Api publ 329 1994 scan (american petroleum institute)

~ A P I PUBLu329 ~ ~~ ~ 0732290 054397b 908 m AND MANAGEMENT `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale 9 A P I PUBLu329 0732290 0543977 844 Generation and Management of Residual Materials Petroleum Refining Performance 1991 Survey Health and Environmental Affairs Department API PUBLICATION NUMBER 329 PREPARED UNDER CONTRACT BY: GAIL LEVINE SUMMATIONS WASHINGTON, D.C WENDALL CLARK WC CONSULTANTS HOPEWELL JUNCTION, N.Y MAY 1994 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 PUBLlir329 0732290 0543978 780 = FOREWORD API PUBLICATIONS NECESSARILY ADDRESS PROBLEMS OF A GENERAL NATURE WITH RESPECT TO PARTICULAR CIRCUMSTANCES, LOCAL, STATE, AND FEDERAL LAWS AND REGULATIONS SHOULD BE REVIEWED API IS NOT UNDERTAKINGTO MEET THE 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 Copyrighi Q 1994 American Petroleum Institute 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*327 94 = 0732270 O543779 bLï W ACKNOWLEDGMENTS THE FOLLOWING PEOPLE ARE RECOGNIZED FOR THEIR CONTRIBUTIONS OF TIME AND EXPERTISE DURING THIS STUDY AND IN THE PREPARATION OF THIS REPORT API STAFF CONTACTís) Barbara Bush, Health and Environmental Affairs Department Genevieve Laffly Murphy, Manufacturing, Distribution & Marketing Tim Sampson, Manufacturing, Disuibution & Marketing Wendy Sams, Information Services John Wagner, Office of General Counsel Paul Wakim, Statistics Amita Gopinath, Statistics MEMBERS OF THE REFINING SURVEY WORKGROUP: `,,-`-`,,`,,`,`,,` - Mark Hopkins (Chairman), Chevron Corporation Norbert Dee, National Petroleum Refiners Association John Lemen, Texaco, Inc Richard Lindstrom, Ashland Petroleum Company Mark Luce, Chevron Corporation Mary Spearman, Ammo Corporation < III 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 94 W 2 0543980 339 PREFACE To improve the quality of the data collected, and its relevance to current developments, each year the American Pemleum Institute (APO reviews ail data collected in this survey, and evaluates and revises, as necessary, the data collection forms and instructional materiais Consistent with this ongoing effort to promote the integrity of the survey findings and its utility to the industry, API has implemented a change in the terminology used in this survey Beginning in 1990, API used the term “residual materials or residuals” instead of “wastes and secondary materials.” This change in terminology reflects indusuy practice-the use of many of these materiais as feedstocksor for recycling, reuse, and reciamation This change helps to reconcile the utilization of these materials in our indusuy with the regulatory usage of the term “waste.” `,,-`-`,,`,,`,`,,` - IV 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*329 ỵ Y 0732290 05i13ỵưL 275 TABLE OF CONTENTS Section EXECUTIVE SUMMARY e5-1 INTRODUCTION 1-1 METHODOLOGY 2-1 2-1 2-1 RESULTS 3-1 3-1 3-1 3-5 3-15 DATA COLLECTION FORMS DATA ANALYSIS RESPONSE RATE RESPONDENT CHARACTERISTICS RESIDUAL GENERATION POLLUTION PREVENTION 3-21 MANAGEMENT PRACTICES FOR RESIDUAL MATERIALS Recycling Treat ment Land Treatment Disposal 3-25 3-26 3-29 3-32 3-33 TOTAL QUANTITY OF RESIDUALS MANAGED 3-37 AQUEOUS MATERIALS 3-37 Other Aqueous Residuals TCLP Impact on Refining Wastewaters 3-37 DISCUSSION APPENDIX APPENDIX APPENDIX APPENDIX APPENDIX A Questionnaire B Statistical Procedures C Summary of Pollution Prevention Initiatives (by Stream) D SAS Data Tables E Trend Data on Generation and Management Practices (by Stream) `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale 4-1 0732290 0543982 101 M A P I P U B L X 94 LIST OF TABLES Table Refining Residual Streams Table Estimate of All Residuals Generated by the U.S Refining Industry: 1991 2-3 3-6 3-7 3-9 `,,-`-`,,`,,`,`,,` - Table Estimate of Residual Materials Generated by the U.S Refining Industry: 1991 Table Number of Refineries Reporting Each Stream Table Covariance Data on Residual Generation Rates: 1987-1991 3-14 Table Number Refineries Reporting Each Pollution Prevention Activity Table Summary of Pollution Prevention Activities 3-17 3-22 Table Estimates of Residual Materials Managed in 1991 Table Comparison of Residual Material Managed: 1991-1 987 3-24 3-27 Estimated Quantities of Recycled Materials 3-28 3-29 3-29 3-31 3-32 3-33 3-34 Table 10 Summary of Recycling Practices Table 11 3-15 Table 12 Location of Recycling Activities Table 13 Summary of Treatment Methods Table 14 Estimated Quantities of Residuals Treated Table 15 Location of Treatment Activities Table 16 Estimated Quantities of Land Treated Residuals Table 17 Summary of Disposal Practices Table 18 Estimated Quantities of Wastes Eliminated by Disposal Table 19 Location of Disposal Activities Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS 3-35 Not for Resale 3-36 A P I PUBL*329 = 0732290 0543983 048 LIST OF FIGURES 2-4 2-8 3-2 3-2 Figure A Pollution Prevention Question and Code Categories `,,-`-`,,`,,`,`,,` - Figure B Statistical Estimation Procedures Figure C Number of Respondents by Capacity Group Figure D Distribution of Respondents by Location Figure E Distribution of Respondents by NPDES Complexity Classification 3-3 Figure F Distribution of Respondents by Refinery Age 3-3 Figure G Distribution of Respondents by Sewer Type 3-4 Figure H Residual Generation in the Petroleum Refining Industry: 1991 1987 Figure I Trend Analysis Plot for API Separator Sludge 3-5 Figure J Generation Trends for FCCU and Hydroprocessing Catalysts 3-11 3-12 Figure K Residual Generation Curves for Streams with Significant Trends Figure L Residual Generation Curves for Streams with Unexplained Variability Figure M Summary of Residual Management Practices for 1991 3-13 Figure N Longitudinal Comparison of Residual Management Practices: 1991-1987 Figure O Techniques Used to Manage TC Hazardous Wastewater Figure P Generation of K-Wastes: Comparison of 1987 & 1991 Figure Q Management of K-Wastes: 1987 1991 Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS 3-25 3-26 3-37 4-2 Not for Resale 3-10 4-3 A P I PUBL*329 0732290 0543984 T EXECUTIVE SUMMARY In 1991, domestic refineries generated 14.8 million wet tons of residual materials This population estimate was based on the American Petroleum Institute's survey on residual management practices The survey has now amassed five years of consecutive data, with each cycle representing at least 70 percent of the refining capacity This analysis of the 1991 data includes information from APl's new question on pollution prevention activities, which when combined with the five years of data, provides a better understanding of trends in residual generation and management improvements The 14.8 million wet tons was the smallest quantity generated by the industry during the survey The differences between the 1991 quantity and all previous years were statistically significant, even though the 16 million wet tons estimated for 1987-1989 were only slightly larger API makes a distinction between two classes of materials: there are 29 specific Residual Streams and another group of miscellaneous dilute materials, Other Aqueous Residuals As illustrated below, Other Aqueous Residuals constitute the largest quantity of residuals Rather than representing a typical industry generation pattern, however, these materials are generated by only several refineries that have deep-well injection capability As displayed, the quantity of these Other Aqueous Residuals dropped in 1991 Generation of Residual Streams and Other Aqueous Reslduals: 1987-1991 Millions h 12 10 ov I 1987 / 1989 1990 Residual Streams / / / / 1988 1991 Other Aqueous Resids Reductions were also observed in 1991 for several of the specific streams that make up the Residual Streams category These include Pond sediments and Contaminated soils that dropped from the peak quantities reported in 1990, and the K-Wastes which have shown a more systematic downward trend over the survey period The estimated quantity for several streams increased in 1991, including Spent caustics and the newly reported class of primary sludges (F037 and F038 listed wastes) ES-1 `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale The trend analysis revealed distinct generation patterns for certain streams For some, such as Spent FCCU and hydroprocessing catalysts, generation remained consistent over time This would be expected since these streams are related to throughput For others, like Spent caustics, the generation quantities have increased It is believed that this reflects improved and more consistent reporting over the course of the survey Another grouping of streams was based on the occurrence of pronounced, periodic spikes such as the peak quantities of pond sediments and contaminated soils generated in 1990 In these instances, larger quantities of waste equate to environmental progress, such as site remediation and construction of new process and residual management units `,,-`-`,,`,,`,`,,` - API separator sludge and DAF float belong to a group of streams where progressively smaller quantities were generated over time These reductions reflect the industry’s concerted effort to minimize generation of these streams, largely through pollution prevention activities Indeed, refiners reported that a variety of pollution prevention activities accounted for a reduction of over 300 thousand wet tons of API separator sludge and DAF float (Note that unlike the estimates for the population of refineries that are presented in this report, the pollution prevention information are not U.S totals and only represent the amount reported by those refineries that responded to the pollution prevention question) APl’s survey is the only ongoing effort to document pollution prevention activities across an entire segment of industry In 1991, approximately half of the refiners responded to the pollution prevention question indicating that they had performed at least one source reduction or beneficial recycling activity This accounted for 715 thousand wet tons of material Pollution prevention activities were reported for 26 of the 30 residual streams In an effort to promote technology transfer, API includes narrative summaries of the various methods used with each stream in its report In addition to these pollution prevention achievements, 1991 also witnessed improvements in how the refining industry manages non-aqueous residual materials This is graphically depicted below, with the quantities handled by each technique on the left and a percentage display on the right Summary of Residual Management ‘Practices: 1987-1991 Wei T a 40 30 20 10 O ES-2 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*329 94 0732290 4 4 T Hydroprocessing Catalysts 6o - 50 - 40 - !i?$ o c k a I - w 30- o rir v 20 - 10- O 1987 1988 1989 YEAR 1990 1991 Generation Z OF TOTAL MANAGED I 100, - RECYCLE TREATMENT LAND TRMT DISPOSAL I1987 ml988 01989 mi990 Hl991 Management `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale 0732270 0544325 08b A P I PUBLX327 `,,-`-`,,`,,`,`,,` - Other Spent Catalysts NOS O' 1987 1988 1989 YEAR 1990 1991 Generation X OF TOTAL MANAGED ' 80 60 ° E 40 20 O RECYCLE TREATMENT LAND TRMT DISPOSAL mi987 mi988 01989 mi990 El991 Management 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*329 9Y O732290 054412b T L = Biomass O00 joI 700 600 500 400 300 200 100 - O' 1987 I I 1988 1989 YEAR 1990 1991 Generation X OF TOTAL MANAGED 60 c - RECYCLE TREATMENT LAND TRMT Management `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale DISPOSAL ~ A P I PUBL*327 74 0732270 0544127 957 Oil Contaminated Water Not Wastewater 150 125- 100- O' 1987 1988 1990 i989 YEAR 1991 Generation X OF TOTAL MANAGED 100, 80 - 60 - 40 - 20 - 0- RECYCLE TREATMENT LAND TRMT DISPOSAL mi987 ml988 9 mi990 Bl991 Management `,,-`-`,,`,,`,`,,` - 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*329 94 0732270 0544328 895 W High pHILow pH Waters `,,-`-`,,`,,`,`,,` - 251 O' 1987 1988 1989 YEAR 1990 1991 Generation X OF TOTAL MANAGED 80, 60 40 20 ,i (I RECYCLE TREATMENT LAND TRMT DISPOSAL ml987 mi988 01989 mi990 Hi991 Management 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*329 94 M 0732290 0544129 721 Spent Sulfite Solution 6om 50 " 1987 i989 YEAR 1990 1991 `,,-`-`,,`,,`,`,,` - Generation X OF TOTAL MANAGED RECYCLE TREATMENT LAND TRMT DISPOSAL ml987 a1988 01989 mi990 al991 Management 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*329 94 O732290 0544330 443 W Spent Stretford Solution 60 50 40 vi% z u 6UI 30 c s L I v `,,-`-`,,`,,`,`,,` - 20 10 O 19'87 1988 1989 YEAR 1990 Generation Management Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale 1991 0732290 0544131 B T A P I PUBL*329 94 Other Aqueous Residuals NOS 20 181716 - VI e - 15Z - O 1413 - I 12- 1987 1988 1989 YEAR 1990 1991 `,,-`-`,,`,,`,`,,` - s- Generation % OF TOTAL MANAGED O0 80 60 40 I I i 20 O RECYCLE TREATMENT LAND TRMT ml987 m i 8 9 ml990 \ Management Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale DISPOSAL A P I PUBL*329 94 O732290 0544132 21b W Spent Caustics O00 900 800 700 300 200 O0 O I 1987 1988 1990 1989 199 YEAR Generation Z OF TOTAL MANAGED O0 80 60 40 20 O RECYCLE TREATMENT LAND TRMT DISPOSAL mi987 ml988 ni989 al990 ml991 Management `,,-`-`,,`,,`,`,,` - 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 PUBLr329 94 m 0732290 0544333 352 Spent Acids YEAR Generation X OF TOTAL MANAGED RECYCLE TREATMENT LAND TRMT DISPOSAL U1987 a1988 01989 mi990 B i 9 Management `,,-`-`,,`,,`,`,,` - 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 PUBLlr329 = 0732290 0544134 O99 M Residual Amines `,,-`-`,,`,,`,`,,` - O' 1987 1988 1989 YEAR 1990 1991 Generation X OF TOTAL MANAGED ioa 80 60 40 20 O RECYCLE TREATMENT LAND TRMT DISPOSAL ml987 mi988 01989 mi990 mi991 Management 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*329 94 m 2 0 4 3 T25 Other Inorganic Residuals NOS 500 450 `,,-`-`,,`,,`,`,,` - 400 350 G300 z u o c I - o + w 250 o 5200 150 O0 50 O 1987 1988 1989 YEAR 1990 1991 Generation X OF TOTAL MANAGED O0 80 60 40 20 O RECYCLE TREATMENT LAND TRMT DISPOSAL ml987 mi988 01989 al990 Hi991 Management 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 PUBLX329 O732290 0544136 961 Other Residuals NOS `,,-`-`,,`,,`,`,,` - 500 450 O 1987 1989 YEAR 1388 1990 1991 Generation ir OF TOTAL MANAGED 1O 80 60 40 20 O E RECYCLE TREATMENT LAND TRMT DISPOSAL m i mia988 9 ml990 m i 9 Management 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*329 94 0732290 0544337 BTB RELATED API PUBLICATIONS PUBL 300 DATE February1991 PUBL 303 The Generation and Management of Wastes and Secondary Materials in the Petroleum Refining Industry: 1987-1988 , Generation and Management of Wastes and Secondary Materials: Petroleum Refining Performance, 1989 Survey DATE June 1992 PUBL 324 Generation and Management of Waste and Secondary Materials: Petroleum Refining Performance, 1990 Survey DATE August 1993 To order, call API Publications Department (202) 682-8375 I `,,-`-`,,`,,`,`,,` - Order No 849-32900 05946C1 P 172PP Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale r American Petroleum Institute 1220 L Street, Northwest Washington, D.C 20005 T Strategies for Today5 Environmental Partnership `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale