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Region 7 Air Program

Serving Iowa, Kansas, Missouri, Nebraska and 9 Tribal Nations

Lead Redesignation and Maintenance Plan for Doe Run Resource Recycling Facility in Western Iron County near Bixby, Missouri

Background: Primary smelting of lead began at this location in 1968, and the facility continued to operate as a primary smelter under a variety of ownerships until the latter part of 1988. Violations of the national ambient air quality standard (NAAQS) for lead were recorded in the first two calendar quarters of 1988. The area was designated as nonattainment for lead in November 1991, effective January 6, 1992. Also in 1991, the Doe Run Company began the production of lead through secondary smelting and resource recovery utilizing various pieces of equipment which were associated with the primary smelting operation.

Historical SIP: On August 4, 1995, we published a Federal Register notice (60 FR 39851) to approve the Part D nonattainment SIP submitted by the state of Missouri to bring this area into attainment of the NAAQS for lead. This SIP included:

  1. A revision to Missouri regulation 10 CSR 10-6.120 which established stack emissions and production limits for the facility.

  2. A Consent Order between the Doe Run Company and MDNR, dated July 2, 1993.

  3. A Consent Order amendment, signed by the Doe Run Company on August 30, 1994, and by MDNR on November 23, 1994.

  4. The Doe Run-Buick Work Practice Manual submitted July 2, 1993, and revisions to this Manual submitted June 30, 1994.

The SIP addressed emission reductions for primary and secondary smelting operations and retained Doe Run's ability to resume primary smelting at the facility. Doe Run did not resume primary smelting and no exceedances of the lead standard have been measured since 1991.

Summary of the Redesignation and Maintenance Plan: This plan, submitted on May 17, 2000, included a request for EPA to redesignate this nonattainment area to attainment for lead. The submission included a consent order for the facility, a maintenance plan for the area and modeling to show that the area will continue to maintain the ambient air standard for lead. The submission also met all of the criteria under section 107(d)(3) of the 1990 Clean Air Act Amendments for redesignation of a nonattainment area to attainment.

Emission Reductions: The permanent and enforceable emission reductions at the Doe Run Resource Recycling Facility include implementation of the part D nonattainment SIP, permanent closure of the primary lead smelting operation, controls on the secondary lead smelting operation, and the installation of reasonable available control technology (RACT) and reasonable available control measures (RACM).

Since 1993 Doe Run has implemented additional engineering projects to meet the maximum achievable control technology (MACT) standards for secondary lead smelting facilities, which include construction of building enclosures for the blast, reverberatory, and sweat furnace feed/screening processes and installation of a bag leak detection monitoring system.

In addition, the company also implemented projects to improve operation efficiency and reduce lead emissions from the facility. These projects include corrective action cleanup, installation of de-watering screw conveyors, and utilization of an air control system designed to regulate airflow through the blast furnace which has reduced the number and severity of monitored "spikes" of airborne lead levels.

Stationary Source Regulations: As part of the redesignation request, Missouri rule 10 CSR 10-6.120, Restriction of Emissions of Lead From Specific Lead Smelter-Refinery Installations, was revised to ensure permanent and enforceable emission reductions by clarifying the emissions limits for the Doe Run Resource Recycling Facility, and removing the text which could have allowed this facility to resume operation as a primary smelter.

Other Features: Two ambient air monitors continue to measure ambient air concentrations for lead.

The following contingency control measures shall be implemented when a violation of the NAAQS for lead is monitored. These contingency measures are included in the Consent Order for the Doe Run Resource Recycling Facility and address both fugitive and source emissions.

  1. Pave remainder of the employee parking area northwest of the administrative building.

  2. Increase the frequency of facility roadway sweeping and wash down to two shifts daily.

  3. Replace bags in main baghouse compartment #1 with teflon coated bags to improve ventilation capacity to the furnace process and process fugitives.

  4. Replace compartment #8 bags in main baghouse with teflon coated bags the first full quarter following installation of compartment #1 bags, if the standard has not been achieved.

Plan Approval Date: The redesignation to attainment for the lead standard and approval of the maintenance plan was published on October 18, 2000 (65 FR 62295), and became effective December 18, 2000.

EPA Region 7 Contact: Josh Tapp, (913) 551-7606, tapp.joshua@epa.gov

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