Api publ 339 1997 scan (american petroleum institute)

S T D - A P I I P E T R O PUBL 337-ENGL 1797 0732270 b L D American % Petroleum Institute MANAGEMENT OF RESIDUAL MATERIALS: 1995 PETROLEUM REFINING PERFORMANCE HEALTH AND ENVIRONMENTAL AFFAIRS DEPARTMENT PUBLICATION NUMBER 339 JUNE1997 `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale S T D * A P I / P E T R O PUBL 337-ENGL 1777 0732270 05b7I.1'40 Yb0 `,,-`-`,,`,,`,`,,` - One of the most significant long-term trends affecting the future vitality of the petroleum industry is the public's concerns about the environment, health and safety Recognizing this trend, API member companies have developed a positive, forward-looking strategy called SlEP: Strategies for Today's Environmental Partnership This initiative aims to build unberstandingand credibility with stakeho\dersby continually improving our industry's environmental, health and safety performance; documenting performance; and communicating with the public API ENVIRONMENTAL MESION AND GUIDING ENWROWMENTAL PRINCIPLES The members of the American Petroleum Institute are dedicated to continuous efforts to improve the compatibility of our operations with the environment while economically developing energy resoutces and suppíying high quality products and services to consumers We recognize our msponsibiiity to work with the public, the government, and others to develop and to use natural resources in an environmentally sound manner while protecting the health and safety of our employees 8nd the pubtic To meet these responsibilities, API members pledgeto manage our businesses accordingto the following principles using sound science to prioritize risks and to implement cost-effective management practices: To recognize and to respond to community concerns about our raw materials, products and Operations - To operate our plants and faciïiies, and to handle our raw materials and products in a manner that protects the environment, and the safety and health of our employees and the public To make safety, health and environmentalConsiderations a priority in our planning, and our development of new products and processes To advise promptly, appropriate officiais, employees, customers and the public of information on significant industry-relatedsafety, health and environmental hazards, and to recommend protective measures To counsel customers, transporters and others in the safe use, transportationand disposai of our raw materials, products and waste materials To economically develop and pmduce natural resoums and to conserve those resources by using energy efficiently or supporting research on the safety, health and environmental effects of our raw matedais; products, processes and waste materials To extend knowledge by conducting To commit to reduce overall emission and waste generation To work with others to resolve problems created by handling and disposal of hazardous substances from OUT' operations To participate with government and others in creating responsibỵe laws, regulations and standards to safeguard the cammunity, workplace and environment To promote these principles and practices by sharing experiences and offering assistance to others who produce, handle, use, transport or dispose of similar raw materials, petroleurn products and wastes Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale - S T D * A P I / P E T R O P U B L 3 - E N G L 2797 2 05b7LLiL B T D Management of Residual Materials: 1995 Petroleum Refining Performance Health and Environmental Affairs Department API PUBLICATIONNUMBER 339 PREPARED UNDER CONTRACT BY: ROBFERRY THETGB PARTNERSHIP HILLSBOROUGH, NORTH CAROLINA JUNE 1997 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 ~ S T D * A P I / P E T R O PUBL 339-ENGL 1997 2 05b71LI2 733 `,,-`-`,,`,,`,`,,` - 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 LE'ITERS PATENT All rights reserved No part of this work may be repmduced stored in a retrieval system, or transmitted by any m a n s , electronic, mechanical, photocopying recording, or otherwise, without prior written permissionfrom the publishex Contact the publisher; API Publishing Services, 1220 L Street, N.W Washington, D.C 20005 Copyright O 1997 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 ~ ~ S T D - A P I I P E T R O PUBL 337-ENGL 1997 m 0732270 05b7LL13 b T 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 CONTACT Kyle Isakower, Health and Environmental Affairs Department ANNUALREFINING SURVEY WORK GROUP Thor Hanson, Shell Development Company Lawrence Hudson, Texaco, Inc James Metzger, Conoco, Inc Gary Robbins, Exxon Company, U.S.A Vickie Stephens, Ashland Petroleum Company J A Stirling, Phillips Pipeline Company THE RFFINERS At each refinery participating in the survey, one or more individuals assumed the responsibility to complete the survey questionnaire Their efforts deserve special recognition and thanks from the industry Carol Gosnell (MI)is recognized for her contribution to the cover art for this publication iv `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale ~ S T D - A P I I P E T R O PUBL 337-ENGL 1777 0732270 05b7144 50b TABLE OF CONTENTS ExecutiveSummary e5-1 l.Method010gy 1-1 ListingofRefineries 1-1 Rationale for Survey Clarifications 1-1 Residual Streams 1-2 Management Practices and Techniques 1-2 Data Analysis 1-3 2.Results 2-1 Response Rate 2-1 Reprocessing of Used Oil 2-3 Wastewater Treatment Faciltty 2-3 PollutionPrevention 2-7 Residual Stream Profiles 3-1 API Separator Sludge 3-2 Biomass 3-6 Contaminated Soils & Solids 3-9 DAFFloat 3-13 FCCCatalyst 3-16 Hydto.Catalyst 3-20 OtherSpentCatalysts 3-24 PondSedunents 3-27 PrimarySludges 3-30 Slop Oil Emulsion Solids 3-34 Spent Cresylic Caustic 3-37 SpentNaphthenicCaustic 3-40 Spent Sulfidic Caustic 3-43 TankBottoms 3-47 Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale `,,-`-`,,`,,`,`,,` - section S T D A P I / P E T R O PUBL 3 - E N G L 1777 = 0732290 0567345 442 4.CombinedStreams 4-1 Oily Wastewater Residuals 4-1 Spent Caustics 4-3 Appendix A ELECTRONIC SURVEY FORM A-1 Appendix B DESCRIPTION OF STATISTICAL PROCEDURES B-1 Appendix c DATATABLES C-1 LIST OF FIGURES Sample Screen from the Survey Form 1-2 Response Rate by Refinery Capactty 2-1 U.S.Deparûnent of Energy’s PAD Regions Resp = the variance of the unbiased estimate for nonrespondent faciitty h, and n is the number of nonrespondent facilities The sum of the variances of the unbiased estimate for the nonrespondent facilities for the 1995 survey is 12,833,574,260 Percent Error for the Estimate of Total Residuals The percent error is based on the prediction interval for the estimate of total residuals, which is dependent upon the total variance and the confidence level chosen For a 95% confidence level, the prediction interval is calculated by the following equation^:^ Tu = T + m where Tu and T, are the upper and lower limits,respectively Using the above equations, the prediction interval for the total industry is 2,822,206 to 3,275,347 wet tons The percent error, E%, is then expressed as: E%= 2@m -x 100% The percent error for the 1995 estimate is 7.43% 'BOX,George E.P., William G Hunter, and J Stuart Hunter, 1978, Statisticsfor Experimenters: An Introduction to Design, Data Analysis, andModel Building, John Wiley gt Sons, New York, pp 8788 60p.cit., Applied Linear Statistical Models, pp 1-74, B-5 Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale `,,-`-`,,`,,`,`,,` - Estimated Nationwide Total Residuals The estimated total quantity of residuals for the U.S.petroleum refínhg industry is the sum ofthe residual quantities reported by the respondent facilities plus the unbiased estimates for the nonrespondent facilities The total quantm reported by the respondat facilities was 1,708,45 wet tons, resulting in an estimate of 1,340,324 for the nonrespondent facilities The total nationwide estimate of the quantity of these residual streams for the petroleum refining industry is therefore 3,048,776 wet tons ~~~~~~ ~~ ~ S T D - A P I / P E T R O PUBL 339-ENGL 1997 W 0732270 05b7234 548 m RESIDUAL STREAM ESTIMATES The estimated total quantity of residuals for the U.S.petroleum refining industry was subdivided into individual residual streams and management techniques based on the proportion of each in the respondents’ total This mhod of proportioning the total to the individual categories assumes that the regression equation developed for the total is also valid for each residual stream and management technique This assumption is not knownto be valid, but the procedure is used for consistency with previous surveys It was deemed, however, that the unknown validity of this assumption renders error or precision estimates of the individual streams meaningless, and therefore stream variances were not calculated for the 1995 survey The proportioning procedure begins with the calculation of the ratio of the quantq reported by respondents for a given category to the total quant&y reported by respondents This ratio is then multiplied by the total quanttty estimated for nonrespondents The sum of the quantity reporteá by respondents plus that determined by proportion for nonrespondents is then the estimated nationwide total for that category This procedure may be illustrated by cansidering the API Separator Sludge stream This stream represents 20,756 tons of the 1,708,451 total tons reported by respondents, or 1.215% Applying the 1.215% proportion to the estimated nonrespondent total of 1,340,324 yields 16,285 tons Adding the respondent and nonrespondent quantities yields an estimated nationwide total quantity of API Separator Sludge of 37,039 wet tons `,,-`-`,,`,,`,`,,` - B-6 Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale - S T D - A P I / P E T R O P U B L 3 - E N G L 1797 œ 0732270 b 484 œ Appendix C DATA TABLES `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale S T D - A P I / P E T R O PUBL 337-ENGL 1777 m 0732270 05b723b L O m C o o o o o o T c o E- 'p'p `,,-`-`,,`,,`,`,,` - o? m m o o o o o m c mN Co 'p in :- ( D o o o o o b c "- N N Y o o o b o m o c a m i n O b m- yN Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS c-7 Not for Resale _ _ _ ~ ~ S T D = A P I / P E T R O PUBL 337-ENGL ~ _ _ _ _ _ ~ ~ ~~ 1777 0732270 05b7237 257 W i I- I , (o `,,-`-`,,`,,`,`,,` - '4 3o o O c, w m 33: dva Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS c-2 Not for Resale ~ ~ ~~ ~ ~~~~ S T D - A P I / P E T R O PUBL 337-ENGL 1777 W 0732290 05b7238 173 m o ~ o o o w c o m r r m r o ( v - m ( D o o c `,,-`-`,,`,,`,`,,` - r 0 Q O O O O C O O < D r o o o m o o o c 0 O V ) O O O C O 0 0 0 g N O O V : o o o ' p o o o c O - N O h ( V O O O O ~ C o m r o m r o r o r o r m O ~ C U O ( v N C r w o r r r 0 0 r e 0 0 ~ - O c F 0 $ ) h r O n O 0 0 0 o V ) r o c r ( v O O o O O C o o m o o CI r ~ c w - o o o q ~ W - o w r o w o ( c 0 0 o 0 m N r O O O Q > O O ( v ( V O < D O O r 0 r o - o m r o o o a > m o r N r I - n o r o o o o a D 0 - 0 > O < D - - O ( D ( v O r r T Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS c-3 Not for Resale c b O O o O h r 0 r m o o o S T D * A P I / P E T R O PUBL 337-ENGL 1777 2 05b7237 T I RELATED API PUBLICATIONS PUBL336 MANAGEMENT OF RESIDUALMATERIALS:1994, PETROLEUM REFINING hRFORMANCE, SEPTEMBER 1996 PUBL 333 GENERATION AND MANAGEMENT OF RESIDUAL MATERIALS: 1992/1993, FEBRUARY 1995 PUBL329 GENERATION AND JUNE 1994 PUBL324 GENERATION AND MANAGEMENT OF RESIDUAL MATERIALS: PETROLEUM REFINING PERFORMANCE: 1990, SURVEY, AUGUST 1993 PUBL303 GENERATION AND MANAGEMENT OF WASTES AND SECONDARY MATERIALS: REFINING PERFORMANCE, JUNE 1992 1989, PETROLEUM PUBL300 THE GENERATION AND hhNAGEMENT OF WASTE AND SECONDARY hhTERIAL,S MANAGEMENT OF RESIDUAL MATERIALS: 1991, SURVEY, INTHE PETROLEUM REFNNG INDUSTRY:1987/1988, FEBRUARY199 U To order, call MI Publications Department (202) 682-8375 06972C1 P `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale STD.API/PETRO PUBL 337-ENGL 1777 ia 0732270 05b72LiO 841 American 1220 L Street, Northwest Petroleum Washington, D.C 2ooo5 Institute 2 - ~ - ~ ~ httpJ/wwwapi.org ~ - - `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale