Api publ 303 1992 scan (american petroleum institute)

`,,-`-`,,`,,`,`,,` - 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*303 92 D 0732290 051082b T25 I Generation and Management of Wastes and Secondary Materials Petroleum Refining Performance 1989 Survey AMERICAN PETROLEUM INSTITUTE `,,-`-`,,`,,`,`,,` - HEALTH AND ENVIRONMENTAL AFFAIRS DEPARTMENT JUNE 1992 Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale l ', \ FORWARD API PUBLICATIONS NECESSARILYADDRESS PROBLEMS OF A GENERAL NATURE WITH RESPECT TO PARTICULAR CIRCUMSTANCES, LOCAL, STATE AND FEDERAL LOWS AND REGULATIONSSHOULD BE 'REVIEWED ~ API IS NOT UNDERTAKINGTO 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 UNDERTAKINGTHEIR 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 INFRINGEMENTOF 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 PUBL*303 92 , 0732290 0530828 T Ackno wiedgements I `,,-`-`,,`,,`,`,,` - APl's Pollution Prevention Task Force sponsored this survey, which was directed by Barbara L Bush, a Senior Regulatory Analyst in the Health and Environmental Affairs Department (HEAO) Other individuals who made significant contributions to the project include: Genevieve Laffly Murphy, in APl's Refining Department, who served as liaison with the General Committee on Refining and the Committee on Refinery Environmental Control (CREC); Mark Hopkins from Chevron, the Chairman-of the Solid Waste Survey Workgroup that stewarded the project; Gail Levine from SUMhMTIONS, the,prime contractor for the project; Wendy Sams in APl's Information Systems that developed the automated version of the questionnaire; and Wendall Ciark, the expert consultant on refining practices This core group was assisted by/sfaff members from APl's Statistics Department, the Office of General Counsel and the Editotial and Special Issues Department I \ \ , I I \ I - , , 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 PUBLx303 M 0732270 05L0829 734 ' ' TABLE OF CONTENTS Executive Summary Introduction ; _ : i : - Methodology Survey Design -DataCollection Waste Minimization Automated Questionnaire Survey Administration DataAnalysis Discussion Waste Generation i Source Reduction Waste Management 35 35 - `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale < \ 39 - - 38 APPENDICES A Questionnaire B Statistical Procedures C Summary of Source Reduction Activities D -JYaste Management Summary Tables E Summary of Waste Management Practices for Individual Waste Streams - , a6 9 12 12 15 15 16 18 21 21 25 29 31 34 \ L , 3 Results *Response Rate Respondent Characteristics Total Waste Management Quantity , Waste Generation Treatmerit Additives Storage Totat Quantity of Waste Managed Source Reduction Waste Management Recycling Treatment : Land Treatment Disposal Waste Minimization Programs i I I i A P I PUBLa303 0732290 0530830 TABLES Refining Waste Streams I I - Estimated Wastes from the U.S Refining Industry 14 Number of Refineries Reporting Wastes I Top-five Waste Streams Removed from Storage Top-five Waste Streams Placed into Storage Estimated-Waste Quantities Summary of Source Reduction Achievements 15 16 16 17 18 Methods of Calculating Source Reduction Achievements 19 Summary of Source Reduction Activities 11 Summary of Recycling Practices 10 Incentives for Source Reduction Activities 20 21 I 22 12 Estimated Quantities of Recycled Wastes 24 13 Location of Recycling Activities 25 14 Summary of Treatment Methods 26 15 Estimated Quantities of Wastes Treated 28 16 Location of Treatment Activities 29 * 18 Summary of Disposal Practices 31 17 Estimated Quantities of Land Treated Wastes _ 30 19 Estimated Quantities of Wastes Eliminated by Disposal 32 20 Location of Disposal Activities 22 Barriers to Source Reduction 21 Sources of Variability in Waste Generation Rates 1987-1989 `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale 33 37 38 / API PUBL*303 92 2 05L083L \ FIGUR E S - Number of Respondents by Capacity Group B - Distribution of Respondents by Location 10 C - Distribution of Respondents by Complexity 1O 11 D - Distribution of Respondents by Age E - Distribution of Respondents by Sewer Type 11 A I \ - F Waste Minimization Program Components H - Wastes Generated: 1987-1989 G Wastes Generated: 1989 I -,Waste Management Practices: 1989 K - Management Practices for RCRA Hazardous Wastes J Waste Management -Practices: 1987-1989 34 35 36 40 41 I , / `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale 42 A P I P U B L X 3 92 = 0732290 0510832 229 Eirecutive Summary 1989 Survey Each year, U.S petroleum refineries process 650 million tons of crude oil as they create fuels and o t h y petroleum products vital to the U.S economy and way of life Not much waste results less than percent of those 650 million tons Still, that amount ofwaste is a big number in its own right This is the third annual survey of wastes generated by U.S petroleum refineries and how they handle those wastes Conducted by the American Petroleum Institute, it is the only ongoing industry-wide effort of its kind It is also the first to track "source reduction" in refineries preventing pollution by avoiding the creation of waste - For fhis survey, Generation and Management of Wastes and Secondary Materials: Petroleum Refining Performance, API mailed questionnaires to 183 operating U S refineries The 117 refineries that responded represent 74 percent of domestic refining capacity This high response rate enabled API to develop industry-wide estimates with a high degree of confidence and statistical accuracy Wastes Generated U.S refineries generated roughly 16.3 million wet tons of wastes and secondary materials in 1989 about the same as in 1987 and 1988 The total includes nonhazardous and hazardous wastes (as classified under RCRA, the federal Resource Conservation and Recovery Ad), byproducts, and other secbndary materials The survey obtained information on 28 waste streams, grouped in six categories As shown below, aqueous wastes constitute about two-thirds of the total Four facilities (treated as outliers in the statistical analysis) generate nearly ali of these wastes and dispose of them by injecting them into underground wells In diminishing order of volume, the remaining wastes are oily sludges, chemicals, contaminated soils, "other," and spent catalysts Types of Wastes Generated (millions of wet tons) Non-Aqueous Wastes 4.398 Wet Tons TotalQuantity 16.311 Wet Tons / Al Other Waues SWarIn 11913 1659 \ \ Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale con)unh.lsd sd( 747 `,,-`-`,,`,,`,`,,` - W A P I PUBLx303 0732290 0530833 365 - \ \ ' With the exception of contaminated soil, the amount of each type of waste has remainedxabout the same since 1987 It appears that the 'amount of contaminated soil is on the risp most likely, a result of new construction at refineries and stepped-up efforts to clean up and remediate contamination from past releases i * Waste Management `,,-`-`,,`,,`,`,,` - The U.S Environmental Protection Agency has created a waste management hierarchy that reflects the growing emphasis on reducing the amount of waste generated rather than than treating and disposing of it The ranking (in general order of preference) is source reduction, recycling, treatment, and disposal Trends in handling petroleum refining wastes reflect the shift in'emphasis in the waste management community at large Of the 117 refineries that participated in the 1989 survey, 55 reported progress in source -reduction Their àctivities included technical and procedural modifications, in-process recycling, and improved housekeeping practices Economic incentiyes such as lower treatment and disposal-costs were the main reasons they undertook such source reduction ,activities , \ Recycling 'of refinery wastes is also on the dse Twenty-six percent of refineries' wastes were recycled in, 1989, compared to 21 percent in 1987 In contrast, land farminsg has declined dramatically It was used to dispose of 66 percent of refinery wastes in 1981 and 17 percent in 1987, but just 13 percent in 1989 As the illustration below shows, refineries use other waste management methods as well In 1989, they eliminated 29 percent of their wastes through treatment and 32 percent through disposal about the same proportions as in 1987 and 1988 * Methods of Managing Wastes (millions of wet tons) ' \ RECYCLE 26% r- 13% OUTLIERSREMOVED 5.263 WETTONS / ! \ 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 3 92 = 0732290 0530834 OT3 = \ , ImplicatYons APl's waste management survey is a tool that quantifies the wastes petroleum ' refineries generate It helps individual refineries assess their performance and monitor progress, while providing an overview of the industry's performance as a whole L ' Now that three successive years of data are available, it is also possible to compare the pxformance of individual refineries and the industry as a whole over time Here, "within facility" variations in amounts of wastes generated suggest that the industrywide aggregated data give a false sense of stability , Annual variations in generation quantities for specific waste streams at individual refineries are up to seven times greater than those of the industry as a whole If additional observations validate this trend, it could lend support to the view that sitespecific factors merit consideration espwially, in regulatory decisions \ , \ `,,-`-`,,`,,`,`,,` - 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*303 92 O732290 0530925 T7T LD a3 Y- \ Q) ao I ‘1 cl I- a , I- a n z a W a a o 2 c/) z O I\ a a W n ) W a z a \ b ao W J s O o ll a J 6W I- O a.0 O O O O O 00 CD d= `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS 7- b Not for Resale O cv O Q) r I A P I PUBL*303 = 0732290 `,,-`-`,,`,,`,`,,` - I- a )I J a 2t- a o U U n > Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS 0530’726 906 n W (3 a z J s O ILL O O o o t Not for Resale O * ~ (/> O J a i/ v) O e I- Y v) I n C/) > I I- a n `,,-`-`,,`,,`,`,,` - z a J a z a z I- z w GW U Q I- -C/) W U J o W t W Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS W c3 v) I ci a 0 A ) c D w Not for Resale C u O I\ a a > W A P I PUBLX303 92 0732290 0530928 789 W -J `,,-`-`,,`,,`,`,,` - a v) O e c/) I a a Ia cf) a a J c3 a z a z v) z O IIi z O m r2 w W -J Y o w U 0 0 O o o C D T F m Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS a w Not for Resale \ U a w * A P I P U B L X 3 92 0732290 0530929 b35 J u3 \ w O e t- Q) u3 cn a cv I n s \ Q) ao Q) I- z l- c + * wa a U n =a z a I moo zoo \ U a W > o o cv W J o ) o I O O O O O0 O (O * O `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale Q Cu O = A P I PUBLx303 O732290 0510930 337 CI W c3 a z a a z O I- \ a a W > a W c3 a z a z J ;z O I- L O s 0 0 o o o ( D d - c u `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale m API P U B L r 3 72 m 0732270 05LDï3L 273 `,,-`-`,,`,,`,`,,` - 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*303 0732290 0530932 T a Co O L cf) a I- I- CI z a `,,-`-`,,`,,`,`,,` - s a ,rI- Z w z W a I- W o > o W a o o o o o o c D * n l F , Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale o API PUBLr303 7 2 0 3 O46 , I a cn (f> ' O O a Z cn I n I- r U n I- c3 n cf> z a IZ O oo W r2 Q a I 6) W ' I U Lu U U W I: W a I I- , I o > o W a O O O O0 O CD O d `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS a A r-I W Not for Resale O cv O API PUBL*303 92 m 0732290 0530934 T B a u) O Q u) cn I a t- I- mo, U ICI z a J a W c3 a z a z a z I- O W \ Wa a ) z +o, w W l- a i a z W J 5! o W a o o o c D * Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale n l I- U `,,-`-`,,`,,`,`,,` - z o0 A P I PUBLX303 0732290 0510935 919 , a a O e ao a -a \ a, ao a , r I- a !a z a I- z w W -z VI Y- a, c/> !zW a a W c3 t- a z a W c3 o a z tOo a \ a ao z aa,o ' O I- r 1a \ a W > O c r \ r% ao W J 8t- ? o W a a IL O a-" 0 0 0 c D ~ `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS n Not for Resale c v a , I API PUBLX303 0732290 052093b ô 5 a a O n a I n 5a I- n z a i I- z I W \ a W n a W I- W sz o W a n > o o o o o O c u c D - t C v `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale API PUBLr303 92 m 0732290 0510937 791 O I- Cn ä W c3 a *< CK ui 3% O z - = \ W n Fc9 W Cu c3 c9 a z a / Lu J I- J zO o LL U W O O O Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS W O a o CD Not for Resale O w O a O `,,-`-`,,`,,`,`,,` - z CWo J O Q Co I O I- r a IQ 6) oo I- 6) C/) z a a W c3 a z a I u3 z r- i- oo r" a , W Q W r -0 W a c3 a z a I- W r s O J o 6W iIA' U O s O O Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale O I- \ a a > w `,,-`-`,,`,,`,`,,` - cn O z cn W a u3 I r -/ _- I Order Nd 849-30300 \ I 'I > `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale / i