neighbors
The Doe Run Company’s Herculaneum:
200 Years and Counting
Sharing the Spotlight
Navigating the
Global Metals Market
2007 Report to Our Communities
The
The Doe
Doe Run
Run Company Company “Because no one can share
our story better than those who
do the work daily, we’ve tapped
some of our talented leaders to
share their unique expertise
and perspective.” bruce neil,
President and Chief Executive Officer,
The Doe Run Company
2
Read Gary Hughes’ story
on the accomplishments
and challenges his team
faced in Herculaneum, Mo.
8
Meet our customers, and
learn more about where
our products go once they
leave our operations.
12 Navigating the Global Metals Market 14 Generations of Growth 16 Responsible Reuse 25 TRI Report
20
Learn how safety is a
way of life and a source
of pride for Doe Run
employees.
24
Hear from Angie Nations
on how we share our
knowledge through
educational initiatives.
About the cover photo: Doe Run has a long-standing partnership with the
Herculaneum Fire Department. In fact, the company helped purchase the
department’s first new fire engine to serve the growing community. Today,
the tradition continues. In December, Volunteer Firefighter Stephen Partney,
Captain Chris Baker, Herculaneum smelter General Manager Gary Hughes
and Herculaneum Fire Chief Bill Haggard broke ground for the new
Herculaneum Fire Station, slated for completion in July 2008. Both the old
and new firehouses stand on Doe Run property; company-owned houses
are also used by the firefighters for training.
2007 Report to Our Communities
Message from the CEO
Welcome to
Neighbors, The
Doe Run Company’s
2007 Report to Our
Communities. Thank
you for reading this report and showing
an interest in learning more about
Doe Run. We are pleased to share
with you how our values and promises
are reflected in the ways we conduct
business every day.
As we maintain our tradition as a
global provider of premium metals and
services, Doe Run’s business is dedicated
to enhancing our communities, the
environment and the economy. Stories
communicate how we live up to these
commitments, especially through
education, recycling, technology and
community contributions.
Because no one can share our story
better than those who do the work daily,
we’ve tapped some of our talented leaders
to offer their unique expertise and
perspective. We are eager to share our
knowledge and passion with you. After
all, we depend upon your support — our
communities, customers and employees.
Inside this year’s edition, Gary Hughes,
general manager at the Herculaneum
smelter, shares the accomplishments
and challenges his team faced this year.
Others share their insights on today’s
global metals market, such as Jim
Grubbs, vice president of sales and
marketing, along with Jerry Pyatt, vice
president of North American operations
and chief operating officer. You will also
hear from some of our customers and
Message from Doe Run’s
Management Team
Many people think The Doe Run Company’s reach stops at the Mississippi River.
We trust that by reading this report, you’ll learn how this Missouri company has
grown into a respected leader in the global marketplace.
Over the past hundred-plus years, the world has changed, and so has our industry.
Our operations have progressed. Our expertise has grown. The demand for metals
has increased worldwide. On behalf of Doe Run, we appreciate your interest in
learning how we’re meeting this need.
Inside, readers will also get a closer look at Doe Run’s lasting contributions to
several stakeholders: our neighbors, our employees and our loyal customers.
Their partnerships and incredible insights on the evolving uses for our products
and services allow us to stay relevant, informed and successful.
Our commitments remain steadfast: to make tomorrow better than today,
to practice environmental stewardship, to operate safely and to engage our
employees. In this year’s report, you’ll get a sense of how our facilities are
performing against these commitments.
We know the keys to a sustainable business are meaningful communication
and support from our local communities. We welcome your feedback on how
we’re doing.
learn about where our products go once
they leave our operations.
As an industry, we continue to learn, evolve
and invest in our communities and society.
With that in mind, we’re proud of the
milestones we’ve reached and have
shared many of them in the following
pages. We hope you’ll enjoy learning
more about our company.
Sincerely,
bruce neil
President and Chief Executive Officer,
The Doe Run Company
[email protected]
Jerry Pyatt
Vice President,
North American Operations
and Chief Operating Officer
[email protected]
Steve Arnold
General Manager,
Buick Resource Recycling Division
[email protected]
Gary Hughes
General Manager,
Primary Smelting Division
[email protected]
Bob Roscoe
Vice President — Mining;
General Manager, Southeast
Missouri Mining and Milling Division
[email protected]
bill wold
General Manager,
Fabricated Products, Inc.
[email protected]
The Doe Run Company Herculaneum:
200 years and counting
Looking ahead to the bicentennial year of Herculaneum,
Gary Hughes, general manager of the Herculaneum
Primary Smelting Division, shares his thoughts on
2007’s substantial accomplishments and challenges.
By Gary Hughes
In 1808, Moses Austin and Samuel
Hammond founded Herculaneum, Mo.
Doe Run’s predecessor acquired land in
the city nearly 80 years later, and soon began construction of
its lead smelter. Ever since, the histories of Herculaneum and
Doe Run have been intertwined.
Plans for a brighter future
Consistent attainment of the
air standard was a challenge
for us in 2007. To address the
challenge, we’re applying new
technology to reduce emissions.
We’re also expanding monitoring,
adjusting internal processes and
As we’ve grown side by side, we have each overcome obstacles
working with the community
and celebrated accomplishments. This past year is no exception.
to establish greater distance
At Doe Run, we are committed to environmental stewardship
between operations and our
and communicating openly with our neighbors. In 2007, our
closest neighbors.
communications centered on the vision we share with our
We believe this combination of
community: providing for a vibrant, clean and safe community,
technology and additional space is
while operating a viable business that supports our local economy
important to meeting our long-term
through jobs, taxes, donations and community involvement.
goal — consistent attainment.
In April 2007, we were pleased that after working with the
This latest SIP builds on the tremendous progress we’ve
local community, state officials and regulators, we were able to
made over the years, and it outlines specific measures to
agree upon a revised State Implementation Plan (SIP). The plan
be taken, including approximately 60 engineering and
identifies steps designed to help us reach our goal of continuous
administrative control measures.
attainment of the National Ambient Air Quality Standard
(NAAQS) for lead.
See measures on pages 3 and 4
2007 Report to Our Communities
These measures were defined and agreed to by Doe Run and the Missouri
Department of Natural Resources (MDNR) and then unanimously approved
by the Missouri Air Conservation Commission. So far, Doe Run has:
• Installed a new $3.5 million
furnace designed to improve
emissions. The location of
the new furnace improves
ventilation and dust capture,
which reduces the potential
for emissions.
• Redesigned the ventilation
system, which improves
dust capture in the front
of the furnace.
•S
hortened the feed conveyor,
which transports feed to the
furnace, thereby reducing dust.
• Installed automated baghouse
malfunction alarms on both
furnaces. These alert Doe Run
to failures in the baghouse or
the ventilation systems early,
while automatically reducing
process air to the furnace.
•A
dded improved bags in
the baghouses, representing
a new technology in the
production and performance
of this key filtering system.
These bags significantly
boost the performance of
the baghouses.
Top photo: Doe Run began constructing a
concentrate truck unloading enclosure in 2007.
The receiving station will limit windblown dust
when concentrates are unloaded at the smelter
for further processing.
Opposite page: Doe Run’s Broad Street
monitor is one of 10 that monitors air emissions
and attainment in Herculaneum. The State
Implementation Plan (SIP), which was approved
in April 2007, will help the area reach consistent
attainment of the air standard for lead in the
future. The SIP is a process used throughout
the U.S. to improve air quality and help achieve
federal air standards.
The Doe Run Company planning
for the future
The Herculaneum smelter expects to complete all engineering and administrative controls,
and improvements, in the revised State Implementation Plan (SIP) by April 2008. These include:
• Raising the stack elevation
for baghouses 7, 8 and 9 to
150 feet. This height increase
will lessen the impact of
emissions on the community.
• Partially enclosing the lead
concentrate receiving station
to limit the potential for
windblown emissions
during unloading.
• Updating the plant-wide
sprinkler system to reduce
roadway dust created by
in-plant traffic.
• Establishing a green space
between the plant and the
neighboring community.
• Enclosing the south end of
the railcar unloader, which will
completely enclose the railcars
while they are being unloaded.
• Continuously recording fan
amperages. Fan amperages
allow employees to see
and track how well fans
are operating so that
buildings remain under
negative pressure.
• Recording air flow from
baghouses 3 and 5 to ensure
proper ventilation for the
sinter plant and blast
furnaces, respectively.
• Unloading concentrate
trucks directly into railcars
to minimize handling
and stockpiling of lead
concentrate.
• Enclosing the baghouse 5 dust
wetting system (pugger)
to better control potential
emissions from the handling
of baghouse dust when the
sinter plant is undergoing
prolonged maintenance.
2007 Report to Our Communities
Trading spaces
Challenges and celebrations
In June, we were pleased to close on a real estate transaction
For those who follow our news, it will come of little surprise
with the city of Herculaneum as the next step in creating more
that 2007 provided us with ample opportunity for challenges
space between our facility and our neighbors.
and celebrations. Sometimes both came wrapped in the
At the request of the city, Doe Run sold about 20 acres of its
same package.
land for $420,000 at the southeast corner of the Herculaneum
For example, in August, we were eager to bring the new
exit, along Interstate 55, for a shopping center development.
$3.5 million furnace on line. As a major project in the SIP,
In turn, following unanimous approval by the Board of
we expect it to help deliver more efficient — and thereby
Aldermen, the city sold 10.32 acres of streets and adjacent
cleaner — operations. As a new design, however, it required
land near the smelter to Doe Run for $410,000.
several modifications to realize its full potential.
These land transactions benefit the community and Doe Run.
During the same period, our No. 2 furnace became inoperable.
The land acquired by Doe Run allows us to create greater distance
Having both furnaces down forced us to delay deliveries to
around the plant. In addition, plans are being developed for an
customers and tackle multiple restarts. Thanks to the efforts
architecturally pleasing fence to be built in 2008. The fence
of many, both furnaces became operational in early September.
will limit public access and provide an unfettered view of the
We ended the fiscal year with 134,000 tons of lead produced.
green space.
Transportation improvements were also evident in Herculaneum,
We’re also pleased to be a part of the Herculaneum Fire
and many people shared our enthusiasm for the reopening of the
Department’s “trading of spaces,” as it moves to a new facility
Joachim Bridge in November. The reconstructed bridge provided
at the corner of Riverview Drive and Riverview Plaza. Doe Run
us the opportunity to reroute all plant traffic and reduce impact
will invest $750,000 in building a new station for the department
on the community.
on company property.
Story continued on page 7
We understand from Fire Chief Bill Haggard that the new
location will improve the fire department’s access to all areas
of the community. The 6,000-square-foot station will include
five apparatus and equipment bays; training and conference
room space; a weight training room and showers; separate
communication and fire chief offices; expanded restrooms; and
a bunk room. We marked this milestone with the community
on Dec. 1, when we officially broke ground for the new station.
The newly constructed Joachim Bridge, reopened in November, is a project
more than two years in the making. Approved in 2004 as the largest in the
Department of Transportation’s Bridge Discretionary Program, the new
construction replaces the previous 90-year-old bridge and helps divert city
and Doe Run truck traffic away from residential areas.
The Doe Run Company Bicentennial support symbolizes appreciation
for shared history and vibrant future
growing
side by side
Two hundred years ago, Herculaneum’s
founding fathers likely had several
conversations under shade trees
overlooking the Mississippi River.
Few could have predicted that the
sleepy pioneer town of Herculaneum
would become a thriving Missouri
community, rich with heritage.
In 1808, the town boasted some
35 homes, a school house, post office,
jail, inn and ferry stop. Situated at the
confluence of the Mississippi and
Joachim Creek, and near lead smelting
operations that produced ammunition,
the town prospered as a shipping port.
Lead sales ceased during the War of
1812, when the British blockaded sea
routes. Overnight, the city and its
businesses withered. Overlooking a
ghost town, the trees stood, silhouetted
against desolate streets.
city firsts …
Along with being the first major employer,
Doe Run and its predecessors helped
finance and build several city firsts: the
first steamboat crossing, ferryboat stop
and firehouse. Doe Run also assisted in
the creation of Bates Memorial Park,
Dunklin Fletcher Memorial Park, Joachim
Golf Course and the Tri-City Little League
Complex ball fields.
Fast-forward 80 years. The need for
lead resurged and New York-based
St. Joseph Lead Company entered
the booming Missouri Lead Belt as the
premier investor. The company acquired
a 540-acre tract of land along the
Mississippi and in 1890, construction
began on what is now The Doe Run
Company’s Primary Smelting Division.
The facility blossomed with jobs.
Residents returned. And Herculaneum
flourished as a budding and influential
force along the mighty Mississippi.
Since then, Doe Run
has grown in tandem
with Herculaneum. By
working together, residents,
city leadership and the
company have cultivated
a prosperous community.
In 2007, on the eve of
the city’s 200th birthday,
Doe Run and its neighbors joined
together to celebrate the past and
prepare for the future.
In honor of the milestone, Doe Run
contributed to the Herculaneum
Bicentennial Committee, signing on
as platinum sponsor for the yearlong
bicentennial celebration. Employees
participated in the October launch
event, the Herculaneum Fall Festival.
To recognize Herculaneum’s past,
and its promising future, the community
officially dedicated a 200-year-old
“Bicentennial Tree.” The more than
50-foot-tall white oak tree stands on
2007 Report to Our Communities
“Our contributions to the community
symbolize our appreciation for where we’ve
been and our enthusiasm for the future.”
gary hughes,
General Manager of the Primary Smelting Division,
The Doe Run Company
Doe Run property at Mott Street and
is now marked with a granite plaque.
“Our contributions to the community
symbolize our appreciation for where
we’ve been and our enthusiasm for
the future,” said Gary Hughes, general
manager of the Herculaneum smelter.
“The facility has the privilege of having
served as the city’s first major employer.
Along with that comes the responsibility
we have to our community. We recognize
that without the public’s support,
we wouldn’t be here today.”
Sowing seeds for the future, the
Herculaneum Today and Tomorrow
(HT&T) organization was recently
awarded a $10,000 grant to help the
city work toward a symbolic milestone.
Herculaneum will use the funds to
attain “Tree City USA” status. The
city and Doe Run will plant 200 trees
to commemorate the bicentennial.
“Doe Run has always been a
major supporter of our city.
Together, we’ve transformed
what was once an industrial
hub into a comfortable suburb
in which people live, work
and play,” said HT&T member
Jim Kasten. “Thanks in part to
Doe Run’s involvement, the
bicentennial celebration has
provided a chance for everyone to
recognize our heritage. We look
forward to a bright future.”
During the year, we also reduced our impact on roadways with
the addition of a new Tymco street sweeper. This sweeper uses a
regenerative air system, in which air dislodges dust and particles
from crevices in the roadways and captures particles in the
sweeper, leaving roads cleaner.
In October, we joined with the city to kick off a yearlong
celebration of Herculaneum’s bicentennial. Festivities are
planned over the course of the year, culminating in a grand
celebration in October 2008. As the only platinum-level
sponsor, we are proud to donate our time, talent and resources
toward this community-wide initiative.
Now, after almost two centuries, I often wonder what Moses
and Samuel would say about our community. We started as a
riverside town with a modest lead shot tower producing bullets
for the Army. Today, our community is home to our nation’s
only primary lead smelter, providing materials necessary to
power our cars, wireless communications and emergency
power sources globally.
As we look ahead, I envision an interesting and vibrant place
to work, a quality place to live and a well-balanced community.
We’re honored to be part of Herculaneum, and we look forward to
celebrating our past, present and future this coming year.
I hope to see you around town, and I invite you to stop by
and share your thoughts. Left: Herculaneum Today and Tomorrow (HT&T) member Jim Kasten
stands beside the Bicentennial Tree located on Doe Run property. The tree
symbolizes Doe Run’s partnership with the city and HT&T to help become a
Tree City USA community as part of the bicentennial celebration. Doe Run
planted 100 of the 200 trees needed to achieve this distinction. The city
of Herculaneum plans to name a second Bicentennial Tree in 2008.
Visit www.herculaneum2008.com to learn more.
The Doe Run Company sharing
the spotlight
The Doe Run Company emphasizes a company-wide dedication to meeting changing
customer needs and finding ways to improve service. By leveraging technology, know-how,
synergy and opportunity, the people of Doe Run deliver on these promises in very real and
valuable ways. Read on to learn more about the relationships that have made Doe Run an
industry leader and global metals provider.
A Resource for Natural Resources
Oil prices reached record highs last summer, which was good
news for Doe Run customer Baker Hughes Centrilift.
Among its electrical submersible pumping system products,
Centrilift makes cable that stretches thousands of feet below the
Earth’s surface to power pumping systems in oil wells. The higher
demand for oil is driving the market for more pumping systems,
which in turn drives Centrilift’s demand for lead.
“About half of our cable designs use lead sheathing,” explained
Larry Dalrymple, manager of engineering, cable operations.
Centrilift’s 1-inch-thick cables carry up to 8,000 volts. “Our entire
pumping system depends on cable. One short can shut down
an entire on-shore or off-shore project.”
Inside Centrilift’s Claremore, Okla., operation, 2,000-pound blocks
of lead are melted down, then formed into lead pipe that fits snugly
around a copper rod. “We have to make everything consistent,”
said Randy Wilbourn, plant manager. “Having a tight fit of the
lead and consistent thickness is critical to this application.”
This “wall” of lead acts as an impervious shield against the
incredibly corrosive environment found around oil wells, where
hydrogen sulfide gas can corrode copper in a matter of days.
“Oil is somewhat foul when it comes out of the ground,” said
Charlie Fowler, vice president of supply chain for Centrilift. “Lead
is a cost-effective material to protect the copper in what we like
to think of as a really long extension cord.” Right: Centrilift requested Doe Run’s expertise to gather best practices
for safely working with lead. This dense, flexible metal is pliable enough
to sheath copper wiring (shown here in large spools), yet strong enough
to protect it from the harsh environments found in oil wells.
Centrilift At a Glance
Doe Run customer: 12 years
Based near Tulsa, Okla., Centrilift sends all scrap lead pipe
back to Doe Run’s Buick Resource Recycling Division.
Centrilift’s lead comes from Doe Run’s Herculaneum smelter.
Centrilift has been extruding lead since 1995, and has taken
cues from Doe Run on the safe handling of lead.
2007 Report to Our Communities
Lead Shapes Up at Fabricated Products Inc. (FPI)
Among metals, lead is flexible, versatile and strong. FPI, a subsidiary
of Doe Run, brings out the best in lead by forming it into shapes
that maximize performance in specialized applications.
For instance, employees at FPI’s oxide
plant in Vancouver, Wash., produce one
major product: a lead-oxide powder used
to produce a lead-oxide paste, which is a
key component of all lead-acid batteries.
At the Seafab facility in Casa Grande, Ariz.,
lead takes other forms. “Our goal is to be
the best fabricated lead products company
in the world,” said Bill Wold, general
manager of FPI.
“Twenty-pound lead chunks are tumbled
around in a ball mill, where lead creates
its own friction and oxidizes,” explained
Ken Bartel, plant manager with FPI. “More
than 5 million pounds of lead oxide were
created in October 2007, setting an
all-time monthly production record.”
Three techniques create different lead
shapes at Seafab. At the rolling mill, warm
lead slabs are rolled like pie crusts into
sheets for roof flashings and shielding
against sound waves, X-rays and nuclear
radiation. With a press, lead can be
extruded into pipe or wire. Lead can also
be cast into various shapes and sizes for
use in copper and zinc plating. Lead’s low melting point, 621.5 degrees
Fahrenheit, allows Seafab to roll large blocks
of lead into 1/4-inch sheets. The facility
also fabricates pieces like this star
anode, a critical component in
copper electroplating.
FPI At a Glance
Doe Run subsidiary: 10 years
Locations: Casa Grande, Ariz.,
and Vancouver, Wash.
Products: Lead oxide (Vancouver);
rolled, extruded and cast lead products
(Casa Grande).
FPI mirrors Doe Run’s commitment to safety.
Casa Grande has marked eight years without
a lost-time accident; the Vancouver plant
has surpassed three years.
Above: Seafab’s 35 employees in Casa Grande,
Ariz., maintain some of Doe Run’s best safety
records. Seafab has earned a “Perfect Record
Award” from the National Safety Council every
year since joining the organization in 2000.
10 The Doe Run Company Straight Shooters for Remington
Doe Run’s Buick Resource Recycling Division supplies secondary,
or recycled, lead to Remington Arms Company in Lonoke, Ark.
Lead plays a vital role in most ammunition
produced by Remington, according to
Vic Bettis, purchasing manager. Primarily,
lead is processed into a thick wire that is
fed into a machine to create rimfire, as well
as centerfire bullets for rifles and pistols.
Lead is also used to make lead shot
for shotgun shells.
The primer mix used to ignite cartridges
also features lead. Non-lead options
do exist in some bullet and shot varieties,
but each has limitations. Non-lead bullets,
for example, can be used as training
ammunition. “If you just want to shoot
targets, it’s fine. But these other materials
do not have the mass, energy and
properties of a lead bullet,” Bettis said.
“A lead bullet is designed to mushroom
when it hits.”
Doe Run employees are straight shooters
when it comes to solving problems.
Remington recently discovered its typically
spherical shot was instead forming as
teardrops. Doe Run’s metallurgical
experts analyzed the processing and
determined that, somewhere along
Remington’s production line, the material
became contaminated with excess
copper. Remington was able to assess its
production line and correct the problem.
Remington Arms Company
At a Glance
Doe Run customer: 7 years
Remington, headquartered in Madison, N.C.,
designs, produces and sells products for the
hunting and shooting sports markets, as well
as military, government and law enforcement.
The company has been in business since 1816.
The Lonoke plant recently celebrated 3 million
man-hours without a safety incident and
earned an award from the state of Arkansas.
In another instance, Doe Run helped
Remington by recycling countless
barrels filled with a combination of lead
shot, gunpowder and buffering material
from shotgun shells. Without Doe Run’s
capabilities, Remington would have had
to place the material in a hazardous waste
landfill, rather than return the metals back
to commerce for reuse. Left: At Remington’s Arkansas facility, Doe Run’s
lead is processed into bullets for rifles and pistols
and lead shot for shotgun shells.
Below: These copper-jacketed bullets consist of
cores made from Doe Run lead; they’re just a few
of Remington’s products, which are distributed
to more than 55 countries.
11 2007 Report to Our Communities
Superior Battery specializes in marine,
or “deep-cycle” batteries, which contain
approximately 20 pounds of lead, 1 gallon
of sulfuric acid and 2 pounds of plastic.
Superior At a Glance
Doe Run customer: 11 years
Superior Battery uses 2,000-pound blocks
to create lead oxide and 60-pound bars
(called pigs), all purchased from Doe Run.
Superior Battery opens its facility to
professors from the local community
for courses on industrial maintenance
and electronics.
Superior Service
Superior Battery in Russell Springs, Ky.,
has the distinction of being the youngest
player in its lead-acid battery niche.
In the world of lead-acid batteries, competition is fierce, and Randy Hart, chief executive
officer of Superior Battery, is proud that his 170-person operation has weathered the
storm. Superior now produces more than 1 million lead-acid batteries annually.
“Once we grew to a certain size, we found that Doe Run could service our lead metal
needs well,” Hart said.
Superior Battery supplies the eastern United States, Canada and some areas of export
with lead-acid batteries for commercial vehicles and deep-cycle marine batteries. The
marine business, in particular, fluctuates with the economy. Boat purchases dip when
money is tight. As past president of the Battery Council International, Hart knows the
value of finding alternative applications.
“The industry buzz is about hybrid vehicles,” he said. “We’re considering how they will
enhance our business, as hybrids still have an engine and a starting battery.”
Doe Run aims to enhance Superior’s business by offering expertise that goes
above and beyond a typical supplier relationship. For instance, two metallurgists from
the Buick Resource Recycling Division have repeatedly assisted on site to help address
production issues. “For them to take the trouble to come down was a value-added
service; one that really helped our process,” Hart said. Above: Like Doe Run, Superior Battery values
community involvement. The facility often
serves as a practical teaching environment
for local colleges.
12 The Doe Run Company navigating
Above: These 100-pound bars, commonly
called “pigs,” are banded together before being
shipped to customers. The orange striping is used
by Doe Run to differentiate its end products,
including lead or lead alloys. Like a bar code,
the stripes help customers with storage,
transportation and product selection.
the global
In January 1875, The New York Times described the mines of Missouri as adding to
“the already abundant proof that Missouri is to be the ‘England of the tomorrow.’”
Today, Missouri lead is renowned, and widely followed by members of the London
Metal Exchange (LME), the world’s premier non-ferrous metals market.
In October, Doe Run representatives attended LME Week 2007 in London, England,
to meet with customers and other industry experts associated with this booming market.
Jim Grubbs, Doe Run’s vice president for sales and marketing, met with industry
reporters who track the company as it navigates the global metals market.
“I’ve attended LME Week for years, and I am
amazed by who watches our operations,”
Grubbs explained. “I had complete strangers
from the Middle East and other parts of the
world ask me how ‘Herky’ was running. There is worldwide
interest in what we do.”
“Herky,” short for Doe Run’s plant in Herculaneum, Mo., is the only primary lead
smelter in the United States. Because of its high quality, Doe Run lead is a sought-after
product for applications requiring pure metal. Doe Run’s Herculaneum smelter produced
134,000 tons of lead metal in the fiscal year ending in October 2007. The Doe Run
Company is the world’s third largest lead supplier.
13 70,000
Doe Run’s mines produce approximately
70,000 short tons of zinc concentrates
annually and 20,000 short tons of copper.
80%
Lead-acid batteries, in high demand
worldwide, represent 80 percent of
Doe Run’s end-use applications. The
successful recycling of these batteries
protects the environment and helps
to preserve the finite quantities of lead
ore in the Earth.
metals market
“Increased demand for lead, like many base
metals, is driven largely by the expanding
economies of the world. Recent record
lead prices benefited us directly,” added
Jerry Pyatt, vice president, North American operations and
chief operating officer of Doe Run. “We’re taking this opportunity to
increase investment in our people, our communities and our operations. We also need
to prepare to insulate our company against economic downturns.”
To that end, Doe Run is exploring within the Viburnum Trend and looking at properties
elsewhere in the United States and abroad. The company is also focused on building
workforce capability and new technology to improve its competitive position.
Going forward, a comprehensive scope of services will continue to be Doe Run’s
market advantage. Providing customers with broad capabilities — incorporating
extraction, milling, refining, fabrication and recycling — reflects Doe Run’s
commitment to the metals lifecycle. Additional demand for
lead will come from cell
tower battery needs.
140,000
Doe Run’s recycling division recovered
just over 140,000 tons of lead in 2007.
78%
Lead concentrates from Missouri are
sold to traders worldwide. Concentrates
contain about 78 percent lead.
14 The Doe Run Company generations of growth
Although the metals market has ebbed
and flowed, Doe Run’s employee base
remains strong. Like the branches of a
tree, entire families have spent careers
with Doe Run, sharing the knowledge
rooted within them for generations.
For some, it’s tradition.
15 2007 Report to Our Communities
Tommy Dunlap, a driller at Doe Run’s Southeast Missouri
Mining and Milling Division (SEMO), has mined with the
Tommy Dunlap
Gene Karr
Aurielle Weaver*
Taylor Howze*
company and its predecessors since 1968. A third-generation
employee, Dunlap follows in the footsteps of his father and
grandfather, whose mining roots can be traced back in decades.
Dunlap readily shares his wisdom with newcomers and beginning
miners. “When Doe Run hires new crewmen, I’m one of the
first to tour them around, show them the ropes, and share all
the dos and don’ts. I’ve watched a lot of people grow into great
miners, and I’m proud to pass along what I’ve learned from
previous generations.”
According to Bob Roscoe, vice president — mining and
general manager at SEMO, Dunlap’s work ethic and attention
to safety are priceless. “In nearly 40 years, Tommy hasn’t had
a lost-time incident,” Roscoe said. “That attention to detail is
something you can’t learn from a class or book. We’re grateful
he’s still eager to demonstrate to new miners the attentiveness
it takes to safely accomplish the job. His safety record is one
of the best in the company.”
In fact, in 2008, Dunlap will be eligible for a 40-year Joseph
A. Holmes Safety Association award for 40 years without a
Like Dunlap, Karr joined Doe Run as a third-generation
employee. Although he followed in the path of his father,
a blacksmith, and his grandfather, who worked in sample
preparation, he didn’t always aspire to share their profession.
In his words, “Not many people dream of doing exactly
what their parents do.”
But since Karr began at the smelter, his pride has deepened.
“I’m proud to have seen the company advance — a lot has
changed. When I took my first job, everything was done with
pencil and weigh machine. Now, automated systems help manage
measurements and testing. A lot has been accomplished, and
there isn’t another job I would have rather had.”
Since the year Karr started, in 1969,
the Herculaneum smelter has:
• Achieved numerous awards for safety;
• Produced more than 6 million tons of lead metal; and
• Reduced emissions by more than 90 percent.
lost-time incident.
Karr is now enjoying his retirement. After a family vacation
Despite all he’s accomplished, Dunlap is still excited about each
in Gulf Shores, Ala., he now serves as a part-time bus driver
day’s adventure. “Mining for me has always been like a treasure
for the Dunklin R-5 School District.
hunt. I can hardly wait after each blast — exploring the ore is
Two Herculaneum summer employees trace their Doe Run
like opening a treasure chest. And, I’m aiming for another year
roots back even further. Aurielle Weaver and her cousin,
to reach the four-decade mark,” Dunlap said with a grin.
Taylor Howze, are fifth-generation employees. Their family tree
includes Harrison Casey, the first of their family to work for the
Since the year Dunlap started, in 1968, SEMO has:
• Achieved 23 Sentinels of Safety awards; and
• Milled more than 168 million tons of ore.
company. Casey worked the smelter’s blast furnace in 1907.
Since the days when the first generations of their families
began at Doe Run, the company and industry in which
Just one year later and 100 miles away, Gene Karr began
Dunlap, Karr, Weaver and Howze work in have grown
working at Doe Run’s Herculaneum smelter. He logged 38 years
dramatically. Today, lead continues to be vital in providing
of service before retiring in 2007. He managed the smelter’s
power, protection and convenience in daily life. Doe Run
materials handling department.
will continue to depend on employees, the proverbial roots
who carry years of valuable expertise, skill and knowledge,
to be successful in the future. *Weaver and Howze photos by Sherree Faries, Leader Publications.
16 The Doe Run Company reu
responsible
A roundtable
discussion on
the second life
of lead-acid
batteries and
computer
monitors
There’s an ongoing need to responsibly recycle
items that contain lead, especially products like spent
lead-acid batteries and old computer monitors.
Neighbors spoke with Steve Arnold, general manager
of Doe Run’s Buick Resource Recycling Division (BRRD);
Jim Lanzafame, environmental manager for BRRD;
and Lou Magdits, Doe Run’s director of raw materials,
to get their insights on lead recycling.
Top: Battery recycling is one of the country’s biggest environmental success stories.
The Buick Resource Recycling Division recycles virtually every piece of the battery
— from the plastic casing and battery acid down to the wood pallet.
17 2007 Report to Our Communities
se
Why is the lead-acid battery
Where can batteries be recycled?
an ideal product for recycling?
LM: For U.S. consumers, lead-acid
Lou Magdits (LM):
batteries are collected by automotive
The standard lead-acid
parts and repair shops, battery specialists
battery powers more
and mass merchandisers. Those batteries
than half a billion
are then sent for recycling — many
passenger vehicles globally, as well
arrive at BRRD.
as golf carts, forklifts and other modes
of transportation. Because each battery
How much battery recycling
has to be replaced every two to five
happens at BRRD?
years, it makes sense that we try to
Steve Arnold (SA):
recapture as many of the components
We recycled
as possible. Automotive batteries
13.5 million lead-acid
contain approximately 20 pounds
batteries in 2007. As
of lead, 1 gallon of sulfuric acid and
one of the world’s largest, single-site
2 pounds of plastic, so it has a lot of
lead recycling facilities, we’re proud
valuable, recyclable parts.
of our contribution to recycling.
Jim Lanzafame (JL):
Besides the lead-acid battery,
Plus, the 98.8 percent
how else does Doe Run contribute
recovery rate for
to recycling efforts?
lead-acid batteries is
SA: Lead recycling is a success story —
the highest among recycled products.
for industry, regulators, consumers and
By comparison, the recovery rates
those concerned with the responsible use
are 88.9 percent for newspapers,
of our natural resources. Recycling helps
62.6 percent for office-type papers and
preserve limited natural resources, and
only 44.8 percent for aluminum cans,
our facility recovers tons of materials
according to the U.S. Environmental
that otherwise would be thrown away.
Protection Agency.
JL: That’s right. We process recyclable
Not only is the lead-acid battery
material from customers, too. For
recycled more thoroughly than these
instance, Centrilift in Oklahoma sends
other products, but by recovering the
its process scrap to us because it’s more
lead from the battery, we are also able
economical than disposing of it.
to produce high-quality lead for our
customers’ reuse. This means lead metal
can be recycled over and over again.
Above: Doe Run opened the Buick Resource Recycling Division in 1991 and has steadily increased the
amount of lead-bearing material it recycles each year. In 1998, the facility began accepting and recovering
lead from cathode-ray tube (CRT) glass, which is gaining recycling momentum as consumers upgrade to
flat-screen computer monitors and televisions.
18 The Doe Run Company a responsible
citizen
Employees at BRRD gave
back to their neighboring
communities in 2007.
D
oe Run shared science facts
with attendees at the “Fall
Rocks!” event in Park Hills, Mo.;
and, employees helped staff
the 2007 Old Miner’s Day
Celebration in Viburnum, Mo.
RRD, along with SEMO,
B
donated $50,000 to the Iron
County Hospital’s Tree of
Life fund.
he facility hosted tours and
T
supported Doe Run’s hands-on
minerals education program.
RRD also holds annual open
B
houses for employees and
their families.
In addition, improvements were made
to the blast furnace enclosure to improve
our capture efficiencies. Our Breaking,
Desulfurization and Crystallization
(BDC) department also made great
strides in 2007 by eliminating discharge
contributions of process water into our
wastewater treatment plant.
What does the future look like
for lead recycling and BRRD?
SA: Recycling will continue to be a
critical part of being good stewards of
our resources and minimizing waste.
As consumers switch to flat monitors
and televisions, the number of CRTs
that need to be replaced — and the lead
recovered — is skyrocketing. In addition,
some developing countries don’t have a
LM: Others look to us for assistance
What are the biggest challenges
structured system to recover and recycle
as well. We also recycle spent bullets
in recycling lead products?
batteries, so there’s a real need for a
from law enforcement, military and
JL: Environmentally, there are certainly
leader like Doe Run.
sporting ranges, and process lead-based
challenges. We carefully monitor our
LM: We expect to see a growing
paint chips from restoration and
air emissions and our water discharges.
demand for co-products of the recycling
remodeling projects throughout the
This year, we installed a new tapping-
process as well. In addition to capturing
U.S. Doe Run safely recovers the lead
process for our reverberatory furnace.
lead and other trace metals from batteries,
from the old paint chips, solving yet
It allows us to decrease the amount of
plastic casings are recycled (by third
another waste issue.
waste material we currently dispose of
parties), oftentimes into new battery
off site by about 18,000 tons per year;
cases and other automotive parts. Sodium
decrease the amount of iron we consume;
sulfate, a co-product of the lead-recycling
save about 150,000 gallons of diesel
process, has its own unique story.
fuel per year; and decrease our overall
(See related story on page 19.) SA: BRRD is one of the few facilities
that accepts and recovers lead from
cathode-ray tube (CRT) glass, found
in many computer monitors and
television screens. We recycled more
than 275,000 CRTs in 2007.
sulfur dioxide emissions.
In our efforts to continually make
improvements in our performance,
we have voluntarily installed a vehicle
wash station to minimize the tracking
of materials out of the facility.
Right: The battery recycling process yields
sodium sulfate, a high-quality salt that is used
in the manufacturing of products such as glass,
powdered laundry detergent and carpetfreshening products.
19 2007 Report to Our Communities
sodium sulfate recieves
kosher
certification
Though lead is the primary resource
extracted from lead-acid batteries at the
Buick Resource Recycling Division (BRRD),
the recycling process and technology also
yields approximately 1,200 tons of sodium
sulfate, or salt, per month.
To meet certification standards set forth
by multiple manufacturing industries, a
licensed rabbi from the Chicago Rabbinical
Council, a certification organization, visits
BRRD each year to ensure the salt-creation
process and raw materials are consistent
with kosher requirements.
“Kosher” is a term used to describe
products made in accordance with
Jewish law. Nearly 75 percent of all
prepackaged foods carry some sort
of kosher certification.
“Although none of the sodium sulfate we
produce is contained in food, it is used
in making a corn-based starch,” said
Lou Magdits, Doe Run’s director of raw
materials. “Suppliers of kosher-certified
products require certifications at all
steps in the manufacturing supply chain.”
Doe Run’s sodium sulfate is also used in
the manufacturing of other products such
as glass, powdered laundry detergent and
carpet-freshening products.
20 The Doe Run Company people + technology =
mine saf
For Doe Run’s Southeast
Missouri Mining and Milling
Division (SEMO), pride, dedication
and safety are a way of life.
Just ask the employees.
“One of my proudest
moments in my career
was telling my father I had
officially become a miner
Denis Murphy
Patrick Murphy
with the St. Joseph Lead
Company, Doe Run’s
predecessor,” said Denis
Murphy, SEMO’s safety and environmental manager. “And
I’m even more proud now. This is a dedicated and safe industry
that has really evolved. Through efforts like accomplished Mine
Rescue Teams and exploring new technologies every day, we’re
topping safety records on a regular basis while meeting the
world’s demand for metals.”
A fourth-generation miner with more than 30 years of industry
expertise, Murphy is one of Doe Run’s many legacy employees
Above: Doe Run’s Mine Rescue Teams annually participate in the University
of Missouri-Rolla’s Annual Southeast Missouri Mine Rescue Contest, the only
competition in the country that is held in a real mine setting.
(see more on page 15). His father dedicated 43 years with St. Joe.
Opposite page — right: To help celebrate Women’s History Month in March,
Doe Run’s Carrie Heiling (at left), Lori Young (at right) and Vanessa Eckhoff
(not pictured) submitted workday diaries for a national book project chronicling
women in various professions.
previous mining district, known as the “Old Lead Belt.”
His grandfather and great-grandfather worked at Missouri’s
21 2007 Report to Our Communities
From the U.S. Department of Labor:
539,000
2004 — Total amount of women
employed in mining industries: 539,000
(10.2 percent of total workforce)
687,000
2006 — Total amount of women
employed in mining industries: 687,000
(13 percent of total workforce)
ety
Murphy’s sons are continuing the tradition at the Herculaneum
smelter and the mines.
Murphy’s industry experience and commitment, along with his
zero-injury record, make him qualified to oversee Doe Run’s
two accomplished Mine Rescue Teams.
Underground heroes
Murphy recalls the last two years in mining news. “The
coal-mining accidents make us even more determined to be
better prepared,” he explained. “They also remind us of how
important it is to work carefully
and safely to prevent a situation,
condition or activity that may put
someone in harm’s way.”
working
women
true stories of
After transforming their work reality
into daily snapshots, three women at
Doe Run’s Southeast Missouri Mining
and Milling Division (SEMO) are now
published writers.
In 2007, author Joni Cole selected
three female Doe Run employees for
a 24-hour glimpse into the mining
profession. Sharing their unique
perspectives were Carrie Heiling, mine
geologist; Vanessa Eckhoff, metallurgical engineer;
and Lori Young, technical service engineer III.
“At first, it felt odd journaling my day,” Heiling said. “But I’ve
got a neat job. I get paid to go underground, look at rocks and
get dirty. I love the fact that I don’t have to be in an office every
day. I think it’s great to be able to go out into the mine and
get an up-close look at geological structures and features. It
helps me understand the geology of the ore in the mine, which
helps me do my job better. Besides, how many people can say
they work a thousand feet underground?”
In its three Missouri divisions (mining/milling,
smelting and recycling), Doe Run employs more than
100 women in roles as diverse as raw materials coordinators, chemical analysts, crusher operators and
safety and health specialists.
Cole chose the women of Doe Run because the company
is a leader in what is viewed as a male-dominated industry.
“The women’s journals demonstrate how critical they are to the
company,” Cole explained. “Their writings were very real,
empowering, smart, funny and a joy to read, making them a
home run for the book. The end result transports the reader
into these women’s realities. The result was remarkable.”
“Water Cooler Diaries: Women across America Share Their
Day at Work” is published by Da Capo Lifelong Books, and
available on www.amazon.com. The book will
feature 35 journal entries (two from Doe Run)
from more than 500 that were submitted.
The book hits shelves in March 2008. As the
third in the “This Day” series, it will join Cole’s
two previous works, “This Day in the Life:
Diaries from Women Across America” (2006)
and “This Day: Diaries from American
Women” (2004).
22 The Doe Run Company 2007 mine
rescue results
Gray Team:
Maroon Team:
Wayne Marlin (captain), Ken Wood, Charlie Walker,
William Johnston, Larry D. Barton, Kenny Sherrill, Randal Hill
and Garry Moore, Jr.
Steve Setzer (captain), Shawn Pratt, Luke Davis, Keith Markeson,
Andrew Hampton, Richard Dickerson, Jerry Laramore, Carl Mann
and Ricky Martin
Results from the 25th Annual Southeast Missouri
Mine Rescue Contest:
Results from the 25th Annual Southeast Missouri
Mine Rescue Contest:
• Fifth place, Field Competition
• William Johnston, Randal Hill and Kenny Sherrill:
Third place, First Aid Contest
• Garry Moore Jr.: First place in the BG4 Benchman
Contest with zero discounts* (This was his second
consecutive win at the UMR contest.)
• Ken Wood: First place in the Multi-Gas Bench
Competition, with zero discounts*
• First place, Field Competition
• Also judged: “Best In-State” Team
• Luke Davis: Second place in the Multi-Gas Bench
Competition with only two discounts*
• Ricky Martin: Fourth place in the BG4 Benchman Contest
Hutchinson, Kan., Mine Rescue Contest:
• Second place overall, and awards in every category
• First place in the Gas Bench Contest
• Second place in the First Aid Contest
• Third place in the Field Competition
• Fourth place in the BG4 Competition
For preparation, Doe Run’s Mine Rescue Teams train eight
New Iberia, La., Mine Rescue Contest:
• Second place overall
• Carl Mann: Third place in the BG4 Benchman Contest
Larry Hampton and Danny King serve as team trainers for the Doe Run
Mine Rescue Teams.
*“Discounts” is a mine rescue term used to reflect the number of incorrect
answers on written tests and the number of errors made during the mock mine
disaster competition. With numerous problems to solve on and off the field,
a score reflecting “zero” discounts is a highly respected achievement among
mine rescue competitors.
“What many people don’t know is that lead mining is far different
hours monthly. They’re drilled on emergency scenarios using
than coal mining,” said Greg Sutton, mine manager at SEMO
the most current technology available. The regimen increases
and an industry veteran of more than 20 years. “Our mines consist
to 40 hours monthly during competition season, which sharpens
mainly of dolomite, a rock with inherent geologic properties
skills and brings rescuers together to share best practices.
that make it strong and supported in most cases.”
In fact, as some of the most recognized and skilled in the nation,
Doe Run’s careful, methodic mining practices ensure the
Doe Run’s Mine Rescue Teams continued to garner awards in
naturally stable environment and integrity of the mine are
2007. For instance, at the University of Missouri-Rolla’s (UMR)
not disrupted. SEMO uses the room-and-pillar mining method,
mine rescue competition, both Doe Run teams and team members
in which rock pillars (up to 35 feet wide and 120 feet tall)
won several top awards. (See awards above.)
support the ground above.
Prevention through technology
With six active mines and 200 employees per shift, Doe Run
relies on a naturally stable environment, proactive safety
Doe Run further secures the mine ceiling (known as a “back”),
by installing 5- to 8-foot-long “roof bolts” with steel plates,
each supporting 18 tons of rock every 6 feet.
initiatives, engineering controls and more than a century of
Doe Run’s expertise is shared with universities to help
expertise to create one of the safest mining environments
educate future mining professionals. In 2007 alone, groups
in the world.
from Washington University in St. Louis, the University of
Missouri-Columbia, Indiana University, Southern Illinois
University Edwardsville, Northwest Missouri State and Iowa
State, to name a few, toured the SEMO mines.
23 2007 Report to Our Communities
the art of
Lead may be one of the heaviest
elements found on the periodic
table, yet a key step in extracting
lead from ore requires the
metal to be floated on bubbles.
That’s right — bubbles.
Unearthed lead ore undergoes crushing
and grinding processes to reduce it to a
fine material, much like sand. This material
then enters the “flotation circuit.”
There, in flotation tanks, tiny air bubbles
are introduced. A chemical known as a
reagent is added to the mixture. The
reagent — xanthate in this case —
serves as a collector, bonding to the
tiny lead particles and lifting them to
the surface, where a bubbly froth forms
floating metal
and is skimmed for final processing of
the lead. Any remaining materials, such
as dolomite, sink to the bottom of the
flotation tank.
“Flotation is similar to what happens
in a washing machine, when laundry
detergent latches on to particles of dirt
and lifts them away from clothes,” said
John Boyer, general mill manager at
Doe Run. “But in our process, we are
actually retaining the lead particles —
it’s the equivalent of collecting the dirt
and throwing the clothes away.”
Lead isn’t the only metal to undergo
flotation. Zinc and copper are also
commonly separated this way at
Doe Run’s four mills.
In 2007, Doe Run developed an
innovative copper flotation circuit at its
Sweetwater Mine and Mill. The circuit
includes several novel processes that
allow it to operate more efficiently than
other copper circuits in the industry.
To create this new circuit, team members
used parts from mills that were no longer
operating and from existing circuits that
had excess capacity. The project was
completed ahead of schedule and
under budget.
“The team was willing to take a chance
in the creation of this circuit, and the
hard work has truly paid off,” Boyer
said. “Sweetwater previously didn’t
have a copper circuit, so we were
required to haul the ore to another
mill for processing. With this new
equipment, we are able to generate
copper concentrates on site for sale
to customers.”
Additionally, remote mining allows
Doe Run to return to areas of the mines
once considered “mined out.” Valuable
ore left in the pillars is extracted as
miners work their way out, called
“retreat” mining.
Through people and technology, SEMO
has demonstrated a successful equation
for mine safety.
Employees also work closely with educators and students on
“I am proud and honored to be a part
projects that improve industry safety. For example, Doe Run
of the safety success that Doe Run’s
is working with UMR on a research project that monitors
mining operations are known for,”
ceiling movements at Fletcher Mine. Doe Run provided a
said Bob Roscoe, vice president —
grant to fund the project, slated for completion in 2008.
mining and general manager at SEMO.
Doe Run also utilizes “remote mining,” which was developed
in the 1980s and increased in use around 1991. By equipping
a miner with a unit that allows remote operation of a 25-ton
loader, blasted ore can be safely excavated from hundreds
of feet away.
“Technology has come a long way, but our people are the very
core of the equation. They make the difference.” 24 The Doe Run Company building knowledge through
community
education
By Angie Nations
Some of the
most advanced
technologies on the
planet, including computers and cell
phones, get their start in Doe Run’s
In addition to educating teachers,
Doe Run shares its knowledge on
lead-acid battery recycling through
a featured section in the ninth-grade
textbook “Global Science: Energy,
Resources, Environment.”
mines. We’re proud of what we do, and
Recognizing the need to help support
it’s rewarding to share our knowledge.
our future miners and engineers, we
Here’s a look at just a few examples:
provide valuable skills and a way to
save for college through our summer
Our widely popular Minerals Education
and semester break internship programs.
Program provides K-12 students with
In 2007, nearly 60 students participated
interactive opportunities to learn about
in these paid opportunities.
the minerals we use in our everyday
lives. In one program, for example,
students learn about mining and minerals
The company also offers numerous
Top: At teachers’ requests, Doe Run Minerals
Education Teams travel to dozens of schools each
year, educating nearly 3,000 students annually.
Bottom: Minerals Education Team members Angie
Nations (pictured), Pat Mayfield and Sandy Burkes
spent time in Casa Grande, Ariz., in 2007 to conduct
“birdseed mining” with Stanfield Elementary School
second-graders. Here, students identify Missouri’s
Viburnum Trend on a U.S. map.
scholarships for students in engineering,
chemistry, geology, mining and
efforts. By sharing our earth science
geophysics programs. Scholarships
knowledge in the classroom, our
are available for students attending
minerals education team members are
institutions such as the University of
accomplishing several goals, including:
To share this program with educators
Missouri-Rolla, Mineral Area College
supporting the Missouri Standards and
around the Midwest, we participate in
in Park Hills, Mo., and Jefferson
Grade Level Expectations, engaging
the annual Missouri Minerals Education
College in Hillsboro, Mo.
students in science through fun and
through “chocolate chip cookie mining.”
In another, participants use minerals to
create toothpaste.
Foundation workshop. At the workshops,
hundreds of K-8 teachers acquire
curriculum ideas for mineral and rock
identification, environmental initiatives
and everyday uses for minerals.
Mine tours may be made available for
education, industry-sharing and research
initiatives. Doe Run also supports and
participates in various public events, such
as the Missouri Department of Natural
This past year, I spoke at the 16th annual
Resources’ free “Fall Rocks!” event at
National Minerals Education Conference
the Missouri Mines State Historic Site.
in Bloomington, Ind. The conference
brought together industry professionals
to share experiences and provide
innovative approaches to minerals
and earth science education.
Our commitment to our operating
communities includes supporting
education in various ways, including
financially and through our volunteer
competitive activities, bringing the
importance of rocks and minerals
in our lives up close and personal
and promoting an awareness of the
many exciting and challenging careers
as scientists. Angie Nations serves as community
relations manager for The Doe Run
Company and directs the company’s
popular Minerals Education Program.
For more information about the program,
e-mail: [email protected].
25 2007 Report to Our Communities
2006 Toxic
Release Inventory
what is the TRI?
SEMO (Total releases in pounds)
Materials
The TRI, or Toxic Release Inventory, was initiated under Title III of the Superfund
Amendments and Reauthorization Act (SARA) of 1986. TRI requires that companies
annually report to the federal and state governments the disposal or release of
specific materials listed as “toxic chemicals.” This also covers waste management
activities, including recycling. On the opposite page are The Doe Run Company’s
submissions to the Environmental Protection Agency (EPA) for 2006. The 2007 data
will be available at www.doerun.com by July 15, 2008. Please note that all releases
reported on Doe Run’s TRI are regulated under current federal and state law.
Why do the amounts vary by facility?
The amounts vary because of the size of the operation, the processes used, the
various levels of natural minerals in the materials processed and the emissions
from each operation. Large-volume, low-toxicity materials such as mine tailings
and smelter slag account for more than 98 percent of all TRI submissions for
The Doe Run Company. These materials are stored on Doe Run property
following state and federal guidelines.
Air
Land
Water
Totals
Antimony
—
—
—
—
Arsenic
—
—
—
—
Cadmium
—
—
—
—
Chromium
—
—
—
—
Cobalt
—
—
—
—
2,062
7,143,490
1,095
7,146,647
—
—
—
—
Copper
Dioxin
Lead
44,347 33,123,448
9,290 33,177,085
Nickel
—
—
—
—
Silver
—
—
—
—
Sulfuric Acid
—
—
—
—
Zinc
Totals
9,116 23,541,638
21,774 23,572,528
55,525 63,808,576
32,159 63,896,260
Herculaneum (Total releases in pounds)
Materials
Air
Land
Water
Totals
Aluminum
141
2,099,374
—
2,099,515
Why are some substances listed for certain locations
not listed at other locations?
Antimony
199
72,706
—
72,905
Arsenic
248
54,529
20
54,797
According to guidelines established by the EPA for nearly 650 chemicals and
metals covered in TRI reporting, companies must determine, for each chemical
or metal used in their process, whether the use or manufacture of that chemical
or metal equals or exceeds established threshold values. Only those that exceed
threshold values are reported.
Cadmium
1,024
9,103
123
10,250
—
—
—
—
Why are there such large amounts released to land?
The very nature of metals extraction by mining and smelting operations results in
large volumes of residual materials, which are reported under the TRI. However,
due to the low toxicity of these residual materials, they have been exempted from
hazardous waste regulations by Congress.
Virtually all of Doe Run’s reported “releases” to land represent materials that are
kept in regulated, contained storage or disposal areas such as our permitted slag
storage areas and tailings impoundments. These materials aren’t actually “released”
to public areas, but rather stay on Doe Run’s private property.
When materials are disposed of through off-site, EPA — and state-approved landfills,
under the TRI reporting requirements, the materials are considered “released” to
the environment.
Chromium
Cobalt
49
Copper
758
Dioxin
209,029
209,078
181,764
182,566
44
—
—
—
—
56,838
2,104,380
1,092
2,162,310
Nickel
184
20,089
1
20,274
Silver
—
—
—
—
Sulfuric Acid 512
—
—
512
7,188,766
399
7,194,624
Lead
Zinc
Totals
5,459
65,412 11,939,740
1,679 12,006,831
BRRD (Total releases in pounds)
Materials
Air
Land
Water
Totals
Aluminum
—
—
—
—
Antimony
285 277,961 233
278,479
Arsenic
144
19,854
72
20,070
—
—
—
—
1,340
—
—
1,340
Cadmium
Chlorine
Why aren’t there reports for your Glover or St. Louis sites?
Chromium
—
71,244
—
71,244
The Doe Run Company suspended production at its Glover smelter on Dec. 1,
2003. Therefore, there were no reportable releases from that site in 2006. At the
company’s St. Louis headquarters and at historic sites, no active production is
taking place. Therefore, no reports are required at those locations.
Cobalt
—
—
—
—
Copper
—
—
—
—
—
—
Dioxin*
Lead
5*
5*
8,390
1,499,007
467
1,507,864
Nickel
—
—
—
—
Silver
—
—
—
—
Zinc
—
—
—
—
10,159
1,868,066
772
1,878,997
Totals
*In grams
26 Doe Run Headquarters
1801 Park 270 Drive, Suite 300
St. Louis, MO 63146
Buick Resource Recycling Division
HC1 Box 1395
Boss, MO 65440
SEMO — Mining and Milling Division
P.O. Box 500
Viburnum, MO 65566
Glover Smelting Division
Route 1, Box 60
Annapolis, MO 63620
Herculaneum Smelting Division
881 Main Street
Herculaneum, MO 63048
www.doerun.com
The Doe Run Company