled, and the length of the segment. For example, on segment A-B (outside 

plant haul road) concentrate, refined lead, and lead strip product are hauled . 

The concentrate, refined lead, and lead strip hauled during 2005 were 226812 

tons, 155088 tons, and 2766 tons, respectively . The average payload for the 

trucks is 25 tons which equates to 9072 concentrate delivery trucks, 6204 refined 

lead product trucks, and 111 lead strip product trucks for the year of 2005. This 

equates to 15387 total trucks traveling over the A-B segment. The length of 

segment A-B is 4683 ft, therefore the total vehicle miles traveled for 2005 over 

segment A-B was 27295 miles . 

2005 Haulage on Segment A-B = 

15387 (trucks/yr) * 4683 (ft) / 5280 (ft/mi) * 2 = 

27295 miles/yr 

Emissions were assumed negligible for hours that had at least 0.01" of 

precipitation . 
Paved Haul Roads 

70100-122 

Hwy 55 to Joachim Bridge Exit (Segment A-B) 

Parameters 

Segment Length = 4683 ft 

2005 Annual Traffic Rate = 27295 VMT/yr 

Silt Content = 7.5% 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 7, Paved Haul Roads. 

Dust Loading = 0 .3491 g/m2 

Station Sample 

Silt loading was calculated by multiplying the dust loading by the silt content. 

Silt Loading = 

0.3491 (g/m2) * (7 .5/100) _ 

0.0262 g/m2 

2005 Average Truck Weight = 26.74 tons 

Calculated from the weight and traffic rate of the individual trucks that travel on 

the segment. 

Lead Content of Road Dust = 2.73% 

Station Sample 

Annual Emission Calculation 

2005 Annual Pb Emissions = 

0.082 * [0.0262 (g/mz)/2]o .ss * [26 .74 (tons)/3]1'5 * [Station Sample (%)/100] * 

27295 (VMT/yr) _ 

97 Ib-Pb/yr 

The emissions were calculated for each day and segment. Daily emissions were 

apportioned to each hour using the traffic scalars. Refer to TRC Environmental, 

"Doe Run Lead Emission Inventory Herculaneum Smelter", March 2000, Section 

7. 
70150-213 

Joachim Bridge Exit to Plant Entrance (Segment B-C) 

Parameters 

Segment Length = 12819 ft 

2005 Annual Traffic Rate = 74718 VMT/yr 

Silt Content = 7.5% 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 7, Paved Haul Roads. 

Dust Loading = 0.6545 g/m2 

Main & Curved Sample 

Silt loading was calculated by multiplying the dust loading by the silt content. 

Silt Loading = 

0.6545 (g/m2) * (7 .5/100) _ 

0.0491 g/m2 

2005 Average Truck Weight = 26.74 tons 

Calculated from the weight and traffic rate of the individual trucks that travel on 

the segment. 

Lead Content of Road Dust = 6 .52% 

Main & Curved Sample 

Annual Emission Calculation 

2005 Annual Pb Emissions = 

0.082 * [0.0491,(g/m2)/2]°~65 * [26 .74 (tons)/3]1~5 * [Main & Curved Sample 

(%)/100] * 74718 (VMT/yr) _ 

955 Ib-Pb/yr 

The emissions were calculated for each day and segment. Daily emissions were 

apportioned to each hour using the traffic scalars . Refer to TRC Environmental, 

"Doe Run Lead Emission Inventory Herculaneum Smelter", March 2000, Section 

7. 
70250-252 

Plant Entrance to NW Corner of Strip Mill Building (Segment C-D) 

Parameters . 

Segment Length = 465 ft 

2005 Annual Traffic Rate = 2711 VMT/yr 

Silt Content - 7 .5% 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 7, Paved Haul Roads . 

Dust Loading = 1 .4312 g/m2 

Truck Wash Sample 

Silt loading was calculated by multiplying the dust loading by the silt content. 

Silt Loading = 

1 .4312 (g/m2) * (7 .5/100) _ 

0 .1073 g/m2 

2005 Average Truck Weight = 26 .74 tons 

Calculated from the weight and traffic rate of the individual trucks that travel on 

the segment. 

Lead Content of Road Dust = 7.17% 

Truck Wash Sample 

Annual Emission Calculation 

2005 Annual Pb Emissions = 

0 .082 * [0.1073 (g/m2)/2]o.s5 * [26.74 (tons)/3]1'5 * [Truck Wash Sample 

(%)/100] * 2711 (VMT/yr) _ 

63 Ib-Pb/yr 

The emissions were calculated for each day and segment. Daily emissions were 

apportioned to each hour using the traffic scalars. Refer to TRC Environmental, 

"Doe Run Lead Emission Inventory Herculaneum Smelter", March 2000, Section 

7. 
70300 

NW Corner of Strip Mill Building to Concentrate Hopper (Segment D-E) 

Parameters 

Segment Length = 151 ft 

2005 Annual Traffic Rate = 260 VMT/yr 

Silt Content = 7.5% 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 7, Paved Haul Roads . 

Dust Loading = 1.4312 g/m2 

Truck Wash Sample 

Silt loading was calculated by multiplying the dust loading by the silt content. 

Silt Loading = 

1 .4312 (g/m2) * (7.5/100) _ 

0.1073 g/m2 

2005 Average Truck Weight = 38 .70 tons 

Calculated from the weight and traffic rate of the individual trucks that travel on 

the segment. 

Lead Content of Road Dust = 7.17% 

Truck Wash Sample 

Annual Emission Calculation 

2005 Annual Pb Emissions = 

0.082 * [0.1073 (g/m2)/2]o .ss * [38.70 (tons)/3]1~5 * [Truck Wash Sample 

(%)/100] * 260 (VMT/yr) _ 

11 Ib-Pb/yr 

The emissions were calculated for each day and segment. Daily emissions were, 

apportioned to each hour using the traffic scalars . Refer to TRC Environmental, 

"Doe Run Lead Emission Inventory Herculaneum Smelter", March 2000, Section 

7 . 
70350-358 

Concetrate Hopper to SW Corner of Strip Mill Building (Segment E-F) 

Parameters 

Segment Length = 746 ft 

2005 Annual Traffic Rate = 1360 VMT/yr 

Silt Content = 7 .5% 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 7, Paved Haul Roads. 

Dust Loading = 1 .4312 g/m2 

Truck Wash Sample 

Silt loading was calculated by multiplying the dust loading by the silt content. 

Silt Loading = 

1.4312 (g/m2) * (7 .5/100) _ 

0.1073 g/m2 

2005 Average Truck Weight = 15 .77 tons 

Calculated from the weight and traffic rate of the individual trucks that travel on 

the segment. 

Lead Content of Road Dust = 7 .17% 

Truck Wash Sample 

Annual Emission Calculation 

2005 Annual Pb Emissions = 

0.082 * [0 .1073 (g/mz)/2]o .65 * [15 .77 (tons)/3]1~5 * [Truck Wash Sample 

(%)/100] * 1360 (VMT/yr) _ 

14 Ib-Pb/yr 

The emissions were calculated for each day and segment. Daily emissions were 

apportioned to each hour using the traffic scalars . Refer to TRC Environmental, 

"Doe Run Lead Emission Inventory Herculaneum Smelter", March 2000, Section 

7. 
70400-406 

NW Corner of Strip Mill Building to SW Corner of Strip Mill Building (Segment DF) 

Parameters 

Segment Length = 544 ft 

2005 Annual Traffic Rate = 2234 VMT/yr 

Silt Content = 7.5% 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 7, Paved Haul Roads. 

Dust Loading = 1 .4312 g/m2 

Truck Wash Sample 

Silt loading was calculated by multiplying the dust loading by the silt content. 

Silt Loading = 

1 .4312 (g/m2) * (7 .5/100) _ 

0 .1073 g/m2 

2005 Average Truck Weight = 21 .85 tons 

Calculated from the weight and traffic rate of the individual trucks that travel on 

the segment. 

Lead Content of Road Dust = 7.17% 

Truck Wash Sample 

Annual Emission Calculation 

2005 Annual Pb Emissions = 

0.082 * [0.1073 (g/mz)/2]o .ss * [21.85 (tons)/3]15 * [Truck Wash Sample 

(%)/100] * 2234 (VMT/yr) _ 

39 Ib-Pb/yr 

The emissions were calculated for each day and segment. Daily emissions were 

apportioned to each hour using the traffic scalars. Refer to TRC Environmental, 

"Doe Run Lead Emission Inventory Herculaneum Smelter", March 2000, Section 

7. 
70450-454 

SW Corner of Strip Mill Building to North End of Slag Haul Road (Segment F-G) 

Parameters 

Segment Length = 413 ft 

2005 Annual Traffic Rate = 1013 VMT/yr 

Silt Content = 7 .5% 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 7, Paved Haul Roads. 

Dust Loading = 1 .4312 g/m2 

Truck Wash Sample 

Silt loading was calculated by multiplying the dust loading by the silt content. 

Silt Loading = 

1 .4312 (g/m2) * (7.5/100) _ 

0.1073 g/m2 

2005 Average Truck Weight = 27.25 tons 

Calculated from the weight and traffic rate of the individual trucks that travel on 

the segment. 

Lead Content of Road Dust = 7 .17% 

Truck Wash Sample 

Annual Emission Calculation 

2005 Annual Pb Emissions = 

0.082 * [0 .1073 (g/m2)/2]o'6s * [27.25 (tons)/3]1~5 * [Truck Wash Sample 

(%)/100] * 1013 (VMT/yr) _ 

241b-Pb/yr 

The emissions were calculated for each day and segment. Daily emissions were 

apportioned to each hour using the traffic scalars. Refer to TRC Environmental, 

"Doe Run Lead Emission Inventory Herculaneum Smelter", March 2000, Section 

7 . 
70500-513 

North End of Slag Haul Road to Refinery Dock (Segment G-H) 

Parameters 

Segment Length = 1073 ft 

2005 Annual Traffic Rate = 4716 VMT/yr 

Silt Content = 7 .5% 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 7, Paved Haul Roads. 

Dust Loading = 1 .0094 g/m2 

Dock Exit Sample 

Silt loading was calculated by multiplying the dust loading by the silt content . 

Silt Loading = 

1 .0094 (g/m2) * (7.5/100) _ 

0.0757 g/m2 

2005 Average Truck Weight = 30.34 tons 

Calculated from the weight and traffic rate of the individual trucks that travel on 

the segment. 

Lead Content of Road Dust = 10.62% 

Dock Exit Sample 

Annual Emission Calculation 

2005 Annual Pb Emissions = 

0.082 * [0 .0757 (g/mz)/2]o .ss * [30.34 (tohs)/3]1~5 * [Dock Exit Sample (%)/100] 

* 4716 (VMT/yr) _ 

157 Ib-Pb/yr 

The emissions were calculated for each day and segment. Daily emissions were 

apportioned to each hour using the traffic scalars. Refer to TRC Environmental, 

"Doe Run Lead Emission Inventory Herculaneum Smelter", March 2000, Section 

7. 
70550-553 

South Slag Haul Road (Paved) (Segment G-K) 

Parameters 

Segment Length = 276 ft 

2005 Annual Traffic Rate = 535 VMT/yr 

Silt Content = 7 .5% 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 7, Paved Haul Roads. 

Dust Loading = 1 .0094 g/m2 

Dock Exit Sample 

Silt loading was calculated by multiplying the dust loading by the silt content. 

Silt Loading = 

1 .0094 (g/m2) * (7.5/100) _ 

0.0757 g/m2 

2005 Average Truck Weight = 34 .26 tons 

Calculated from the weight and traffic rate of the individual trucks that travel on 

the segment. 

Lead Content of Road Dust = 10.62% 

Dock Exit Sample 

Annual Emission Calculation 

2005 Annual Pb Emissions = 

0.082 * [0 .0757 (g/m2)/2]o .6s * [34.26 (tons)/3]1~5 * [Dock Exit Sample (%)/100] 

* 535 (VMT/yr) _ 

21 Ib-Pb/yr 

The emissions were calculated for each day and segment. Daily emissions were 

apportioned to each hour using the traffic scalars . Refer to TRC Environmental, 

"Doe Run Lead Emission Inventory He`rculaneum Smelter", March 2000, Section 

7. 
70650-669 

Sinter Plant to Sinter Storage (Segment I-J) 

Parameters 

Segment Length = 1377 ft 

2005 Annual Traffic Rate = 434 VMT/yr` , 

Silt Content = 7.5% 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 7, Paved Haul Roads. 

Dust Loading = 1 .0094 g/m2 

Dock Exit Sample 

Silt loading was calculated by multiplying the dust loading by the silt content. 

Silt Loading = 

1 .0094 (g/m2) * (7 .5/100) _ 

0 .0757 g/m2 

2005 Average Truck Weight = 34.19 tons 

Calculated from the weight and traffic rate of the individual trucks that travel on 

the segment. 

Lead Content of Road Dust = 10.62% 

Dock Exit Sample 

Annual Emission Calculation 

2005 Annual Pb Emissions = 

0.082 * [0 .0757 (g/mZ)/2]o .6s * [34.19 (tons)/3]1~5 * [Dock Exit Sample (%)/100] 

* 434 (VMT/yr) _ 

17 Ib-Pb/yr 

The emissions were calculated for each day and segment. Daily emissions were 

apportioned to each hour using the traffic scalars. Refer to TRC Environmental, 

"Doe Run Lead Emission Inventory Herculaneum Smelter", March 2000, Section 

7 . 
Unpaved Haul Roads 

70600-612 

North End of Main Building to Refinery Dock (Unpaved) (Segment H-L) 

Parameters 

Segment Length = 1229 ft 

2005 Annual Traffic Rate = 2383 VMT/yr 

Silt Content = 8 .3% 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 7, Unpaved Haul Roads. 

2005 Avg . Truck Weight = 32 .59 tons 

Lead Content = 10 .62% 

Dock Exit Sample 

Annual Emission Calculation 

2005 Annual Pb Emissions = 

4.9 * [8.3(%)/12]°~' * [32 .59 (tons)/3]0 .41 * [10 .62 (%)/100] * 2383 (VMT/yr) _ 

2801 Ib-Pb/yr 

The emissions were calculated for each day and segment. Daily emissions were 

apportioned to each hour using the traffic scalars . Refer to TRC Environmental, 

"Doe Run Lead Emission Inventory Herculaneum Smelter", March 2000, Section 

7. 
70700-703 

South Slag Haul Road (Unpaved) (Segment K-M) 

Parameters 

Segment Length = 463 ft 

2005 Annual Traffic Rate = 897 VMT/yr 

Silt Content = 8.3% 

TRC Environmental, "Doe Run Lead Emission Inventory Herculaneum Smelter", 

March 2000, Section 7, Unpaved Haul Roads . 

2005 Avg. Truck Weight = 32 .59 tons 

Lead Content = 3.00% 

Slag Lead Content. Typical is 1%, however the fraction was increased to 3% to 

be conservative . This was agreed upon after consultation with MDNR. 

Annual Emission Calculation 

2005 Annual Pb Emissions = 

4.9 * [8.3(%)/12]0~' * [32 .59 (tons)/3]0 .41 * [3 .00 (%)/100] * 897 (VMT/yr) _ 

298 Ib-Pb/yr 

The emissions were calculated for each day and segment. Daily emissions were 

apportioned to each hour using the traffic scalars . Refer to TRC Environmental, 

"Doe Run Lead Emission Inventory Herculaneum Smelter", March 2000, Section 

7. 
Table 8-1. Material/Storage Pile Information 

Material Dross Conc. Sinter Sla g Sec 

Moisture Content % 2 2 8 

Lead Content % 56 ~ 79 44 1 40 

~ 

Storage Pile Area m2 465 1161 1742 72565 465 

Threshold Friction Velocity ( m/ s ) 1.12 1 .12 1 .12 0.45 1.12 

Wind Erosion 

70002 Dross 

70004 Concentrate 

70006 Sinter 

70008 Slag 

70010 Secondaries 

Fugitive Handling 

70001 Dross 

70007 Slag 

70009 Secondaries 
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