Api publ 300 1991 scan (american petroleum institute)

A P I PUBL*300 '71 0732290 0530424 529 M THE GENERATION AND MANAGEMENT OF WASTES AND SECONDARY MATERIALS IN THE - PETROLEUM REFINING INDUSTRY : 1987 1988 `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale A P I PUBL+300 91 = 0732290 05110425 4b5 THE GENERATION AND MANAGEMENT OF WASTES AND SECONDARY MATERIALS IN THE PETROLEUM REFINING INDUSTRY: 1987 - 1988 HEALTH AND ENVIRONMENTAL AFFAIRS DEPARTMENT February 1991 API Publication 300 This report has been printed on RECYCLED PAPER `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale A P I P U B L X 0 W 0732290 0530426 T D FOREWORD API IS NOT UNDERTAKING TO MEET DUTIES OF EMPLOYERS, MANUFACTURERS, OR SUPPLIERS TO WARN AND PROPERLY TRAIN AND EQUIP THEIR EMPLOYEES, AND OTHERS EXPOSED, CONCERNING HEALTH AND SAFETY RISKS AND PRECAUTIONS, NOR UNDERTAKING THEIR OBLIGATIONS UNDER LOCAL, STATE, OR FEDERAL LAWS NOTHING CONTAINED IN ANY API PUBLICATION IS TO BE CONSTRUED AS GRANTING ANY RIGHT, BY IMPLICATION OR OTHERWISE, FOR THE MANUFACTURE, SALE, OR USE OF ANY METHOD, APPARATUS, OR PRODUCT COVERED BY LETTERS PATENT NEITHER SHOULD ANYTHING CONTAINED IN THE PUBLICATION BE CONSTRUED AS INSURING ANYONE AGAINST LIABILITY FOR INFRINGEMENT OF LETTERS PATENT Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale `,,-`-`,,`,,`,`,,` - API PUBLICATIONS NECESSARILY ADDRESS PROBLEMS OF A GENERAL NATURE WITH RESPECT TO PARTICULAR CIRCUMSTANCES, LOCAL, STATE, AND FEDERAL LAWS AND REGULATIONS SHOULD BE REVIEWED A P I PUBLX300 91 m 0332290 0510427 238 D ACKNOWLEDGEMENTS Wendall Clark (W C Consultants) manned the central clearinghouse throughout the project, answering respondent questions, reviewing all returned questionnaires and claritj4ng ambiguous responses Gail Levine (SUMMATIONS)served as Project Manager, providing expertise in survey design and administration, as well as coordinating the data handling and analysis, and assumed responsibility for reporting the research Oversight for the project was provided by company representative members of the Waste Minimization Survey Workgroup Mark Hopkins from Chevron sewed as Chairman of the group; his committment to the effort and technical guidance in defining the objectives and scope of the survey assured the successful completion of the project, Curt Beyer from Exxon and John Lemen from Texaco provided additional oversight and refining expertise which facilitated completion of the job Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale `,,-`-`,,`,,`,`,,` - This project was performed within the API through the combined efforts of staff members, consultants and company representatives Barbara Bush, a Senior Regulatory Analyst in API’s Health and Environmental Affairs Department (HEAD), served as the Project Director, providing the technical leadership, management guidance and enthusiasm to keep the project on track Nikki Koch, also a Senior Regulatory Analyst in HEAD, assisted in the administrative aspects of the survey Paul Wakim from the Statistics Department contributed to the development of the questionnaire and report Ralph Mitt1 directed the data analysis effort, including the data verification, the development of modeling procedures and the generation of estimates and data tables Mike Robey and Wendy Sams of Information Systems provided computer support and were instrumental in automating the database Administrative support over the two years of preparation was ably provided by Cheryl Hawkins A P I PUBL*300 91 = 0732290 0530428 374 TABLE OF CONTENTS EXECUTIVE SUMMARY 2.0 METHODOLOGY 2.1 SURVEY DESIGN 2.2 DATA COLLECTION 2.3 SURVEY ADMINISTRATION 2.4 DATA ANALYSIS 2.4.1 Data Verification 2.4.2 Non-respondent Estimation Procedures 2.4.3 Estimation of Waste Generation Quantities 3 35 5 9 10 14 14 18 19 20 22 22 25 28 30 3.0 RESULTS 3.1 RESPONSE RATE 3.2 RESPONDENT CHARACTERISTICS 3.3 TOTAL WASTE MANAGEMENT QUANTITY 3.3.1 Waste Generation 3.3.2 Treatment Additives 3.3.3Storage 3.3.4 Total Quantity of Waste ManagedAnput 3.4 WASTE MANAGEMENT 3.4.1 Recycling 3.4.2 Treatment 3.4.3 Land Treatment 3.4.4 Disposal 4.0 DISCUSSION 4.1 WASTE GENERATION 4.2 WASTE MANAGEMENT 4.3 COMPARISONS TO PREVIOUS SURVEYS 4.4 WASTE MINIMIZATION 33 33 34 38 40 APPENDIX A QUESTIONNAIRE APPENDIX B SUMMARY OF QUESTIONNAIRE DEVELOPMENT ISSUES APPENDIX C WASTE MANAGEMENT DATA TABLES APPENDIX D SUMMARY OF WASTE MANAGEMENT PRACTICES FOR INDIVIDUAL WASTE STREAMS Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale `,,-`-`,,`,,`,`,,` - 1.0 INTRODUCTION A P I PUBL*300 91 0732290 0510Y29 O00 TABLES Refining Waste Streams Summary of Outlier Values Estimate of Wastes Generated for the Total US Refining Industry Number of Refineries Responding to the Survey that Reported Generating Each Waste Stream Table V Estimated Net Waste Quantities Removed From Storage for the Total US Refining Industry Table VI Estimated Net Waste Quantities Placed Into Storage for the Total US Refining Industry Table Y I I Estimated Waste Quantities in Wet Tons for 1987 & 1988 Table VIII Estimated Waste Quantities Recycled Location of Recycle Activities Table IX Estimated Quantities of Wastes Treated by Treatment Practice Table X Location of Treatment Table XI Estimated Quantities of Waste Undergoing Land Treatment Table XII Table XII1 Location of Land Treatment Table XIV Estimated Quantities of Wastes Disposed by Disposal Practices Table XV Location of Disposal Practices Table XVI Comparison of Waste Generation with Crude Throughput Table XVII Disposal Frequencies for Listed Wastes: 1981 1987 & 1988 Table XVIII Comparison of Land Treated Incinerated & Disposed Quantities for Listed Hazardous Wastes: 1981 1987 & 1988 Table Table Table Table II 111 IV `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale 17 18 19 20 21 24 25 27 28 29 29 31 32 33 39 39 A P I PUBL*300 91 m 0732290 0530430 822 FIGURES 10 11 12 13 13 16 36 37 `,,-`-`,,`,,`,`,,` - Figure Number of Refineries Responding by Capacity Groups Figure Distribution of Respondents by PAD Districts Figure Distribution of Respondents by NPDES Classification and Refinery Capacity Figure Distribution by Refinery Age Figure Refinery Age versus Sewer Type Figure Refinery Capacity versus Sewer Type Figure Comparison of Waste GenerationA 987 - 1988 Figure Summary of Waste Management Practices Figure Summary of Waste Management Practices (Outliers Removed) Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale API PUBLU300 91 0732290 769 m EXECUTIVE SUMMARY In 1989, the American Petroleum Institute (API) initiated a census survey of domestic rlefineries The goal of this effort was to document the management of waste and secondary materials in 1987 and 1988 To so, the survey described "waste" more broadly than RCRA's definition of "solid waste", including hazardous and non-hazardous wastes and secondary materials that might otherwise be considered byproducts or recyclable materials To generate data that could be used in a variety of contexts, including waste minimization, the survey incorporated the components of the integrated waste management hierarchy Thus, waste management activities were categorized as either source reduction, recycle, treatment or disposal A,dditionalgoals of the survey were to: 1) evaluate possible factors, such as refinery size, clomplexity or location, that might influence the amount of waste generated; 2) evaluate historical trends in the management of waste by comparing 1987 and 1988 data to the data gathered for 1981; and 3) establish baseline information on current waste rrianagement practices from which future industry progress can be evaluated SURVEY PROCEDURES A census approach was used wherein all U.S refineries were sent survey materials These data collection forms requested quantitative information on the generation and subsequent recycle, treatment and disposal of 28 possible refining waste streams Refineries were also asked to supply information on their facilities, including age, size, complexity and segregation of wastewater system Survey materials requesting data for 1987 and 1988 were sent out in September 1989 All survey responses were initially reviewed and questionable answers were followed up with telephone calls to respondents to verify the data To generate estimates of the waste management quantities for the entire U.S refining industry, two regression models were developed: one for facilities with capacities greater than 200,000 barrels per stream day and another for smaller refineries All waste quantities contained in this report represent estimates for the entire refining industry generated by these models RESULTS There was an excellent response to the survey: 115 refineries out of the total U.S population of 176 refineries participated These respondents represent 80 percent of the domestic crude refining capacity This outstanding response aided in making confident estimates of the amount of waste managed by the entire U.S refining industry i `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale A P I PUBL+300 93 m 0732290 0530432 bT5 Waste Generation The amount of waste managed by the refining industry in a given year includes the amount generated, any pre-treatment additives used and the net amount removed from/placed into storage Total Quantity Waste Managed - Quantity Generated + Treatment Additives + Net From Storage The total amount of waste generated by the 176 U.S refineries is estimated to be: o 16.1 million wet tons in 1987 and o 16.0 million wet tons in 1988 When the data is arrayed according to the six refining waste stream categories used in the survey (Figure 1), the Aqueous Waste category represents approximately 76 percent of all wastes generated in both years This is due to the fact that four refineries generated extremely large amounts of the individual waste stream, "Other Aqueous Wastes NOS (Not Otherwise Specified)." (The large quantities of these waste streams are directly related to the facilities' use of deep well injection disposal techniques a practice that does not necessitate pre-treatment to reduce the quantity of waste.) Among the other waste categories, Oily Sludges/Other Organic Wastes was the largest, followed by Chemicals/lnorganic Wastes and Contaminated Soils/Solids As noted in Figure , the relative proportion of the six waste categories remained coinparable over the survey period Similarly, the quantities of the 28 individual waste streams that comprise each category (e.g., API Separator Sludge is a waste stream in the Oily Sludge/Other Organic Waste category) that are generated in the two survey years also remained relatively constant The use of treatment additives and the amount of wastes removed from or placed into storage did not significantly change the amount of waste managed in either survey year Comparison of the total amount of waste generated to the total crude throughput provides an appropriate context for viewing the quantities of waste generated in the petroleum refining industry: 1987 16.1 631 2.56 Waste Generated (Million wet tons) Crude Throughput (Million tons) WasteCrude Throughput (%) 1988 16.0 650 2.47 As indicated, the amount of waste is less than percent of throughput When the `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale m A P I P U B L X 0 W 0’732290 0530433 531 = FIGURE - COMPARISON OF WASTE GENERATION : 1987 - 1988 1987 Total Waste Quantity Non-Aqueous Wastes Other Wastes 203 / - / - - - Chemicals 1139 Spent Catalysts 246 All Other Wastes Aqueous Wastes 12303 3841 - Oily Sludges 1944 - 16,144 Wet Tons Contaminated Soil 309 3,841 Wet Tons Thousands of Wet Tons 1988 Total Waste Quantity Non-Aqueous Wastes / - _ / - - Other Wastes 412 Chemicals 1032 Ail Other Wastes 3921 Aqueous Wastes 12124 Spent Catalysts 266 -16,045 Wet Tons Oily Sludges 1811 Contaminated Soil 400 3,921 Wet Tons `,,-`-`,,`,,`,`,,` - Thousands of Wet Tons Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale A P I PUBL*300 91 = 0732290 O530529 T93 Figure D - 16 SUMMARY OF WASTE MANAGEMENT PRACTICES +-J CB O O 00 00 Ca Co m cd rn c, O I- c> - Co cn a, O U a o I U O O h II a D-16 `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale A P I PUBL*300 91 0732290 0530530 703 Figure D - 17 SUMMARY OF WASTE MANAGEMENT PRACTICES `,,-`-`,,`,,`,`,,` - O O cv a- I\ 00 m o) a, -N v) al a, C - E c a, -0 U v) - I= rd c O -a, c a D-17 Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale A P I RJBLs300 91 m 0732290 OSLO531 bliT m Figure D - 18 SUMMARY OF WASTE MANAGEMENT PRACTICES E a, -N VI a, _ Q a, a, c _ I c ! al U VI - m c O c D-18 Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale `,,-`-`,,`,,`,`,,` - U API P U B L X 0 93 0732290 0530532 586 M Figure D - 19 SUMMARY OF WASTE MANAGEMENT PRACTICES O O oi 0z L a `,,-`-`,,`,,`,`,,` - U a + cd S O O Cu I - € c O' N - o - u) -al a O al > c cd - L al c - : c I- al U u) rJ c O c 0-19 Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale A P I PUBLX300 91 0732290 0510533 412 = Figure D - 20 SUMMARY OF WASTE MANAGEMENT PRACTICES O O c3 a5 o0 o0 CB CT) a * L c7 z" O I I Q c -Ul I O O O c\ o0 m NVJ _ U al C _ E c al 73 D - 20 `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale API PUBL*300 93 m 0732290 0530534 359 m Figure D - 21 SUMMARY OF WASTE MANAGEMENT PRACTICES O O 00 00 m a Tt - CI `,,-`-`,,`,,`,`,,` - 0- rd O I- O O c\ rn 00 Cu- a al -N v) al _ a al -C E al al U c o I- (d c O c a, - a D - 21 Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale A P I PUBL*300 91 = 0732290 0530535 295 = `,,-`-`,,`,,`,`,,` - Figure D - 22 SUMMARY OF WASTE MANAGEMENT PRACTICES 'C a, -N o a, _ Q a, _ a D - 22 Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale A P I PUBL*300 91 0732290 O530536 1i23 Figure D - 23 SUMMARY OF WASTE MANAGEMENT PRACTICES O O OCo b O O0 00 cd fz ci O I- # a # E O a O O O a, ci `,,-`-`,,`,,`,`,,` - *o I- N _ ln a, - Q -a, a D - 23 Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale I A P I P U B L X 0 91 0732290 0510537 Ob8 Figure D - 24 SUMMARY OF WASTE MANAGEMENT PRACTICES O O Lo Lo- 00 a3 rn a o) cn o I - CI cn - cd g$? VIO o + E* I- U c S O0 o) al N v) -Q) a al > _ c m - o! al -C i c al U m v) c O c -al a D - 24 `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale A P I PUBL*300 91 = 0732290 0510538 T T Figure D - 25 SUMMARY OF WASTE MANAGEMENT PRACTICES O O * O CD m T + b m O I- cn ‘U + m SZ g.? a, -%& Q n O O T O c7 T -N m a, _ n a, c _ !i c `,,-`-`,,`,,`,`,,` - a, D D - 25 Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale A P I P U B L X 0 91 0732290 0510539 930 Figure D - 26 SUMMARY OF WASTE MANAGEMENT PRACTICES `,,-`-`,,`,,`,`,,` - O O 03 00 00 o c $ I- € m :8 St-m i O O a > _ c m - L a -c -E a, a, -0 a, _ a D - 26 Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale A P I PUBLa300 D 0732290 0530540 652 Figure D - 27 SUMMARY OF WASTE MANAGEMENT PRACTICES O O c/) O z O0 O0 CD - z CI 3o - CI cd L O S I - O O L a c A Cu- O0 cv cc) - al (d CI O I- -N u) a, _ a -a, a D - 27 `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale A P I P U B L X 0 91 0732290 05105qL 9 Figure D - 28 SUMMARY OF WASTE MANAGEMENT PRACTICES 00 00 o, `,,-`-`,,`,,`,`,,` - v) - (d c O c W _ Q D - 28 Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale A P I PUBL*3OO 91 07322’70 5 425 Order No 849-30000 `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale A P I PUBL*300 91 rn `,,-`-`,,`,,`,`,,` - American Petroleum Institute 1220 L Street, Northwest Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale 2 05110543 rn