ILLINOIS ENVIRONMENTAL'PROTECTION AGENCY M E M O R A N D U M

DATE: H ' , June 22, 987—

TO: \^ t* Division File

PROM: Gregory W. Dunn

'-"000

SUBJECT: 0270200002 — Clinton CountyBeckemeyer/Clrcle Smelting CorporationSuperfund/HRS

3 0 198'/Program

Support Section

NARRATIVE SUWARY

Circle Smelting Corporation is located off Route 50, east of the citylimits of Beckemeyer, Illinois. The site covers the Wij, NE*s, NWV ofSection 22, Township 2 North, Range 3 West in Clinton County. Thefacility was involved in primary zinc smelting until 1962, when theplant was converted to a secondary smelting operation. Currently,the site is reprocessing selected scrap metals. Past owners includeMissouri Zinc Company, Clinton County Zinc Company, and the AmericanSmelting and Refining Company (ASARCO).

Circle Smelting filed a RCRA permit in November 1980 for waste associatedwith primary and secondary zinc alloying. The permit was withdrawnper the request of the company in 1982 after the materials on-sitewere found to be non-hazardous. The facility also has a permit fromthe Division of Air Pollution Control (027 813 AAA) for their primaryzinc and white metal smelting area of the plant.

The plant uses lead, zinc, zinc oxides, magnesium oxide, copper oxide,borates and associated iron compounds in their operations. Most ofthese compounds are blended together to form a mixture used as fertil-izer. Waste materials consist of Iron and zinc solids, dusts or powders.A site inspection on July 11, 1986 by IEPA personnel revealed a pileof materials referred to by plant workers as lead and coke wastes.A sample was taken and analyzed for lead by the EP Tox method. Theresult of the waste was 3800 mg/1 (ppm).

No documented releases of contaminants to the environment have occurredfrom this site. Sample results and nearby residents' complaints indicatesignificant problems at the site. A drainage ditch (off-site) northof the facility was sampled for total metals and EP Toxidty (for lead,zinc and cadmium only). The results showed a 7.54 mg/1 (ppm) for leadby the EP Tox method. This value is above the 5.0 mg/1 (ppm) standardset for lead to be considered a hazardous waste (Title 35, Subtitle G,page 93, Characteristics of EP Toxlcity). Air releases have not beendocumented, but air emissions from the facility have created numerouscomplaints. The complaints prompted the Illinois EPA, Division ofAir Pollution Control, to install an air monitor at the site. Themonitor has been taking air samples since March 22, 1987, with theresults of the first tests to be received shortly.

Page 2

The facility has taken action to clean portions of the site and toconform to violations noted by inspectors. Numerous scrap piles andmetal drums have been removed to metal recyclers for salvage, whilethe construction debris has been removed to an IEPA approved landfill.The waste piles and excessive amounts of fine materials on the plant'sgrounds have been removed for drying, to be sold to other companies.

The clean-up procedures have solved the immediate problem, but thelong term problems still exist. A medium priority is assigned, witha site inspection recommended. Groundwater, soil and stream sedimentsamples need to be taken with a priority pollutant analysis on each.

GWD:tk:4/22/5-2

cc: Don JosifSouthern Region

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M E M O R A N D U M

DATE: July 17, 1986

TO: Division File/*tP^"

FROM: Mike Grant

SUBJECT: 0270200002 - Clinton Co. - Beckemeyer/drcle Smelting, Inc.ILD050231976 - Compliance

On July 11, 1986, Jeff Benbenek, DAPC, and myself conducted an inspection atthe subject facility. Upon arrival we met Dave Heyer, the facility's plantmanager. Circle Smelting 1s a secondary zinc and aluminum smelter. Thefacility operations consist of several aluminum furnaces and several zincfurnaces. Associated with the smelting operations are controlling of theemissions. I.e. baghouses, and milling and screening of the by-products.

We walked through the aluminum operations and observed the aluminum potfurnaces and the aluminum sweating furnace 1n operation. The aluminumreverberatory furnace was shut down for repairs. Aluminum dross from thefurnaces 1s used to feed the rotary furnaces to recover the zinc. However,dross from the aluminum sweat furnace 1s shipped to Chicago along with thealuminum sklmmlngs for further processing. The aluminum reverberatory andsweat furnaces have been recently added to the operations. A baghouse 1s usedto collect the emissions from the sweat furnace. Mr. Meyer stated that thebaghouse has not generated much dust. He stated. 1f emptied, 1t would be lessthan one drum. These areas appeared to exhibit good housekeeping practices.

The facility's zinc operation consists of three rotary furnaces, andassociated baghouses, milling and screening operations, zinc dust blowing andtwo associated pot furnaces. However, only two rotary furnaces and themilling and screening process are currently in operation. A baghouse 1s usedon each of the furnaces. Upon Inspection, 1t was observed that the baghousewas not 1n operation. Baghouse dust was observed scattered all over the floorin the building containing Rotary Furnaces A and Z. A sample of the dust wascollected just north of the baghouse for Rotary Furnace A. As I walked out ofthe building, a similar material appeared to be spread over the groundapparently by equipment driving through the buildings and transporting thedust. A sample was collected from the ground northeast of the building. Wethen walked through the next building which contained Rotary Furnace Y. Thisfurnace was not operational as 1t was awaiting repair work. The samecondition of spillage existed 1n this area as 1n the other building.

The milling Operation Is used to crush the sklmmlngs and dross from the zincfurnaces. The baghouse dust 1s only screened since milling of this materialIs not necessary. Mr. Meyer said that the milled drosses and sklmmlngs andthe screened baghouse dust are bagged. This material 1s sold to fertilizermanufacturers. Oust was also observed on the floor in this area. A sign wasposted in this area stating "Lead Poison Area - Respirators Required". Asample was collected from the floor Just northwest of the milling operation.

RECEIVED

JUL 211986

1EPA-OLPO

0270200002 Page 2Clinton Co.Beckemeyer/drcle Smelting

We then walked around the outside areas of the facility. Along the southernportion of the facility many stacked, empty drums were observed. Mr. Meyersaid empty drums are baled 1n one of two balers, however, one of the balerswas Inoperable. The bales are sold to scrap Iron dealers. It also appearedthat from years of operation, dust is scattered on the ground throughout thefacility. As we walked the eastern portion of the facility, an area wasobserved which contained empty drums, broken concrete, piles of grey and whitedust and other nonearthen materials. This dump area was approximately oneacre in size. One sample and two photographs were taken 1n this area.

We then walked to the area on the northern portion of the facility. This areaIs similar to the dump area on the eastern portion, however, 1t 1s much largerIn size. As we walked this area eleven photographs and two samples weretaken. Drainage from the eastern area had eroded small trenches to the ditchwhich drains off-site. One sample of the soil was taken from a trench todetermine if the heavy metal contaminants expected at the facility hadmigrated off-site. We noticed a pile of black material. Mr. Meyer statedthat this was a mixture of lead and coke. A sample and a photo of this pilewas taken. He also said that a lot of this material was placed 1n this areabefore his employment with the company 18 years ago.

Since analyses were not available for the spilled sklmnrlngs, dross andbaghouse dust, a violation of 722.111 exists. These materials are exempt ifhandled properly, however the spillage 1s not. Also, apparent violations ofSection 12(d) and 21(a) of the Act were observed for the outdoor areas. Amulti-media CIL will be sent addressing the previously mentioned violations aswell as those observed by Jeff Benbenek concerning violations of the A1rPollution Control Regulations. Upon receipt of analyses of samples takenduring this Inspection, further action will be taken as deemed necessary.

MDG:pbo/0138L

cc: DLPC ColUnsvlllecc: OAPC Colllnvlllecc: DAPC Central Filecc: Regional Coordinator

RECEIVEDJUL 211986lEPA-OLPC

GLGA CHARtCS UCHT INGINIERING ASJOCIATIS. IHC

.H E. H 0 R A N D U M

DATE: October 21, 1986

TO: Office of Emergency Hanagemnt

FROM: Tom POM 11 - Colllnsvllle

SUBJECT: LPC 0270100002 - APC 027 313 AAA - Clinton County -Beckemeyer/drcle Smelting

On July 20. 1986, Ralph Foster, OEM - Duty Officer, called this writer'sresidence at 5:45 p.m. to report that a fire had broken out, and a majorbuilding at the facility was Involved. According to Foster, 400*600 tons ofzinc shavings, powder and Ingots were In storage within the building. Theresponding fire departments were reportedly using water, dry chemical/foam toextinguish the fire. Winds were generally fro* the north. This writer wasplaced on stand-by until more Information fro* the scene could be obtained.

During the phone conversation, Foster was told of the recent Inspection (July11, 1986) that took place at the facility and the extremely poor wastemanagement practices that were noted at the facility. (On August 29, 1986,the Enforcement Decision Group net and determined that the site should bereferred to RPHS-IRU for overslte of company clean-up activities. Circle'sconsulting engineer has contacted FOS - Colllnsvllle requesting clean-upguidance.)

On July 21, 1986, Joe Goodner called this regional office with additionalInformation, as well as requesting Information that 1s applicable to theChemical Safety Act. (P. A. 04-852) Per Mr. Goodner, an evacuation did takeplace effecting 7-6 person In 2-3 hones. Questions arose that Included: Oldzinc compounds drift beyond plant boundary? What kind of ealsslons weredocumented? What type of personnel protection did the firemen wear? It wasthe Initial feeling of Mr. Goodner that because of the events, this fire wouldbe classified a significant release under the Chemical Safety Act.

Chuck Trlckey (618/227-8557), a neighbor Immediately south of Circle, hadcontacted OEM - Springfield requesting samples be taken, to en Inside andoutside his home. (The Trlckey family was evacuated during the fire.) Thiswriter then contacted Mr. Trlckey to sample his residence.

This writer arrived at the site at approxloately 2:30 p.m. to sample. Mr.Trie key's major concern was the smoke/dust that occurred because of the fire.Me also voiced his desire tnat the Agency n»re closely monitor Circle, becauseof the continued emissions from the plant. Trlckey stated that smoke/dustfrom the plant Is sometimes so bad that one can hardly see the plant from hishome (a distance of ISO feet).

Three (3) samples were collected while at the Trlckey residence.

Sample II - a 3 point composite taken from the Trlckey back yard.BECEWEO

1EPA-OLPC

LPC 0270100002APC 027 813 AAAClinton CountyBeckemyer/Clrcle Sotltlng Page 2

Sample it - a 7 point composite2 points from Foster's back yard, 2 points from Foster's front yard,(Foster Is Immediately east of Trlckey's) 2 points from a garden areaeast of Foster's, 1 point from Trlckey front yard.

Sample 13 - Oust/lint samples taken froa various areas Inside the Trlckeyresidence. (Sample results are attached.)

Upon the coopletlon of obtaining samples, Mr. Trlckey complained of thegeneral air pollution violations that effect his residence. He alleged thatthe stunted com growing south of his home 1s related to emissions froa theplant.

On July 28. 1986, this writer attempted to contact Dave Meyer - Plant Managerof Circle. Meyer was not 1n, but returned ay call the following day.

Mr. Meyer was questioned about his facility's compliance wth the ChemicalSafety Act. He did state his facility had 30 full-tint employees, but didn'tknow for sure 1f he had a contingency plan adopted specifically for the Act.He requested that I contact Circle's Chicago contact Paul Garland at ImperialSmelting (312/264-5911) or Charles Llcht of Llcht Engineering (312/755-0075)for answers. It was obvious that Mr. Meyer had little, 1f any, knowledge ofthe Chemical Safety Act. Since Mr. Meyer 1s the Plant Manager, he should havesome basic Idea as to the emergency coordinator and his duties as applicableto the facility.

On July 24, 1986, Al Ripperda called this regional office to complain aboutthe facility. This writer, however, was not available. Mr. Ripperda againcalled on July 31, 1986. He stated he Is an employee of Circle that livesJust west of the Trlckey residence. He complained of the excessive amount ofsmoke that the facility was emitting the evening before. Ripperda went on tosay that the two (2) furnaces art now operational, but the crusher 1s stilldown, because of the fire. Plant personnel are trying to repair the bagger tofill customer orders.

(The operational status of the furnaces Is contrary to the letter dated July24, 1986 from Charles Llcht Engineering. Copy Attached.)

On September 10, 198G, results were forwarded to this office froa the soiltesting of July 21, 19S6. On September 11, 1986, this writer receivednotification, from OEM, that IOPH nay be Interested 1n coordinating avoluntary blood testing program for residents near the soelter. This writercontacted Beckemeyer Mayor Joe Thomas at his residence (618/227-8803) toInform Mayor Thomas of the possibility that IDPH maybe testing residents. Hewas told that IOPH should be making contact with him to outline the pendingProgram.

OCT 2 2IEPA-DLPC

LPC 0270100002APC 027 813 AAAClinton CountyBeckemtyer/Clrcle Smiting Page 3

On September 12. 1986. this writer then contacted the village clerk for namesand numbers of occupants In those hoots closest to Circle. (Copies Attached.)

On September 25, 1986* soil sampling was conducted off-site from Circle.Dennis Newoan* IEPA; Randy Marshall of MARZA Environmental Services and thiswriter were present. The sampling report Identifies sample locations. Atthis time, sample results have not been completed.

TEP:Jlr/0225L

Attachments

cc: Joe Goodner -OEM /cc: Dennis Kewman - RPMS/cc: DAPC - Colllnsvlllecc: OLPC - Colllnsvlllecc: DLPC - Division Filecc: Bruce Carlson - Enforcement

ILLINOIS ENVIRONMENTAL PROTECTION AGENCYEMERGENCY RESPONSE UNIT

INCIDENT CONTROL SHEET

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*AMKLe NUMBER :POINT OESC. : BECKEMEYERXCIRCLE SMELTING X1Q2

SUBMITTING SOURCE » :UATfe COLLECTED : 860711

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ILLINOIS ENVIRONMENTAL PROTECTION AGENCYTRANS DIVISION OF LAND POLLUTION CONTROLCODE CHEMICAL ANALYSIS FORMLAJ -

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P**« 1 of

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ALKALINITY TOTAL Jmff/l M C.CO3J - Field 505F

REDOX POTENTIAL (ailUvolU - Field 506F

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TO: Jan«« Janaien, ManagerInmedlace Removal UnitRemedial Fr.ojecC' Management SectionDivision of Land Pollution Control

FROM: Randall Marshall, Springfield SupervisorHarza Environmental Services* Inc.

YSUBJECT: Circle Smelting, 0270\00002Clinton County, Project Manager - Dennis Newman

On September 25, 1986 Dennis Nevman and I left the IEPA Office to travelto Beckemeyer, Illinois to sample soils around Circle Smelting. We net TomPovell of the Colllnsvllle Office at about 9:30. We began sampling at about10:00 and finished at about 13:30. Dennis and I arrived back In Springfieldabout 16:30.

My report on the sampling is attached to this memo.

RECEIVED

OCT 1 5 19bo'EPA-OLPC

CIRCLE SMELTING SAMPLING REPORT

On September 25* 1986 the Illinois EPA conducted soil sampling aroundCircle Smelting ia Beckemeyer, Illinois* Dennis Kevman did the actualphysical sampling with a trowel or scupola. This sampling equipment wasdecontaminated between samplings with distilled water. THe sample containerswere plastic quart jars. All samples were store in a cooler with ice.

Tom Powell of the Colllnsvllle Office served as a guide and as liaisonwith town residents whom he had contacted previously. Randall Marshall ofHarza Environmental Services took the field notes and assisted with thesampling.

Sampling was planned to occur along the eight standard points of thecompass radiating from Circle Smelting. Because only parts of the area wereaccessible to us, we used the eight compass points as an ideal to guide us Inchoosing available sampling points. Our purpose was to define soilcontamination around all sides of Circle Smelting. When we had chosen asample location. Dennis Newman would use a clean trowel or scupula to scrapeaway any surface vegetation and then would composite a soil sample from thefirst two Inches in depth. Compositing meant that Dennis Newman would takeseveral scoops of soil from an area of about three feet in diameter et eachsample point in order to make the sample as representative of the location aspossible. Sixteen locations were sampled.

All soil samples will be analyzed for total lead, cadnlum and zinccontent. Nine of the sixteen samples will be analyzed by the E.F. TozicityTest for lead, cadmium and zinc. Four soil samples will be analyzed for allmetals on the Illinois Target List because these samples cane from soilslocated either downwind (east of Circle Smelting) or in the ditch drainingpart of the site. Dennis Newman prepared the samples and paperwork forshipment to the lab.

The sample number, time and location of these samples are:

Sample X1C1; taken 10:10; located 25 yds. frore the railroad tracks on thewestern edge of thr Rlpperda/Tricky backyard.

Sample X102; taken 10:33; located 20 yds. from the railroad tracks straightbehind blue trailer in the middle of Al Ripperds's backyard.

Sample X103; taken 10:A3; located directly across the road from theRipperda/Tricky residence in a tree line between fields and 18 yds fron road.

Sample X104; taken 10:56; located on top of a hillock about 30 yds. south ofthe railroad tracks on a lot facing the southeast corner of Circle Smelting.A trailer wan located on this lot in the aerial photographs.

Sample X105; taken 11:03; located 30 yds. south of the railroad tracks in aweedy field across from southeast corner of Circle Smelting.

RECEIVED

OCT 1 5 I9boi PC

Page 2

Sample X106; taken 11:44; located In a strip of veeda about 18 yds. fromrailroad track* in the Koenler backyard on 1st Street.

Sample X107; taken 11:51; directly behind trailer about 20 yds. from railroadtracks in the middle of the Lee backyard.

Sample X108; taken 12:09; located about 8 yds. from south side of access roadto Circle Smelting. This sample was taken about halfway down the road betweenfirst intersection and the gate at the west side of Circle Smelting.

Sample X109; taken 12:15; located about 40 yds. to the vest of Circle Smeltinggate about 5 yds. to the north of access road at the edge of a timber yard.

Sample X110; taken 12:65; located In a drainage ditch across Rt. 50 from thenortheast corner of Circle Smelting. This ditch drains the eastern side ofCircle Smelting and then run* under Rt. 50. The sample was taken of sedimentIn the ditch about 15 yds. from the north side of Rt. 50.

Sample Xlll; taken 12:50; located in southeast corner of La whom lot about 5yds. from the road and directly across Rt. 50 from Circle Smelting.

Sample X112; taken 13:04; located directly across Rt. 50 from the ForthSawmill about 5 yds. from road at edge of an alfalfa field. This sample wastaken near the northwest corner of Circle Smelting.

Sample XI13; taken 13:08; located directly across the alfalfa field fromSample X112 and the Forth Sawmill. This sample was taken at the boundarybetween the alfalfa field and a woods.

Sample X114; taken 13:19; located to the ease of Circle Smelting about 9 yds.from Rt. 50 by billboards standing to the south of the road. Taken in weedyarea. These billboards are the first billboards co the east of CircleSmelting on Rt. 50.

Sample X115; taken 13:24; located in a.weedy field to the east of CircleSmelting adjacent to an alfalfa field about 73 yds. from the south edge of thebillboards along Rt. 50 and about 18 yds. further west than the billboards.These src the first billboards to the east of Circle Smelting and on the southside of Rt. 50.

Sample XH6; taken 13:27; located in a weedy field to the east of CircleSmelting adjacent to en alfalfa field about 165 yds. from the south edge ofthe billboards along Rt. 50 and about 18 yds. further west than thebillboards. These are the first billboards to the east of Circle Smelting andon the south side of Rt. 50.

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