air land 2002 Annual Report to our Community water
2002 has been another outstanding year for our employees. Through the dedication, expertise and commitment to excellence of our staff, Doe Run s Resource Recycling Division processed 10.5 million batteries recovering and recycling more than 400 tons of lead per day. Mike Sankovitch, General Manager
1 Message to our Communities The Doe Run Company is pleased to share with our communities a report on our 2002 activities and accomplishments. As a natural resource company focused on environmentally sound mineral production, recycling and metals fabrication, Doe Run is North America s largest integrated lead producer and second-largest total lead producer worldwide. Here in Boss, Mo., Doe Run s is proud to be the largest lead recycling facility in the world. As a lead recycling facility, our operation recovers and recycles lead and other materials from discarded products such as the batteries that start our cars or power our nation s fighter jets; lead-lined TV and computer screens; lead products that protect us from x-rays; as well as used film from the medical industry. 2002 has been another very productive year for our employees. Through the dedication, expertise and commitment to excellence of all our people, Doe Run s processed 10.5 million batteries recovering and recycling more than 400 tons of lead per day. For the fourth time in our history, we exceeded 750,000 work hours without a lost-time accident. Additionally, for the first time in Doe Run history, our facility has achieved an average blood lead level for employees below 20 micrograms of lead per deciliter of blood. These accomplishments as well as others have contributed to our ability to provide more than $563,229 in local property taxes and $9,737,780.92 in salaries and wages. As always, our impact on our community and environment is of paramount concern to all of us. We re pleased to share that once again we were well within the state specifications for air, water and hazardous waste. Finally, we want to recognize the support of our local communities in helping us achieve our goals. We encourage and appreciate your open communication with our employees and management team. We welcome you to visit with us and tour our facility. We hope you ll continue to let us know how we re doing and what we can do better for the Resource Recycling Division and its surrounding communities. Yours truly, Michael Sankovitch General Manager 573-626-3495 msankovich@doerun.com Message to our Communities
Bill Martin and Sheila Martin REVERBATORY FURNACE OPERATOR, EIGHT YEARS OF SERVICE MAINTENANCE ENGINEERING CLERK, FOUR YEARS OF SERVICE One of five married couples working for Doe Run, Bill and Sheila Martin make a great team. A reverb operator with a knack for crossword puzzles, Bill encouraged his wife to apply for a position in the maintenance department. When their work schedules coincide, they often share lunch together. Outside of work, Bill is an avid fisherman and accomplished woodworker, and Sheila co-directs children s church and teaches vacation Bible school.
2 3 2002 Annual Report to our Community Who We Are Doe Run staff members are a group of close-knit specialists committed to our work, co-workers, families and communities. Each of our employees contributes to our collective goals in their own unique ways. Bill and Sheila Martin are just two of 268 employees who care about their company and their community. What We Do and How We Do It Located in the rolling hills of southeast Missouri in the small town of Boss, Doe Run operates the world s largest recycling lead smelter. Our smelter recovers and recycles products that contain lead and other materials producing lead bars, blocks and billets sold to companies requiring this natural resource for products such as car batteries, TV and computer screens, lead crystal and more. In 2002, we recycled 205,000 tons of batteries, representing approximately 10.5 million batteries. These batteries, along with other recycled products enabled us to recover and refine 152,888 tons of lead in 2002, just 4,676 tons short of our all-time record of recycled lead. To accommodate future anticipated production increases, the applied to the Missouri Department of Natural Resources for an air permit which would allow a 25 percent increase over the current allowable production levels. This application was under review at the end of 2002.
Quality Performance In addition to a strong production year, Resource Recycling Division maintains its ISO 9002 designation. Only companies that maintain stringent commitment to quality in their operations can earn ISO certification. Resource Recycling Division (RRD) Lost-Time Injury Rate for 2002 10.0 Average Lost-Time Accidents per 200,000 hours worked 8.0 6.0 4.0 2.0 0.0 Similar Industries RRD Safety Performance BUICK FACILITY Once again for the fourth time in our 11-year history, our facility reached 750,000 hours worked without a lost-time incident truly a remarkable achievement for every single employee. Resource Recycling Division s safety record consistently ranks well ahead of industry standards.
4 5 Along with recycling lead, our facility recovers and recycles a variety of materials including tin, antimony, steel, copper, as well as the plastic from battery casings, battery acid and separator material contained within batteries. From these we produce recycled lead, plastic and a form of sodium sulfate used in the paper pulp, detergent, glass and other industries. In addition to the products recycled from batteries, a growing concern is lead waste from the electronics industry. Electronic devices such as computer monitors and televisions contain Cathode Ray Tubes (CRTs). A typical computer CRT may contain one to 11 pounds of lead. In many communities across the U.S., Canada and Europe regulations banning landfill disposal of CRTs are either in place or under consideration. In 2002, approximately 76 million CRTs were sold in North America and forecasters predict there will be hundreds of millions of CRTs in need of recycling in the next few years. Doe Run has been successfully recovering and recycling lead from CRTs since 1991. In total, recovered 239,000 tons of material in 2002 that might otherwise have ended up as waste in a landfill. Assuring Quality In addition to a strong production year, maintains its ISO 9002 designation. Only companies that maintain stringent commitment to quality in their operations can earn ISO certification. The company is audited annually to ensure full compliance with all standards. Working Safely and in Good Health Perhaps the most rewarding achievement for the division was the dedication of our staff to working safely. Once again for the fourth time in our 11-year history, our facility reached 750,000 hours worked without a lost-time incident truly a remarkable achievement for every single employee. As an incentive to work safely, all employees share in a financial reward at various milestones of no lost-time incidents. s safety record consistently ranks well ahead of industry standards. In addition, the employees of have the lowest blood lead levels in the history of the facility, representing an 8 percent reduction over 2001. In the month of September, we also achieved a facility first an average blood lead level under 20 micrograms of lead per deciliter of blood.
160,000 140,000 120,000 100,000 Lead Production Tons 80,000 60,000 40,000 20,000 0 1996 1997 1998 1999 2000 2001 2002 Ambient Air Quality The facility s 2002 ambient air levels for lead place it just under one-third of the National Ambient Air Quality Standard. Average Ambient Air Lead Levels Micrograms of lead per cubic meter of air 2.00 1.75 1.50 1.25 1.00 0.75 0.50 0.25 0.00 1996 1997 1998 National Ambient Air Quality Standard 1999 2000 2001 2002
6 7 Concern For Our Environment As many of those who live, work and raise families in the community of Boss and other Missouri towns, we are concerned about keeping our environment clean. In 2002, 90 percent of our new capital budget was spent on environmental projects. The installation of three new baghouses in 2002 enabled better collection of dust and fugitive emissions within the facility to prevent dissipation into the environment. Air Since 1991, when began operating, it has complied with federal clean air standards. Today, we continue to produce emissions levels far below the standard set by federal and state regulations. The facility s 2002 ambient air levels for lead place it just under one-third of the National Ambient Air Quality Standard of 1.5 micrograms of lead per cubic meter of air. Land is extremely proud of the contribution it makes to recover and recycle products (i.e., lead, plastic) that might otherwise find their ways to landfills. Through our recycling facility, we are able to recover, recycle and distribute for re-use 239,000 tons of used batteries and other materials. The facility s only waste product, slag a glassy and sand-like material is produced in a manner that renders it as a non-hazardous waste. This material is sent to a landfill for non-hazardous material. The makes ongoing aesthetic improvements to our facility and surrounding property. Repainting of buildings, landscape improvement and general property maintenance are a few ways we work to improve our facility.
Water Water is a vital additive to the process at. Each year we use millions of gallons of water for production. During the process, the water we use comes in contact with lead and therefore must be treated and cleaned at our on-site facility. Much of the production wastewater used is recycled back into the production process. Federal regulations require that any water discharged back into the environment must meet stringent standards for metal content. The facility was well within these standards in 2002, and we continue to sample, analyze and monitor water at discharge sites as well as in nearby streams to ensure water quality. We did experience one stormwater-related overflow that had to be reported to the state. In order to further improve the quality of our discharge water, we plan to install a constructed wetlands area to remove salt from the water. Concern For Our Community Our nearly 265 employees live in the communities surrounding our. We re proud to be part of the community. In 2002 we again participated in the Mineral Education Workshop sponsored by the Missouri Minerals Education Foundation (MMEF). The workshop provides information and resources for primary and middle school teachers about the natural rock and ore found in Missouri, how and what minerals are mined, and the value and uses of Missouri s minerals. This year the workshop instructors helped to educate more than 60 teachers from across the state. also supports secondary education through scholarships to the Mineral Area College and the University of Missouri-Rolla. In 2002, we were again pleased to host a variety of on-site tours for the public, the media, and local and state officials, to adopt a two-mile stretch of Highway KK and to donate our time, talents and support to local school programs, local athletics and other local agencies. During 2002, paid $9,737,780.92 in salaries and wages and paid $563,228.70 in property and real estate taxes.
8 9 Resource Recycling Toxic Release Inventory Data Amounts Reported for 2001 (in pounds) Materials Air Land Water Totals Antimony 992 542,191 233 543,416 Arsenic 445 25,589 120 26,154 Chromium 11 11 Dioxin <1 <1 Lead 22,400 3,275,263 37 3,297,700 Totals 23,837 3,843,053 390 3,867,280 Toxic Release Inventory Data
Doe Run Headquarters 1801 Park 270 Drive St. Louis, MO 63146 HC1 Box 1395 Boss, MO 65440 www.doerun.com