The Doe Run Company :: NEIGHBORS

neighbors
The Doe Run Company’s 2005 Report to Our Communities
Beyond Metal
Trading Places
Welcoming Wildlife
into Your Life
Off-the-Clock
Employee Profiles
Learn more on page 2
2 Beyond Metal
Getting involved is just
as important OFF the
clock as ON
10 Twilight Town
14 Stewards of
the Forest
16 Purely Lead
What comes to mind
when you hear the
word “pure?”
20 Trading Places
Doe Run partners with
Peruvian counterparts for
educational exchange
22 A Terrible Thing
to Waste
Recycling the lead-acid
battery
28 Lead at Work
32 TRI Report
On the Cover
Whether at halftime,
pre-game or post-game,
Ed Fadler, human
resources and safety
assistant at Doe Run’s
Buick Resource Recycling
Division, embraces the
time-honored role of
football flagman for
the St. Louis Rams.
Hundreds of Doe Run
employees volunteer
time off the clock to go
“beyond metal” and
contribute to their local
communities.
message from the CEO
Welcome to Neighbors, our yearly report to our stakeholders.
We appreciate your time to learn more about our people, our
products and our operations, which produce high-quality metals
for enhancing daily life.
This is my last opportunity to communicate with you in this fashion.
I am retiring fully in April, ending my 39 years in the mining and
minerals processing business. For the last 21 years it has been my
privilege to serve Doe Run. I firmly believe that I am leaving the
company in strong and capable hands, and that the company will
realize a brilliant future. I thank each of you for your continued
support and interest in what we do.
The Doe Run Company is proud to be a global provider of
premium lead and associated metals and services. On the following
pages, please take time to read about these important and unique
products in “Lead at Work” and discover some of the overlooked,
everyday uses of lead. We are committed to producing and recycling
these products in a safe and environmentally responsible manner.
In “A Terrible Thing to Waste,” you’ll learn about techniques that
make our recycling operation innovative, efficient and
environmentally sound.
If mysteries intrigue you, delve into “Twilight Town” to explore
the depths of our mines, then meander to “Stewards of the Forest”
and let us walk you through our forestry management programs.
Along the way, check out our short features called “Off-the-Clock”
and meet some of our most valuable resources — our employees.
Like you, we at Doe Run care about our families, our communities
and sharing what we have with others.
Finally, as we strive to make tomorrow better than today, your
viewpoints, and those of our neighbors are important. I invite your
comments and feedback on our operations, this report or any
other subject. Please contact me by e-mail at ceo@doerun.com
or by mail at the address on the back cover.
Thank you and best wishes,
JEFFREY L. ZELMS
Vice Chairman, President and Chief Executive Officer
1
letter from the COO and general managers
Thanks for reading Neighbors, The Doe Run Company’s 2005 Report to Our
Communities. We’re pleased to share some new, interesting information with our communities,
employees, customers and friends. In addition to the accomplishments of our Missouri operations, you may also learn about Doe Run’s company-wide commitment to offering time,
talent, expertise and support “Beyond Metal.”
2005 presented both challenges and successes. We’ve introduced lean principles, improved
our recycling techniques, excelled in customer service and earned our 23rd Sentinels of Safety
Award. While we hope the stories in Neighbors will shed light on the importance and scope
of our operations, we also trust you’ll find helpful tips for everyday use — such as
“Welcoming Wildlife into Your Life” on page 15 and “Give it a Jump” on page 26.
Neighbors also includes environmental performance information in the Toxic Release
Inventory (TRI) tables on the inside back cover.
For more information on these or related subjects, visit our Web site at www.doerun.com.
Again, we appreciate your support and welcome your comments as you review Neighbors.
Best wishes for a prosperous year!
Sincerely,
JERRY PYATT
Vice President,
Domestic Operations and Chief Operating Officer
jpyatt@doerun.com
GARY HUGHES
General Manager,
Herculaneum Smelting Division
ghughes@doerun.com
BILL LANE
General Manager,
Southeast Missouri Mining
and Milling Division
gmsemo@doerun.com
STEVE ARNOLD
General Manager,
Buick Resource Recycling Division
sarnold@doerun.com
BOB ROSCOE
General Manager,
Southeast Missouri Mining
and Milling Division
gmsemo@doerun.com
2
beyond
metal
Getting involved is just as important
OFF the clock as ON
Tracing its roots back more than 100 years,
If you look deeper into the Doe Run
Doe Run has long been known for the metals
organization, you’ll see hardworking, dedicated
it produces, along with its adherence to safety,
people who are helping to make tomorrow better
quality and purity standards. But defining
than today. But who are they? Some you may
Doe Run as a leader in the metals industry is
have already met.
just scratching the proverbial metal surface —
what lies beyond that?
People like Mike Yount, Brushy Creek hoist
engineer (featured on page 13), make this
Missouri-based company special. He’s logged
hundreds of hours constructing intricate theatre
sets that have decorated high school stages. His
contributions help the productions come to life.
off-the-clock
employee profiles
Hundreds of Doe Run employees volunteer time off the clock to go “beyond metal” and
contribute to their local communities. Learn more about how the following four employees
connect with their communities.
7
Steve Stack
SECONDGENERATION
LEADER
13
Mike Yount
BLUEGRASS AT
BRUSHY CREEK
17
Tim Streisel
PAINTBALL OF
YOUTH
25
Ed Fadler
RAMS FLAGMAN
(featured on cover)
The Doe Run Company’s 2005 Report to Our Communities
Supporting our
neighbors
Doe Run’s commitment to helping the
communities in which it operates extends
near and far. In total, Doe Run provided some
$12,000; 26,000 pounds of donated goods;
and 1,500 tons of timber (to replace downed
utility poles) for Hurricane Katrina and Rita
victims in 2005.
Community
involvement
BRRD donated funds to help the Quad County
Volunteer Fire Department purchase smoke
detectors for area residents as an extension of
the facility’s internal safety program. Pictured left
to right: Larry French, BRRD human resources and
safety manager; Clyde Hayes, Doe Run retiree and
fire board secretary; Karen Willhite, fire district
secretary; and John DeNoon, fire board president
and BRRD senior production coordinator.
Educational
support
Through its Minerals Education program,
Doe Run helped educate hundreds of children
in 2005. Presenters use math and science
fundamentals to help students prepare for
Missouri Assessment Program (MAP) testing,
a performance-based series of tests required
each spring.
3
4
Committed to the community
Nearly all people spend their off-hours making life
more meaningful, and so do employees of The
Doe Run Company. On a corporate level, Doe Run
leverages its global reach to provide valuable
philanthropic services and goods to Missouri residents and those living far away — where residents
benefit from Doe Run’s mission to improve the
communities in which it does business.
Hurricanes Katrina and Rita are just two
examples. After enduring one of the largest natural
ABOVE Thanks to the efforts of BRRD and SEMO
employees, more than 26,000 pounds of clothing,
goods and toys reached Theodore, Ala. Doe Run
provided the fuel and time of the driver to make
the 1,400-mile round-trip a success.
RIGHT Held each fall, Old Miners’ Days provides
a chance for Viburnum, Mo., residents to celebrate
the community’s rich mining history with parades,
crafts and food. Doe Run offers free mine tours as
part of this community celebration. Pictured are
(left to right) Olivia Morton, Elizabeth Olkkonen
and Leah Gibbs.
BELOW Learning is fun! After a hands-on session
led by Doe Run’s Minerals Education Team, Dylan
Johnston was eager to show his knowledge of
some of the Earth’s most valuable resources.
disasters in American history, neighbors in the
Southern states needed help more than ever in
2005 — and Doe Run employees stepped up.
In early September, Doe Run encouraged its
employees to support hurricane victims in any
way they could. Employees began by offering
monetary donations that, in turn, Doe Run committed to match. In just two weeks, hundreds of
employees raised more than $12,000. Doe Run
doubled it, contributing a total of $24,540 to
the American Red Cross.
The Doe Run Company’s 2005 Report to Our Communities
But the buck really didn’t stop there. Employees
5
To learn more about the Tree of Life campaign,
of Doe Run’s Southeast Missouri Mining and
contact Tonnie Jackson, vice president, Iron
Milling Division (SEMO) and Buick Resource
County Hospital District, and campaign
Recycling Division (BRRD) extended the effort,
chairperson, at
working with a local insurance agency to collect
573-546-7065
TREE OF LIFE CAMPAIGN
over 26,000 pounds of donated goods, clothing
or tonniejackson@
and toys. In addition, Doe Run supplied the
yahoo.com.
Iron County Hospital District
573-546-7065
tonniejackson@yahoo.com
tractor/trailer, driver and fuel to deliver the
When off the
supplies to a distribution site in Alabama. SEMO
clock, numerous Doe
also tapped its Forestry Management Program to
Run employees use what they’ve learned on the
provide 1,500 tons of timber to replace downed
job to help educate and guide young people.
utility poles in Louisiana and Mississippi.
Many employees lead scouting troops, teach
“When we heard the news about the storm,
Sunday school or baby-sit. Doe Run’s Steve
we feared for the victims, some of whom we
Stack, manager of North American sales (high-
know as friends, vendors and customers,” said
lighted on page 7), uses his spare time to help
Barbara Shepard, Doe Run vice president of
steer local youth in the right direction. Sure, he
human resources and community relations.
often steers the bus too — as his church youth
“It’s not unusual for Doe Run employees to go
group bus driver — but he also does much more.
above and beyond expectations when it comes to
“The kids and I have really connected,” said
helping others. We’re proud of them for donating
Stack. “We support their lives outside of church,
and were equally happy to match their donation.
often attending school sporting events, plays
We wish residents the best as they rebuild
and concerts. It’s all part of building a trusting
their communities.”
relationship with the kids. Everything we can
Although corporate donations such as
Doe Run’s significantly helped the American
Red Cross, help is still needed. To donate, or learn
more about efforts in your community, visit
AMERICAN RED CROSS
1-800-HELP-NOW
www.redcross.org
do to be present for these kids helps shape them
into better people, plus it’s a lot of fun!”
Research supports Stack’s vision. In fact,
mentoring enables kids to help overcome life
www.redcross.org or
challenges. If you’d like to help young people
call 1-800-HELP-NOW.
in your area, try Big Brothers Big Sisters, the
Doe Run’s Glover
oldest and largest
Division has been on
youth mentoring
BIG BROTHERS BIG SISTERS
care and maintenance
organization in the
1-888-412-BIGS
www.bbbsa.org
status since December 2003. But that didn’t
United States. To get
stop it from continuing to support Doe Run’s
involved or find a
minerals education program and donating to
little brother or sister near you, visit
the Iron County Tree of Life campaign for the
www.bbbsa.org or call 1-888-412-BIGS.
construction of a new hospital in Pilot Knob, Mo.
6
The Doe Run Company’s 2005 Report to Our Communities
Like Big Brothers Big Sisters, Doe Run
SEMO employees also shared their expertise
believes in the power of sharing knowledge
in 2005, hosting various student groups in its
with the next generation. Through its Minerals
underground mines. As part of the University
Education program, Doe Run helped educate
of Missouri-Rolla’s (UMR) Summer Explosives
thousands of children in 2005. Presenters use
Camp, college students received a behind-the-
math and science
scenes look at SEMO’s underground blasting
MINERALS EDUCATION
fundamentals to help
operations and experienced a live blast — a means
Angie Nations
mineralseducation@doerun.com
students prepare for
of accessing deposits of galena, the mineral that
Missouri Assessment
comprises lead.
Program (MAP)
“We were thrilled to give students their first
testing, a performance-based series of tests
real-life mine experience,” said Doe Run’s
required by the state each spring. Doe Run’s
Greg Sutton, general mine manager at SEMO.
musical trio, the Doe-Re-Mi’s, provides enter-
“Educating young minds about the importance of
tainment via the Rockin’ to the Rhythm of
the Earth’s natural resources is a vital component
Minerals song-and-dance trivia performance.
in maintaining our way of life. We take pride in
To learn more about bringing Minerals Education
our operations and want to share this appreciation
to your school, contact Angie Nations, Doe Run
with future mining engineering professionals.”
community relations manager, at
Doe Run also provides educational working
mineralseducation@doerun.com.
opportunities. Several divisions, including SEMO,
the Herculaneum Smelting Division and BRRD,
When off the clock, numerous Doe Run employees
use what they’ve learned on the clock to help
educate and guide youngsters.
Doe Run’s Minerals Education Team travels to
numerous Missouri schools each year, providing
children with math and Earth science fundamentals to help prepare for standardized testing.
7
off-the-clock
employee profiles
Steve Stack
SECOND-GENERATION LEADER
Doe Run’s Steve Stack, manager of North American sales, spends
more time volunteering in one week than most people do in an entire month. When
he’s not fulfilling customers’ multi-metal needs at Doe Run’s headquarters, Stack
dedicates 10 hours each week as an adult counselor for the Webster Hills United
Methodist Church youth group (see photo below).
A second-generation Doe Run employee also serving as a second-generation youth
counselor, Stack uses skills learned from watching his parents serve as group leaders in
his first church, Grace United Methodist Church (Sullivan, Mo.), to help a new generation
build character, confidence and faith.
So far, his methods are working. Stack’s knack for reaching students has helped triple the
group’s size in just two years. Stack says he takes his “life-forming” experiences with him,
whether on the clock or off.
“I never underestimate
someone and what they may
have to offer,” Stack explains.
“Both professionally and
personally, I’ve learned to
navigate life’s many twists
and turns and appreciate the
people and cultures that I
encounter along the way.”
give students the opportunity to save for college
Meanwhile, BRRD also hosted several fresh
while learning valuable skills during summer
faces over the summer, including four college
student work programs.
interns (junior and senior engineering majors)
“My brother and I participated in the program
and eight student workers. “We work with the
during high school, and like many of today’s
interns on projects that add value to their own
participants, we sought full-time employment
educational development and to our customers,”
here after college,” said Rick Batts, Herculaneum
said Steve Arnold, BRRD general manager. “We
human resources manager. “As a leading commu-
build such great working relationships that many
nity business, we consider it our mission to help
students return year after year — we take that as
students build a positive work ethic.”
a compliment.”
peering into
the future
The National Mining Association
(NMA) identifies minerals exploration as key to keeping the U.S.
economy strong and stable. As
demand for metals and minerals
increases, Doe Run’s commitment
to the industry’s future is evident
in its scientific exploration of ore
deposits and mining areas.
Doe Run Exploration
“Forcing U.S. mining operations
Geologist Bruce Ahler
offshore increases our growing
reliance on imports of important
minerals that we can mine domestically,” said NMA President
and Chief Executive Officer Kraig R. Naasz. “We can unlock the
great wealth of our mineral-rich lands for the benefit of all.”
For Doe Run, potential mining areas are not only in Missouri,
but also in other areas that are rich in natural metal deposits.
The Viburnum Trend in Missouri has one of the largest deposits
of lead ore known in North America.
“Our goals for exploration are to keep current mines in
production and to discover new ore bodies for future growth,”
explained Don Taylor, Doe Run’s vice president, exploration.
“In 2005 we made great progress in accessing a new ore body
known as RC-West Fork, about 4,000 feet from the existing
Fletcher Mine. It’s exciting to find future treasures near an existing operation because we can develop it entirely underground.”
The 15 Doe Run geologists charged with exploring for
mineral deposits use some of the most scientifically advanced
techniques available to identify promising ore bodies. The
“geophysical” approach releases a modest electric current into
the ground. Receptors, strategically placed at specific intervals,
receive the charge and provide geologists with information to
gauge amounts of metal deposits in the area. More conventional
methods include “coring,” in which cores of 2-inch-diameter
rock samples are extracted from the ground and checked for
mineral content.
“As geologists, we love our jobs because we act as the tip of
the dog’s nose,” said Taylor. “When we’re successful,
people go to work, and our efforts create jobs
and economic benefit for the entire area.”
cr
Around the globe, world
leaders are calling on big
businesses to step up their
role in reducing world
poverty. In a Sept. 14 issue
of the Financial Times, the
United Nations stressed
that the world can’t solve
poverty without working
markets. The meaning?
Businesses must partner
with local organizations
to build infrastructure
governments cannot. For
eight years, The Doe Run
Company has practiced
a similar policy in Peru
through its subsidiary,
Doe Run Peru.
Spending more than
$6.5 million on vocational
training, agricultural assistance, refurbishing schools
and establishing public
parks and facilities, Doe
Run Peru’s investments in
sustainable development
The Doe Run Company’s 2005 Report to Our Communities
9
change
eating
Peruvian communities benefit
from hands-on approach
projects have benefited
more than 100,000 people
in La Oroya, Peru, and surrounding communities. 2005
brought additional initiatives to
improve agriculture and livestock practices, develop and
conserve energy and promote
public transportation.
In April, Doe Run Peru
again sponsored the 7th annual
High Andes Agricultural Fair,
where farmers from more than
20 communities shared best
practices, evaluated genetic
improvements in livestock
and met potential buyers.
The company also provided
experts on farm management
and livestock acquisition.
Partnering once again with
agricultural groups, Doe Run
Peru helped remove more
than 60 years of accumulated
waste, mud and debris from
a river channel in the Andes
Mountains near La Oroya,
dramatically increasing the
supply of water to 15,000
farmers living near the Mantaro
River. This is the second such
cleanup project since Doe
Run Peru arrived in 1997.
Agriculture Minister Manuel
Manrique said in an interview
with Peru’s Radioprogramas
radio network that the work
would not have been possible
without the company’s
participation.
“This is work that the
Ministry of Agriculture could
not do, so we got help from
Doe Run, which, with great
pleasure, agreed to this collaboration,” Manrique said.
“This is an indication that
concerted efforts between
the public and private sectors
can benefit the farmer directly,
especially when mining and
agriculture work together.”
With help from Doe Run
Peru, including donating
1.7 acres of land and providing
heavy machinery, the City of
La Oroya also built its first bus
terminal in 2005.
In remote areas of Peru,
Doe Run Peru is working with
partners to bring affordable,
environmentally friendly
electricity to isolated communities. The project uses hybrid
solar power and lead-acid
batteries to replace diesel
generators to provide the
region with an economic and
eco-friendly source of energy.
“It’s been extremely
rewarding to work alongside
our neighbors and improve
their quality of life,” said
Dr. Juan Carlos Huyhua, vice
president and manager of
operations of Doe Run Peru.
“Money alone just isn’t the
answer. By sharing best business practices, information,
technology and expertise, we
can help communities develop
stable businesses and achieve
greater prosperity and
independence.”
In addition to these successes, Doe Run Peru has
invested more than $140 million on environmental projects
at its facilities. Ongoing
progress reports are posted
at www.doerun.com.
10
twilight
tow
Deep beneath the Earth’s surface,
a bustling “underground town” makes
up the vast operations of The Doe Run
Company’s Southeast Missouri Mining
and Milling Division (SEMO).
Working hundreds of feet underground requires
creative lighting; light sources are mounted on
hard hats, stands and various equipment. Large
floodlights often provide the bulk of illumination
needed by mining crews.
The Doe Run Company’s 2005 Report to Our Communities
n
11
How’s the weather down there?
A mine is not unlike a natural cave. Typically a pleasant 65˚F, a mine is
rocky and damp. Doe Run’s Missouri mines may be as deep as 1,250 feet
underground, where it is impossible to know what weather conditions
are like on the surface (except by telephone
or two-way radio).
Modern mining operations are fully outfitted
Mines are typically 65˚F
and are as deep as
1,250 feet underground.
with computer networks, air, power, water and
telephones. As in any corporate environment, the tools of the trade are
present, and communication is a key component. A direct line to the surface
is not only a safety measure, but part of the daily process of underground
operations. At SEMO there are about 200 miners underground at a time.
Mining crews are split to cover operations
seven days per week.
Since there are no underground restaurants,
At SEMO, there are about
200 miners underground
at a time.
miners bring lunch to work every day. Lunch
rooms are provided — a clean, well-lighted place for the underground
community to wash up, take a seat and enjoy a meal with co-workers.
Miners use this time to eat and re-energize for the rest of their shift.
It’s difficult to tell from the surface, but mines are large underground
structures that extend for miles. Four of Doe Run’s six mines — Casteel,
Buick, Brushy Creek and Fletcher — are interconnected by 18 miles of
roadway running north and south. From the main road, there are hundreds
of side roads, providing access throughout the four-mine structure. To get
from place to place, miners use tractors, pickup trucks and other vehicles.
The mining is done room-and-pillar style, which means large square
rooms are excavated, leaving pillars of rock to support the ceiling.
Outside of the central shop areas, large floodlights, lights on machines and equipment and
lights affixed to miners’ hard hats create a
“twilight effect.”
Four of Doe Run’s six mines
are interconnected by 18 miles
of roadway running north
and south.
12
The Doe Run Company’s 2005 Report to Our Communities
Each day, millions of gallons of groundwater are pumped to the surface
to keep the mines dry. This water would otherwise fill the mines. Ventilation
is of utmost importance; about 3 million cubic feet per minute of
About 3 million cubic feet per minute of
clean air is circulated for the health and
comfort of the underground workforce.
clean air is circulated for the health and comfort of the underground workforce.
What goes down…
Millions of dollars worth of equipment operates underground including
hydraulic drills, trucks, loaders, charging rigs and scalers — all of which
are disassembled to transport down the shaft and then reassembled
underground. For this reason, any mechanical repairs are done
in an underground maintenance shop. On the surface, additional
support equipment is used to transport ore to the smelter.
Busy places, the Doe Run mines extract nearly 25,000 tons
of lead-bearing ore every day.
Doe Run’s mining operation is one of the largest
employers in Southeast Missouri, providing jobs to over
700 individuals.
Safety before all else
Safety is the watchword among all employees. Each day
the Doe Run mines use the theme of safety to underscore every
communication. Constant commitment to the care of one another
Doe Run’s underground
employees enjoy many of
the same conveniences as
on the surface, including
restrooms, eating areas,
roadways and walkways.
is a hallmark of Doe Run employees. Doe Run’s SEMO mines have
received the Sentinels of Safety Award 23 times in the last 33 years. The
Sentinels of Safety Award is an annual honor that is co-sponsored by the
National Mining Association (NMA) and the U.S. Department of Labor’s
Mine Safety & Health Administration (MSHA). Sentinel Awards recognize
mine operations that work the most hours in a year without a single lost-time
incident in its mining classification.
Doe Run is one of the largest employers in
Southeast Missouri, currently providing jobs to
over
individuals.
700
13
off-the-clock
employee profiles
Mike Yount
BLUEGRASS AT BRUSHY CREEK
When Brushy Creek Hoist Engineer Mike “Slats” Yount
isn’t operating a hoist, he’s pickin’ and grinnin’ with
friends. Yount, a musician in his spare time, picked up
his first instrument when he was 7 years old. He began
to play guitar and moved on to the banjo, mandolin and
the hammered dulcimer, easing into a style of music
known as “progressive bluegrass.” Yount released a
CD, “Mountain Air,” with self-styled instrumentals,
which he sold at the Bixby Store in Southeast Missouri,
a regular eatery for Doe Run employees.
Yount’s talent doesn’t end at making music; he
makes instruments, too. An accomplished woodworker,
Yount builds hammer dulcimers, autoharps and banjos,
which he sells or trades for other instruments, all by
word of mouth.
Yount says his attention to detail and the careful skill required in woodworking
came from his early experience in the company’s carpentry shop. “Those Old Lead
Belt guys taught me that everything had to be precise and that quality was always
valued over quantity.”
Five out of the six SEMO mines have worked accident-free in
the past year, making 2005 the best safety year yet, and the most
Doe Run’s mines extract nearly
25,000 tons of lead-bearing
ore every day.
hours accumulated without a lost-time accident since 1997. The
Brushy Creek Mine accumulated 235,434 hours without a lost-time accident,
earning the 2004 Sentinels of Safety Award. The Fletcher Mine also received
special recognition for exceptional safety performance in 2004.
Doe Run attributes safety success to consistency in safety
procedures and programs. One such program, the Incident Review
Doe Run SEMO mines have received
the Sentinels of Safety Award 23 times
in the last 33 years.
Program, requires every incident, regardless of how small, to be
reviewed carefully, then rigorously evaluated for improvement opportunity.
Miners also credit MSHA’s recent SLAM Risks program, reminding employees
to Stop, Look, Analyze and Manage. This provides a process to prevent injury
and accident by identifying hazards and managing risks.
14
The Doe Run Company’s 2005 Report to Our Communities
stewards
of the
fore
Far more than a steward of the
valuable resources underground,
SEMO is also responsible for managing
some of the Earth’s natural resources above
ground — trees.
In fact, as part of Doe Run’s Forestry
Management program, SEMO has planted
more than 1,250 acres of pine over the last
decade. Now that’s a lot of trees — more than
1,000 football fields-worth!
Seeding is one of the many steps involved
in forestry management, a complex and
ongoing process, which includes harvesting,
thinning, planting and naturally seeding forests
for optimal output.
“Timber is a renewable resource that needs
to be managed in order to provide an effective
environment for wildlife habitats, forest products
and natural water filtration,” explains Dave
To better manage your own
“personal forest,” Doe Run’s
Forestry Management
Coordinator Dave Patterson
provides the following tips:
Doe Run selects the best type of tree for each
acre of ground (above). The SEMO operation’s
mines and mills (below) produce valuable ore,
which is used by the Herculaneum smelter to
produce materials vital to daily life.
To establish a thriving forest near your
home, first consult the Conservation
Department for information on the
most suitable vegetation for your needs
and location.
st
Patterson, Doe Run’s Forestry Management
Coordinator. “As part of the process, we
work with nature to grow the best-suited
tree for each acre of ground, improving the
forest’s quality and ensuring its longevity
for future generations.”
According to Patterson, one of the most
important steps in forestry management is
harvesting trees. Doe Run selects timber that
is over-mature, crooked, diseased, insectinfested or in need of thinning. Once
harvested, this Doe Run timber can be
found in many Missouri products, including
red oak cabinetry, pallets and railroad ties;
pine fence posts, structural lumber and
log homes; white oak wine barrels; and
oak flooring.
Before planting, thin out thick patches
of trees to allow for more sunlight
penetration to the soil.
Still not growing? Encourage new sprouts
by disturbing soil through disking (turning
the soil) or burning. But before you start,
you MUST provide local authorities with
your plans and location and take the
proper precautions, such as ensuring
adequate supervision and tools to maintain control of the fire. (Some counties,
for example, allow controlled burns,
while others require permits.)
welcoming
wildlife into
your life
1
2
3
4
Backyard wildlife includes welcome
species such as birds, bats, small
mammals, butterflies and other insects.
Creating a healthy habitat for these
creatures in your backyard can
provide an exciting front-row seat
for experiencing nature.
Here are four tips to make your
yard wildlife-friendly:
Create your guest list — which
creatures do you want to attract? When
drafting your plans, be sure you’re not
inadvertently attracting unwelcome
backyard inhabitants.
In the beginning — start with the basics
by providing a source for water and a wide
variety of plants and trees to provide a
range of available animal shelter.
No dirty birds — birdbaths attract
feathered friends; if you decide to install
a birdbath, consider providing a heated
model so your yard will be the meeting
place for winter flyers.
Create a “love nest” — hedges, rock
piles and other low-lying shelter are
conducive to wildlife reproduction
(and baby creatures are cute, too).
16
The Doe Run Company’s 2005 Report to Our Communities
le
purely
What comes to mind when you
hear the word “pure?” Chances are
lead,” said Gary Hughes, general manager of
you don’t immediately think of lead; but for
“Our lead concentrates are purer, and through
those working for Doe Run, purity and lead
customized smelting and refining we are able
go hand-in-hand. Why? Because Doe Run sets
to deliver a superior product.”
the standard for lead purity.
Historically “Doe Run” lead was recognized
the company’s smelter in Herculaneum, Mo.
Doe Run’s Missouri lead ore (galena) contains
some zinc (sphalerite) and copper (chalcopyrite)
for its consistent purity. Thus, customers began
and trace amounts of silver, all of which are
referring to high-purity lead as “doe run” lead.
separately recovered. Concentrates from other
This standard of quality continues today.
“Customers across the world know precisely
what they’re getting when they specify Doe Run
The Herculaneum smelter delivers
99.99% pure lead in everything from
32/1,000-inch sheets of rolled lead
to 1-ton blocks.
17
off-the-clock
employee profiles
Tim Streisel
PAINTBALL OF YOUTH
ad
ore bodies often contain other metals more
difficult to remove. Taking advantage of what
nature has to offer, the smelter adds value for
its customers by delivering 99.99 percent pure
lead in everything from 32/1,000-inch sheets
of rolled lead to 1-ton blocks.
While “pure” lead is a Doe Run hallmark,
alloyed products are also important to
Doe Run’s customers. Customized alloyed
products containing antimony, aluminum,
selenium, calcium, tin and silver bring special
characteristics to the product. For example,
The saying goes, “You’re never too old
to have a happy childhood.” Tim Streisel
agrees. At 38, this Herculaneum electrical
engineer is no kid, but if you visit him on
weekends, you might discover his “hidden
child” within. Suited-up in paintball combat gear and an approved mask, Tim has
been playing paintball for nearly three years.
Introduced to the sport by his brother-inlaw, a former Marine, Tim’s comrades and
foes include deputies from local sheriff
departments, firefighters and other
members of the Jeffco Paintball Group.
“It’s all good fun,” Streisel said. “And
although it’s not a sport for younger kids,
we get to act like kids when we play.” A
strong advocate of safety and teamwork,
Streisel says, “If you wander off on your
own, you’ll be taken out in five minutes.
But in teams, you can accomplish much
more. We set goals, define responsibilities
and communicate our intentions.” Sounds
like a good strategy for work or play!
18
calcium increases the life of a car battery and
is necessary for the production of the “maintenance-free” battery. Tin increases hardness and
strength and gives the alloy the ability to bond
with other metal such as steel and copper.
Practice Makes Perfect — The Herculaneum smelter,
known for its high-quality lead and customized lead
alloys, closely monitors the purity of its products
through frequent test sampling. Here, an arc-spark
spectrophotometer is used to analyze metallic lead
and lead alloys.
Overall, Doe Run produces 55 different
alloys in 75 various shapes and weights. “Our
customers have come to count on us to provide
specialty alloys to help them improve their
products,” explains Jose Hansen, director of
global metal sales. “So while we do not produce
automotive batteries, our metals help make those
batteries last longer.”
Tin increases lead’s hardness
and strength, and gives the
alloy the ability to bond with
other metal such as steel
and copper.
Doe Run’s industry
leadership attracts
international visitors
eager to learn from the
company’s experiences. In February, the World
Affairs Council-St. Louis brought visitors from
Ethiopia, Ghana, Nepal and Serbia to the
Herculaneum smelter and other U.S.-based
industries to learn how companies work with
community groups, businesses and local
government to provide products and services
in an environmentally responsible manner.
Pure, not simple
Lead production dates back to Roman times;
however, today’s techniques are regulated by strict
environmental standards. These standards are monitored by Doe Run, the Environmental Protection
Agency (EPA) and the Missouri Department of
going the
extra mile
When you manufacture a product, people
expect it to meet their quality standards and
to arrive on time.
At mid-year, Doe Run was recognized by EnerSys, a leading
manufacturer of industrial batteries, for outstanding communication
and the ability to overcome seemingly insurmountable obstacles
to deliver critical products. In Kansas, EnerSys’ Hays plant manufactures large reserve power batteries for telecommunications,
uninterruptible power supplies and utility applications.
By communicating quickly and openly with the Hays plant
regarding production delays resulting from storm damage and
repairs at the Herculaneum facility, Doe Run personnel Deb Medley,
Laurie Cole and Gwen Stover helped the Hays plant meet its
customers’ needs on time. EnerSys attributed Doe Run’s ability
to meet its urgent product needs to the dedication and candid
communication of Doe Run customer service personnel, along
with their counterparts at the Hays plant.
The Doe Run Company’s 2005 Report to Our Communities
Natural Resources (MDNR) and include permitted
out. We expect to maintain our momentum as we
emissions to the air, water and land.
seek ways to further improve our performance.”
In 2005, the company complied with all work
In January 2005, independent tests verified
outlined in the smelter’s State Implementation
that Doe Run is meeting the stringent EPA
Plan, a step-by-step program designed to keep
Maximum Achievable Control Technology
the area around the facility in attainment with the
(MACT) standards for lead emissions.
National Ambient Air Quality Standards (NAAQS)
The Glover Smelting Division, offline since
as set by EPA. Earlier in the year, data from the
December 2003, continued to meet and exceed
Broad Street monitor nearest the smelter regis-
all environmental and safety requirements.
tered an average level above the standard,
thereby preventing the company from attaining
the standard for the first three quarters. The seven
remaining monitors, including two monitors along
Main Street, the monitor at the high school and
the monitor at City Hall, were well within the
standard. By the end of 2005, all eight air
monitoring stations were in attainment with the
NAAQS. The company continues to work with
EPA and MDNR to develop strategies to further
reduce air emissions.
“Our team in Herculaneum made incredible
progress this past year,” added Hughes. “By
overcoming challenges and duplicating successes,
we are demonstrating how teamwork and a
dedication to quality yield success inside and
Celebrating success
The Herculaneum smelter celebrated several
milestones this year. In June, the plant marked
one year without any lost-time incidents. In
October, the office staff reached 1 million hours
worked without a lost-time accident, and in
November, the maintenance department reached
600,000 work hours without lost time. The
Herculaneum smelter also earned the Business
Partner of the Year award from the Dunklin R-5
School District. The primary smelting division
donated $5,600 in scholarships to the Dunklin
R-5 and South Iron school districts, Arcadia
Valley High School and Jefferson College.
19
20
trading
p
Ever heard of the popular
TV show Trading Spaces?
This year, Doe Run did a
little trading of its own.
Trading places, that is.
This spring, Doe Run
Peru served as a classroom
where six University of
Missouri-Rolla (UMR)
students observed its
operations, environmental
improvements and
community involvement.
“I’ve had the privilege
of teaching numerous
students that later found
successful careers at
Doe Run,” explained
Jerry Tien, project leader
and associate professor
of mining and engineering
studies at UMR. “We
picked Doe Run Peru
because I knew from my
colleagues that it would
provide a chance to put
the students’ knowledge
to work beyond borders.”
Beyond borders — A subsidiary of The Doe Run Company, Doe Run Peru’s
La Oroya metallurgical complex and Cobriza mines served as veritable
classrooms last summer, offering UMR students and other visitors from around
the world the chance to see its multi-metal mining and smelting operations.
The Doe Run Company’s 2005 Report to Our Communities
21
laces
Doe Run partners with Peruvian counterparts
for educational exchange
Doe Run provided travel
expenses and accommodations
for the trip. In turn, students
compiled ideas for improving
Doe Run Peru’s efficiency and
operations.
“We’re known for innovation,
so we’re constantly looking for
ways to improve our facilities,”
said Bob Roscoe, co-general
manager of SEMO and Doe Run
Peru’s Cobriza Mining Division.
“We were thrilled to participate
in a project that could enhance
our facilities and enable potential
industry leaders to experience
mining on a global scale.”
Doe Run Peru Metallurgical
Engineer Godofredo Oporto
traded places the opposite
direction. This summer, he and
his family visited Doe Run’s
Missouri operations. While
touring the Herculaneum
smelter and Buick recycling
facility, the Oportos observed
recent upgrades to the facilities
and the processes involved in
refining, producing and recycling
domestic lead.
“In Peru, engineering is viewed
with the same respect as practicing
medicine is in the United States,”
explained Oporto. “Mining is such
an important part of our Peruvian
culture that we were thrilled with
the chance to get an up-close
perspective of how our industry
varies around the globe.”
In Peru, engineering is
viewed with the same
respect as practicing
medicine is in the
United States.
“We were thrilled to participate in a project that
could enhance our facilities and enable potential
industry leaders to experience mining on a
global scale,” said Bob Roscoe.
22
Civil rights pioneer Arthur Fletcher once aptly said
that a mind is a terrible thing to waste. In the minds of
more than 270 employees at the world’s largest single-site lead recycling
facility, this same philosophy applies to lead-bearing products and millions of
spent lead-acid batteries — lead that might otherwise go to waste, literally.
In Missouri, The Doe Run Company operates the Buick Resource
Recycling Division (BRRD), now a leader in lead recycling. Back in 1991,
the company realized an opportunity to turn discarded products into
demanded products. Recognizing that Americans toss more than 230 millions tons of trash each year and that of those tons, 70 percent could be
reused, reconfigured or recycled, BRRD saw a promising business model.
With a little forethought, valuable materials such as metal, glass and paper
can become alternative products. Furthermore, recycling waste material into
a terrible thing to
raw material is one of the best ways to preserve natural resources and
ensure that future generations aren’t faced with shortages — or worse,
depletion of valuable products.
“It’s such a shame to throw away items like lead-acid batteries, which
still contain valuable materials that can be recycled for reuse,” explained
Steve Arnold, general manager of BRRD. “By recycling for reuse, we’re
able to solve problems for our industry, the battery manufacturers
Americans toss more than 230 million
tons of trash each year, of which
70% could be reused, reconfigured
or recycled.
and consumers in general. We’re proud to serve this multi-faceted
role; it’s just good environmental stewardship.”
Lead recycling helps reduce potential environmental impacts
of landfills and incineration while adding economic benefits including jobs
and tax revenues.
How does trash turn into economic impact?
A big part of the answer lies in your automotive battery. The No. 1 leadbearing product remains the lead-acid battery. Batteries power more than
600 million passenger vehicles globally, plus heavy equipment and backup
power sources for hospitals, telephone companies and airports. In 2005,
BRRD processed 410 million pounds of material, including 13.5 million
lead-acid batteries.
The Doe Run Company’s 2005 Report to Our Communities
23
waste
Recycling the lead-acid battery
The No. 1 lead-bearing
product remains the
lead-acid battery.
24
The Doe Run Company’s 2005 Report to Our Communities
Using innovative techniques, BRRD recycles, processes or reuses tons
of materials normally considered waste. In addition to batteries, the division
processed 950,000 pounds of lead bullets and shot; 16 million pounds of
lead-containing glass from approximately 800,000 cathode ray
75% of the lead recycled at BRRD
comes in the form of automotive and
industrial batteries.
tubes; and 1.5 million pounds of lead-based paint chips from
abatement projects.
Battery recycling also yields a useful byproduct, sodium sulfate,
which is used in the laundry detergent, paper and glass manufacturing
industries. And thanks to new drying equipment, BRRD was able to
increase sodium sulfate production to 1,200 tons per month, up from
700 tons per month last year. This new equipment also boosted the
recovery of sulfur from the recycling process and further reduced air
emissions. The facility remained below all National Ambient Air Quality
Standards, including those for lead and sulfur dioxide.
Interestingly, lead-acid batteries have a longer life, lasting an average
of 51 months (more than four years) without service needs, according to
the Battery Council International. Still, 75 percent of the lead recycled at
BRRD comes in the form of automotive and industrial batteries. Here’s
a quick look at how it’s done:
Arrive and unload — Batteries arrive at BRRD
in Boss, Mo., by truck. They are unloaded and placed
into the “battery bunker.” Approximately one-third
of all batteries that are received still have an electrical
charge on them, so the batteries are picked up by a
loader and are placed into a stainless steel shredder.
Shred and break down — The whole battery is
broken in the shredder, and the battery acid (a weak
Mission control — Within
the BRRD control room,
employees monitor the
battery separation and
salt production processes
— two crucial steps in
recycling America’s most
recycled product, the
lead-acid battery.
sulfuric acid) is drained and collected in safe storage tanks. (This acid is
used later in the process.) The shredded batteries are placed in a vibrating
feeder that feeds a conveyor belt into the hammer mill. The hammer mill
pounds the battery into smaller pieces.
Separate the pieces — Each lead-acid battery contains a set of metal
grids, lead post, plastic components and a lead sulfate paste. The paste is
removed by washing through a set of screens for further processing. After
going through the hammer mill, the pieces go into a “hydroseparator,”
25
off-the-clock
employee profiles
Ed Fadler
RAMS FLAGMAN
When the Rams arrived in St. Louis in 1995,
Ed Fadler took notice and took the field. Fadler,
Buick Resource Recycling human resources and
safety assistant and Rams season ticket holder,
crafted his own tailgating flag and decided to
run it in the stands to boost morale for the new
team. After a cameo on the JumboTron and a
visit with Rams officials the following Monday,
he went to work as an official “flagman” for the
team. Ten years later, Fadler, and now his two
sons, trek to the Edward Jones Dome each
home game to play the time-honored role of
football flagmen; bearing flags for pre-game,
halftime, post-game and community events.
“The first game after Sept. 11, 2001, the
Rams contacted me about carrying the American
flag. Since then I’ve gotten to take one of my
sons on the field with me. Before this year’s season, officials called me about
three new flags and wondered if both sons would help. It’s been an amazing
family experience. I just wish we could win more games and make the playoffs!”
where water separates the heavier elements. All of the lead and metal
components sink to the bottom and the floating items are skimmed off
and sent to outside recycling facilities.
Melt the metal and refine — The metallic portions of the batteries,
including grids and posts, are then melted in a rotary melter. Lead from the
rotary melter and furnaces are mixed with other metals to produce alloys that
are cast into various weights, shapes and sizes in the refinery. Lead alloys are
combinations of metal that yield different physical and chemical properties.
This finished lead product is shipped to customers around the globe.
Create usable salt — While the lead components are being processed,
the battery paste is de-sulfurized through a chemical reaction with sodium
carbonate. This yields a lead carbonate in a sodium sulfate solution. The
lead carbonate material is removed by passing the material through a
26
give it a
jump
Jump. The perfect verb when
you’re faced with a dead car
battery — you’re apt to jump up and down
in frustration, and ironically, “jump starting” is
just the thing to re-energize your tired battery.
Lead-acid batteries deliver strong current
during the few seconds it takes to start an
engine. Before calling for help, try these tips for
jump starting made easy, courtesy of Battery
Council International (www.batterycouncil.org).
Here are some tips to consider:
Top quality — Use “jumper” cables that are
12 or 15 feet long with heavy-duty clamps.
Investigate — Ensure your battery isn’t frozen
or damaged. Check for ice crystals in the
electrolyte solution under the fill caps.
Turn off — Position the ignition of the deadbattery vehicle to “OFF.”
Safety — Wear eye protection (like sunglasses)
and don’t lean directly over either battery.
Once you have cables and a donor battery
nearby, begin the jump start process.
TO STARTER
While the donor vehicle has its
engine running:
1. Connect the positive clamp (red) to the
positive terminal of the dead battery.
2. Connect the other end of the positive
cable to the positive terminal of the
donor battery.
3. Connect the negative cable (black) to the
negative terminal of the donor battery.
4. Make the final connection of the negative
cable to the dead car’s engine block, away
from the battery in order to ground the
charge. Wait a few minutes to let the weak
battery recharge slightly.
Start the engine of the dead vehicle, let it
idle for a few minutes, then remove the
jumper cables in reverse order of connections.
(Consult your owners’ manual for specific
information.)
TO STARTER
BOOSTER CABLE
2
1
+
+
DONOR
VEHICLE
BATTERY
DEAD
VEHICLE
BATTERY
-
3
TO GROUND
BOOSTER CABLE
TO GROUND
4
ENGINE BLOCK
OR FRAME
The Doe Run Company’s 2005 Report to Our Communities
27
“filter press.” The remaining sodium sulfate solution is then crystallized to
produce a high-quality salt that is marketed to the laundry detergent, paper
and glass industries.
Heat the remaining paste — The remaining lead carbonate
paste is heated at extremely high temperatures in a reverberatory
BRRD processed 410 million pounds
of material, including 13.5 million
lead-acid batteries.
furnace to produce pure lead and a high-antimony waste product
called slag. This slag is further heated in a blast furnace to recover even
more antimonial lead. What remains is a small quantity of secondary slag,
a glassy sand-like material that encapsulates silica, calcium, iron and less
than 2 percent lead. This slag is transported offsite for disposal.
“It’s a process in which very little goes to waste,” said Arnold.
Nothing wasted
When Doe Run embraced lean manufacturing principles this year, the division
was able to double expected results. Lean manufacturing, simply put, is a
systematic approach to
identifying and eliminating
waste (non-value-added
activities) through continuous improvement by flow
of product at the request of
the customer.
“In the face of increased
production costs — including energy and reagents —
we were able to achieve
notable business success,”
said Arnold. “We led the
company’s efforts on lean
manufacturing, finding areas of improvement that would benefit both our
employees and our community. Through the process, we learned how the
little things can add up to fantastic rewards.”
Special recipe — Grids
and posts from lead-acid
batteries are melted in
the rotary melter (above)
and cast into new lead
alloys that are later used
in the manufacturing of
everyday products.
28
lead
at
work
We don’t often think of lead,
even though it invisibly surrounds
us in our daily life. Yet, lead makes
activities and tasks we often take
for granted possible — and
safer. How is lead used in
everyday products?
Let’s take a look.
The Doe Run Company’s 2005 Report to Our Communities
29
the actual suspended bridge.
the lead in the computer moni-
In seismic isolators, lead is used
tor facing you is keeping you
as a damper between spring
safe from harmful gamma rays
layers of rubber and steel. When
and helping you see the images
7:00 am
the earth shakes during both
more clearly. As you begin
minimal and large earthquakes,
your work day, the lead solders
Start the car and head to work.
the isolator bearings allow the
throughout your computer’s cir-
Yep, there’s lead in that battery
bridge to slide up to 10 inches
cuit board are holding strong,
under the hood. According to
from its original position, and
enabling your computer to send
the U.S. Geological Survey,
return to that position.
electronic data back and forth.
lead-acid batteries account for
The global communication,
more than 90 percent of the
7:45 am
efficiency and simplification
lead used in America today.
As you pull into the under-
of tasks made possible by
Without these batteries, the
ground parking garage, it
computers and the use of the
commute to work would be
probably has never occurred
Internet are, in part, all made
very difficult for most people.
to you that lead is here, too.
possible by the use of lead in
Architects and builders rely on
our everyday work tools.
Since natural resources are
finite, it’s fortunate that lead
lead for a variety of functions.
from car batteries and other
Lead sheet is used as a mem-
10:30 am
products can be recycled.
brane in structures that begin
From your office window,
Doe Run’s Buick Resource
underground, providing a barrier
you can glimpse the church on
Recycling Division is the largest
that is watertight and durable.
the corner. The morning sun
single-site lead recycling facility
catches your eye as it reflects
in the world. Impressively, lead
off a stained glass window.
has the highest recycling rate
Stained glass, particularly those
of all industrial metals used
pieces created for cathedrals,
today. In fact, more than
have traditionally been created
97.1 percent of lead-acid
using lead.
8:00 am
reached its heyday in the 1930s
role in the structural integrity
When you arrive at your office,
when Tiffany lamps were the
of U.S. landmarks, such as the
you sit at your desk and turn on
rage. Most stained leaded glass
Golden Gate Bridge. Here,
your computer. While you’re
today is antique and some is
seismic isolator bearings are
checking your e-mail, you can
quite valuable. Other collectibles
placed on the approaches to
take comfort in knowing that
containing lead that sometimes
batteries are recycled.
Lead also plays a significant
Leaded and stained glass
Test Your Minerals Know-How
are you minerally challenged?
How much do you know about minerals? The following questions,
courtesy of the Mineral Information Institute (www.mii.org), will test
your minerals know-how, while reminding you of the important roles
minerals play in our daily lives.
An automobile is made by combining
at least how many different minerals
and metals?
A. 13
C. 42
B. 39
D. 50
A No. 2 pencil contains how many
ounces of lead?
A. 1/2
C. 2
B. 1
D. Zero
How many tons of aggregates (uncrushed
gravel; crushed gravel, stone or rock;
sand; or artificially produced inorganic
materials — all principal materials used
in concrete) are needed to rebuild one
interstate highway mile?
A. 25,000
C. 65,000
B. 45,000
D. 85,000
5
6
7
8
The 200 million computers used in the
United States today contain more than
how many different minerals and metals?
A. 15
C. 37
B. 26
D. 48
What percentage of America’s electricity
is provided by burning coal?
A. 19%
C. 51%
B. 35%
D. 63%
Today, 97 to 98% of what metal is being
recycled for a second use?
A. Aluminum
C. Gold
B. Copper
D. Lead
True or False: While our mineral intake
represents only about 0.3% of our total
intake of nutrients, they are so important
that without them we wouldn’t be able
to process and use the other 99.7% of
what we eat.
9
10
What is Missouri’s state mineral?
A. Granite
C. Chalcopyrite
B. Zinc
D. Galena
Lead is used in which of the
following products?
A. Automotive batteries
B. Television, microwave and
computer glass
C. X-ray and gamma radiation shielding
D. Nuclear medicine storage containers
E. Soundproofing material for construction
F. Backup power sources
G. Ammunition
H. All of these and more
ANSWERS: 1D, 2B, 3D, 4D, 5C, 6C, 7D, 8 True, 9D, 10H
1
2
3
4
Each American will need approximately
how many pounds of minerals, metals
and fuels during his or her lifetime?
A. 25,000 lbs
C. 617,000 lbs
B. 100,000 lbs
D. 3.6 million lbs
The Doe Run Company’s 2005 Report to Our Communities
appear on the auction block
signs of your child on the day
include the finest lead crystal
he or she is delivered.
goblets and fine china glazed
31
Tonight’s news carries a
story about NASA and the
Hospitals, doctors’ offices
space program. The Space
with lead. The china dishes used
and dental offices have been
Shuttle relies on lead alloy
as official White House dinner-
using lead for years. Many of
solder; in fact, the entire space
ware are glazed with lead.
these buildings have lead in
program uses lead products
the walls as a protective shield
because no other means of
from radioactive rays. Lead
connecting transistors and
aprons have long been used
other electronic components
for dental and other X-rays.
is as dependable. Lead glazes
Nuclear medicine has
protect electronic microcircuits
necessitated the use of lead in
from atmospheric corrosion,
1:30 pm
containers to transport and store
a must for safe space travel.
substances that are radioactive
There has not been another
You get a call from your
and could be harmful to patients,
more reliable resource found to
mechanic, saying that new
professional staff and the public.
replace lead for these purposes.
tires have been mounted on
The need for these medicines
your spouse’s car. Did he
has created a new category of
mention that the tire counter-
lead-enhanced supplies such as
balance weights used to make
syringe shields and carriers that
your car ride smoothly are
use lead to offer hand protection,
made of lead?
lead-shielded waste containers
3:00 pm
You and your spouse are
expecting your first child.
and even lead bricks for temporary or emergency storage or
shielding situations.
10:30 pm
Your head is heavy and the
pillow soft. Before nodding off,
Today will be your first “look”
7-10:00 pm
at your baby. You leave the
Your day at work is over.
giving the lead solder in small
office early so you can both
It’s time for some prime-time
electronics a second thought.
view the ultrasound where a
TV — your favorite part of the
But that’s okay, because we do.
layer of lead is also present.
day surely must be lead-free?
Sleep well!
Lead will be instrumental today
Not so. That high-definition
when you find out whether
television you bought last year
your child is a boy or a girl,
just before the Super Bowl
and may monitor the vital
wouldn’t be possible if it
weren’t for lead.
you set your alarm clock, not
32
what is the
toxic release
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 their disposal
or release of specific materials listed as “toxic
chemicals.” This also covers waste management activities, including recycling. On this
page are The Doe Run Company’s submissions
to the Environmental Protection Agency (EPA)
for 2004. 2005 data will be available on our
Web site at www.doerun.com on July 1, 2006.
Please note that all releases reported on
Doe Run’s TRI are regulated under current
federal and state law.
Herculaneum 2004 Toxic Release Inventory
(Total releases in pounds)
MATERIALS
AIR
LAND
WATER
TOTALS
Aluminum
140
1,900,987
—
1,901,127
Antimony
195
707
—
902
Arsenic
244
1,782
6
2,032
Cadmium 1,017
5,602
4,490
95
Chromium
—
—
—
—
Cobalt
68
106,102
—
106,170
Copper
706
159,194
1
159,901
Dioxin
—
—
—
—
51,906
1,334,954
1,039
1,387,899
Nickel
189
21,223
—
21,412
Silver
—
—
—
—
Sulfuric Acid 505
—
—
505
237
6,584,426
Lead
Zinc
Totals
SEMO 2004 Toxic Release Inventory
5,625
6,578,564
60,595 10,108,003
1,378 10,169,976
(Total releases in pounds)
MATERIALS
AIR
LAND
WATER
TOTALS
Antimony
—
—
—
—
Arsenic
—
—
—
—
Cadmium
—
—
—
—
Chromium
—
—
—
—
Cobalt
Copper
Dioxin
Lead
138
399,766
—
399,904
4,853
7,584,224
697
7,589,774
—
—
—
—
104,968
25,906,154
8,281
18,718,440
Nickel
207
728,212
—
728,419
Silver
—
—
—
—
20,092
18,677,906
20,442
18,715,440
Zinc
Totals
130,258 53,296,262 19,937 53,455,940
BRRD 2004 Toxic Release Inventory
(Total releases in pounds)
MATERIALS
AIR
LAND
WATER
Aluminum
—
—
—
—
Antimony
401
597,766
512
598,679
Arsenic
200
18,393
94
18,687
—
—
—
—
1,260
—
—
1,260
Chromium
—
56,396
—
56,396
Cobalt
—
—
—
—
Copper
—
—
—
—
Dioxin*
5*
—
—
5*
16,016
1,379,460
139
1,395,615
Nickel
—
—
—
—
Silver
—
—
—
—
Zinc
—
—
—
—
17,877
2,052,015
745
2,070,637
Cadmium
Chlorine
Lead
Totals
*In grams
TOTALS
The Doe Run Company’s 2005 Report to Our Communities
inventory
1
(TRI)?
Why do the amounts vary by division?
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.
2
Why are some elements not reported at
certain locations?
3
Why are there such large amounts released
to land?
4
Why aren’t there reports for your Glover,
St. Louis or historic sites?
According to guidelines set by the Environmental Protection Agency (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.
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, Congress
exempted them from hazardous waste regulations.
It’s important to know that virtually all of Doe Run’s reported “releases”
to land are materials that are kept in designated disposal areas such as our
permitted slag storage areas and tailings impoundments, which are entirely
on Doe Run property.
The Doe Run Company suspended production at its Glover smelter on
Dec. 1, 2003. Therefore, there were no TRI-reportable releases from that site
in 2004. At the company’s St. Louis headquarters and at historic sites, no
active production is taking place. There are no TRI-reportable releases of any
sort at those locations.
For more information on TRI, visit www.epa.gov/tri-efdr/.
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