Api publ 4465 1987 scan (american petroleum institute)

Evaluation of Treatment Technologies for Listed Petroleum Refinery Wastes `,,-`-`,,`,,`,`,,` - HEALTH AND ENVIRONMENTAL SCIENCES DEPARTMENT API PUBLICATION NUMBER 4465 DECEMBER 1987 11’ Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale American Petroleum Institute Evaluation of Treatment Technologies for Listed Petroleum Refinery Wastes Final Report Health and Environmental Sciences Department `,,-`-`,,`,,`,`,,` - API PUBLICATION NUMBER 4465 FIELDSTUDIES CONDUCTED BY THE API WASTETECHNOLOGY TASKFORCE REPORT PREPARED BY G ROWE,CONSULTANT WITH THE ASSISTANCE FROM THE API WASTETECHNOLOGY TASKFORCE DECEMBER 1987 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 `,,-`-`,,`,,`,`,,` - 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 UNDERTAKING TO 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 LETïERS PATENT Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale TABLE OF CONTENTS ChaDter Page xiii Preface Executive Summary Scope of Study Technologies Evaluated Data and Correlations Analytical Procedures `,,-`-`,,`,,`,`,,` - 13 Mechanical Treatment 19 Overview Equipment Description and Operation Belt Filter Plate Filter Rotary Drum Vacuum Filter 21 22 22 25 28 Test Procedures Belt Filter Plate Filter Rotary Drum Vacuum Filter 30 Test Results and Discussion Belt Filter Plate Filter Rotary Drum Vacuum Filter 35 38 58 72 Solvent Extraction Thermal Treatment Fixation 92 94 95 96 109 Overview Process Description and Operation Test Procedures, Results and Discussion Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS 77 79 81 84 92 Overview Equipment Description and Operation Test Procedures Test Results and Discussion 32 34 77 Overview Equipment Description and Operation Test Procedures Test Results and Discussion 30 Not for Resale 109 110 113 TABLE OF CONTENTS (CONT.) Page Chapter Other Vendor Technologies (Pyrolysis) Overview Equipment Description and Operation Test Procedures Test Results and Discussion Summary and Perspective 129 129 131 132 132 136 136 144 `,,-`-`,,`,,`,`,,` - Treatment Effectiveness Perspective - iv Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale LIST OF FIGURES Figure 1-1 2-1 Page Reductions In Constituent Weights and TCLP Leachate Concentrations Schematic of Waste Treatment Technologies Evaluated 2-2 Analytical Data and Correlations 10 3-1 Diagram of Belt Filter 24 3-2 Plate Filter 26 3-3 Rotary Vacuum Filter 29 4-1 Simplified Steps of Solvent Extraction Process 78 5-1 General Thermal Treatment Process 93 6-1 Two-step Solidification Process 7-1 Pyrolysis Processor 111 130 Comparison of Alternate Treatment Technology Residuals to Incineration 149 8-2 Concentrations In Raw Feeds and Residues 150 8-3 Integration of Waste Treatment Into a Refinery 151 Alternative Sequences, Treatment of Petroleum Wastes 152 8-1 `,,-`-`,,`,,`,`,,` - 8-4 - v Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale LIST OF TABLES Page Table 1-1 Average Concentrations of Total Residue 1-2 Average Concentrations of TCLP Leachate 2-1 Appendix VI11 Constituents Analyzed 14 2-2 Constituents Analyzed as Indicator or Screening Compounds 15 3-1 Constituents of Refinery Wastes 20 3-2 Oil/Water/Solids Concentrations of Belt Filter Feed and Products - Refinery C2 39 Calculated Mass Balance Based on Oil/Water/Solids Analyses Belt Filter - Refinery C2 40 Constituent Concentrations of Waste Feed and Belt Filter Cake, and Calculated 90 Reduction (Weight) - Refinery C2 41 TCLP Leachate Concentrations of Waste Feed and Belt Filter Cake - Refinery C2 42 Oil/Water/Solids Concentrations of Belt Filter, Feed and Products - Refinery C2 (Duplicate Run) 43 Calculated Mass Balance Based on Oil/Water/Solids Analyses Belt Filter - Refinery C2 (Duplicate Run) 44 Constituent Concentrations of Waste Feed and Belt Filter Cake, and Calculated % Reduction (Weight) Refinery C2 (Duplicate Run) 45 Indicator TCLP Leachate Concentrations of Waste Feed and Belt Filter Cake Refinery C2 (Duplicate Run) 46 3-3 3-4 3-5 3-6 3-7 3-8 3-9 3-10 Oil/Water/Solids Concentrations of - vii Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale 49 `,,-`-`,,`,,`,`,,` - Belt Filter Feed and Products Refinery C1 LIST OF TABLES (CONT.) Table Page 3-11 Calculated Mass Balance Based on ûil/Water/Solids Analyses Belt Filter Refinery C1 50 3-12 Constituent Concentrations of Waste Feed and Belt Filer Cake, and Calculated % Reduction (Weight) - Refinery C1 51 3-13 TCLP Leachate Concentrations of Waste Feed and Belt Filter Cake - Refinery C1 52 3-14 Oil/Water/Solids Concentrations of Belt Filter Feed and Products Refinery C1 (Duplicate Run) 54 3-15 Calculated Mass Balance Based on Oil/Water/Solids Analyses Belt Filter Refinery C1 (Duplicate Run) 55 3-16 Constituent Concentrations of Waste Feed and Belt Filter Cake, and Calculated % Reduction (Weight) - Refinery C1 (Duplicate Run) 56 3-17 TCLP Leachate Concentration of Waste Feed and Belt Filter Cake - Refinery C1 (Duplicate Run) 51 3-18 Oil/Water/Solids Concentrations of Plate Filter Feed (Conditioned) and Products Refinery B2 59 3-19 Calculated Mass Balance Based on Oil/Water/Solids Analyses Plate Filter Refinery B2 61 3-20 Constituent Concentrations of Waste Feed and Plate Filter Cake, and Calculated % Reduction (Weight) - Refinery B2 62 3-21 TCLP Leachate Concentrations of Waste Feed and Plate Filter Cake - Refinery B2 63 3-22 Oil/Water/Solids Concentrations of Plate Filter Feeds and Products - Refinery B1 65 `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS - viii - Not for Resale L I S T OF TABLES (CONT.) Page 3-23 Calculated Mass Balance Based on Oil/Water/Solids Analyses Plate Filter Refinery B1 66 3-24 Constituent Concentrations of Waste Feed and Plate Filter Cake, and Calculated % Reduction (Weight) - Refinery B1 67 3-25 TCLP Leachate Concentrations of Waste Feed and Plate Filter Cake - Refinery B1 69 3-26 Oil/Water/Solids Concentrations of Plate Filter Feeds and Cakes - Refinery B 70 3-27 Indicator TCLP Leachate Concentrations of Waste Feed and Plate Filter Cake Refinery B3 (First Test) 71 3-28,Indicator TCLP Leachate Concentrations of Waste Feed and Plate Filter Cake Refinery B (Second Test) 73 3-29 Oil/Water/Solids Concentrations of Vacuum Filter Feeds and Cakes - Refinery V1 74 3-30 Indicator TCLP Leachate Concentrations of Waste Feed and Vacuum Filter Cake Refinery V1 (First Test) 75 3-31 Indicator TCLP Leachate Concentrations of Waste Feed and Vacuum Filter Cake Refinery V1 (Second Test) 76 4-1 4-2 4-3 4-4 Test Parameters for Pilot and Commercial Solvent Extraction Units 82 Oil/Water/Solids Concentrations of Solvent Extraction Feed and Products 86 Calculated Mass Balance Based on Oil/Water/Solids Analyses Solvent Extraction 88 Constituent Concentrations in Feed and Product Solids and Calculated % Reduction (Weight) - Solvent Extraction 89 - ix Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale `,,-`-`,,`,,`,`,,` - Table L I S T OF TABLES (CONT.) Page Table `,,-`-`,,`,,`,`,,` - 4-5 5-1 5-2 5-3 TCLP Leachate Concentrations of Waste Feed and Product Solids - Solvent Extraction 91 Oil/Water/Solids Concentrations of Product Solids from Thermal Treatment Tests 97 Constituent Concentrations in Feed and Product Solids Low Temperature Thermal Treatment of Belt Filter Cake Feed Refinery C1 101 Constituent Concentrations in Feed and Product Solids High Temperature Thermal Treatment of Belt Filter Cake Feed Refinery C1 102 5-4 Constituent Concentrations of Waste Feed and Product Solids Low Temperature Thermal Treatment of Plate Filter Cake Feed 103 Refinery B1 5-5 Constituent Concentrations in Feed and Product Solids High Temperature Thermal Treatment of Plate Filter Cake Feed Refinery B1 104 TCLP Leachate Concentrations of Waste Feed and Low Temperature (350'F) Thermally Treated Belt Cake - Refinery C1 105 TCLP Leachate Concentrations of Waste Feed and High Temperature (550'F) Thermally Treated Belt Cake - Refinery C1 106 TCLP Leachate Concentrations of Waste Feed and Low Temperature (350'F) Thermally Treated Plate Cake - Refinery B1 107 TCLP Leachate Concentrations of Waste Feed and High Temperature (550OF) Thermally Treated Plate Cake - Refinery B1 108 5-6 5-7 5-8 5-9 6-1 TCLP Leachate Concentrations of API Separator Sludge and Residue from Fixation 116 Process #l - Refinery A - x Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale 111-3 A i r Strippinq T h e a i r s t r i p p i n g t e s t w i l l be p e r f o r m e d as f o l l o w s : m i l l i l i t e r s waste added t o t h e k e t t l e Five-hundred T h e pH w i l l be a d j u s t e d as i n S t e p of t h e steam d i s t i l l a t i o n T h e p u r g e g a s w i l l be t u r n e d o n a t a f l o w r a t e o f 500 mL/min and the c l o c k started A f t e r f i v e m i n u t e s , t h e p u r y e w i l l be s t o p p e d a n d t h e b a g a n d T h i s w i l l be c o n d e n s a t e samples c o l l e c t e d w i l l be r e m o v e d r e p e a t e d a t m i n u t e s , m i n u t e s , a n d 40 m i n u t e s , r e c o r d i n g t h e temperature a t e a c h t i m e ZU A d j u s t p H a s i n S t e p o f t h e steam d i s t i l l a t i o n a n d p u r y e t o r minutes I f a n y phase s e p a r a t i o n o c c u r s , sample h a n d l i n g w i l l be t h e same a s t o r t h e steam d i s t i l l a t i o n p r o c e d u r e Analytical T h e o r g a n i c c o n t e n t ot e a c h of: t h e a q u e o u s p h a s e s s h o u l d b e measured u s i n g s t a n d a r d t o t a l o r g a n i c carbon t e c h n i q u e s 173 `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale Not for Resale `,,-`-`,,`,,`,`,,` - 174 Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS `,,-`-`,,`,,`,`,,` - I cr: ! m - h O, a 175 Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale ATTACHMENT I V MATHEMATICAL MODEL FOR E S T I M A T I N G V O L A T I L E E M I S S I O N S PKOM LANDFARMS `,,-`-`,,`,,`,`,,` - 176 Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale `,,-`-`,,`,,`,`,,` - This a p p m ỵ i x sectim descrihes the d e l t h a t uas developed by Clark Allen (terriied t h o R T I d e l ) The assuiiptions inherent i n the derivation of the RTI niode1 are sumarized i n Table where Ni-air grams of pollutant i emitted i n t o the atnosphere/cm* surface area * g / c J Mio = grams o f pollutant i i n i t i a l l y applied t o the soil/cm2 surface area, g/& Dj-soil e f f e c t i v e d i f f u s i o n coefficient o f pollutant i i n the soi1 matrix, caz/ e = thickness o f the i n i t i a l l y well mixed roil l a y e r , cn e A i = qr3m o f gollutant i i n the gas phase p r ,n3 m i l / grains o f pollutant i i n t h e soi 3er soi , ( c i g / c i J * i '1 -3 tbi = :ime constant for biological decay I 177 Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale 3f pcl!utant i, h e pollutant I s agplled application it CO the surface of the m i l , is m i x e d u n i f o r r l y n t i n a surf- Soon after t h i s layer o f t h e s o i l `,,-`-`,,`,,`,`,,` - The a p p l i e d waste does not f l o w as a l i q u i d w i t h i n the s o i l The adsorption i s o t h e m of t h e p o l l u t a n t i s l i n e a r w i t h i n the a p p l i c a t i o n surface l a y e r and does not change w i t h time, NO h u l k f l o w o f gas i s induced w i t h i n the s o i l S The r a t + of b i o l o g i c a l decay/chemical reactioci i s a f i r s t order process The d i f f u s i o n c o e f f i c i e n t does not v a r y with either c o n c e n t r a t i o n o r time The concentration of p o l l u t a n t s i n the gas phase a t t h e surface of the s o i l i s mch lower than the concentration of pollutant i n t h e gas phase Q w i t h i n the s o i l , i, Liquid-vapor e q u i l i b r i u i s e s t a b l i s h e d a t a i l ti- ir possible ta include t h i s e f f e c t i n the -riu1 178 Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale r i t h i n the s o i l solution, It `,,-`-`,,`,,`,`,,` - estlaratecl froa the p o l l u t a n t ' s % w r y ' s Law constant i f the r a s t e tr p c l m a r i \ y water ( i r for d l l u t e aqueous s o l u t i o n s ) or frcr t h e p o l l u t a n t ' s vapor pressure assminq Raoult's Lau Ye assme that the idcal gas l a r holds for t h e vapor space w i t h i n the s o i l , nie appropriate equations are: A+ 106- "ci RT 8.) cair (la) Euaste R a o u l t ' s Law ' where RT L Hcj = Yenry's Law constant for pollutant i, atm-m3/m1 R = Ideal gas constant = 179 Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale 82.05 m3 atn\/(ml K) t h e cmrtmt, t g , ISr l i q t y the reciprocal of the f i r s t order biological decay rate a v a i l a b l e , t h i s tiie Equation can COnStant I f no biological decay r a t a data are umstarrt can k used as an adjustable parameter a Integrated t o y i e l d , “i - a i r t Mi o Equation dt (2) can be numerically f n t e g r a t d t o d e t e m i n e the total mass o f pollutant i emitted t o the atmosphere a f t e r any time, t specifically when t / t g < 0.2 an-< D i -soi 1A i t 0.2, For m a l ) times, an approximate s o l u t i o n f o r L2 equation i s : The mount of p i l u t a n t left i n t h e soi; Y e have asruied ri59ec: ta N i fhôt that the biological decay rate i s f i r s t order r i t h ir, 34 ~i-biol æ- dt tS 180 Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS a f t e r any t j æ , t, i s simply t h e Not for Resale `,,-`-`,,`,,`,`,,` - ne R e e r , t g I s the r e c i p r o c a l of the first order r a t e coartant Substitutlng equation into equation 5, the follawing expression can k written Because n i - b i o l 1s d function of tise, equations and m i s t be solved For very long times, (Le t approaching i n f i n i t y ) , the f r a c t i o n of p o l l u t a n t i that i s emitted i n t o the atmosphere ( i e , Mi,ai,/Mio) can be estimated using the following correlations ? *hero F , - a j r = fraction o f pollutant i eaitted ta t h e at.rrsghero a t i n f i n i t e time, In order ?CJ = t i m a t e t h e fraction of p l i u t ~ n tni::& ta t h e aSr 3t saaller times without requiring the nuoerical solution of equation 2, an exponential decay f d c t w ras developed cuaift2d t a the a i t a t any ti-, T h i s e x p r e s s i o n relates the fraction t ? , a f t r tilling 181 Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale `,,-`-`,,`,,`,`,,` - sim1 taneously THE INTEGRATED FLUX FROH Un0 TRfATrQñT OF W T E S AS FRACTION ff B I O C I X I C A L M C A Y TABLE Fracticm of ïûỵs emitted t o atmosphere E x t e n t of biological b e c ~ ~ (te M / t ) Cofrelatim Calculated oooa 1.000 10.0 O 964a 0.9679 o O 9397a O 9382 o O 7986a 0.7613 0.5 0.661a 0.6278 0.2 O 4472b 0.4M7 0.1 0.3162b 0.3147 O O5 O 2236h O 2233 0.01 o 1000b o o999 0.00s O 0707b o o706 0.m1 0,031@ 0,3316 ‘Co decay `,,-`-`,,`,,`,`,,` - 182 Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale of the s o i l , to the fraction e d t t e d a t infinite tlw ( a s c a l c u l a t e d from equation or ) dS follows: where t' Fi-air f r a c t i o n of pollutant i a i t t e d i n t o t h e atmosphere a t time, t ' , after t i l ï i l t ' = tim a f t e r t i l l i n g of s o i \ , t tc = ttJ0.69315 = psuedo-f r s t order exponential &cay time c o n s t a n t t h = h a l f l i f e assuming no b i o l o g i c a l decay lhe h a l f l i f e , t h , assuming no biological &cay equation can be s o l v e d a n a l y t i c a l l y to y i e l d or t, = 0,283 ( ) l2 O i -soi 183 `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale (i.e t a * *) i s the Although the time constant ir c a l c u l a t e d assuming no b i o l o g i c a l a c t i v i t y , equation ¿ C C O u n t S for b i o l o g i c a l d e s t r u c t f m through the I n f i n i t e time f r a c t i o n emftted t e n ( I e * by the cilependence of F i - a I r t o t0 as given i n equations and 8) approaches O Muever, equation i s only exact a t t ' = th and Equation i s more accurate than equation for rara11 times independent of F i e a i r Nonetheless, for many cases, the emission e s t i n a t e s using equations 7,8, and c o r r e l a t e well w i t h t h e emission estimates from equation w h i l e o b v i a t i n g the need t o perform numerical i n t e g r a t i o n `,,-`-`,,`,,`,`,,` - Using s i m i l a r l o g i c , equation can be s i a p l i f i e d as f o l l o w s : t' where F i - b i o * t h e f r a c t i o n of p o l l u t a n t i biodegraded a t time t ' Aote t h d t a t i n f i n i t e time, estimations of '+-air, Mi-bio, and consequently, Mi The estimation of Yi i s i r p o r t a n t when we consider t h a t happens a f t e r r e t i l l i n g the s o i l soil i s r e t i l l d ta? can c a l c u l a t e prior :o retillinq denoted Y i ' Yhen t h e c a r r e s g o n d i q t o the tim, t a , j u s t This sass of p l l u t a n t u i l l then 3e everiiy d i s t r i u t e d through the roil and the solution becmes analogous t o the i n i t i a l treataent r o l u t i o r , except ue now hare a t œur ner t' = O, 184 Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale = %' if additional pollutant 1s rdáed before retllllng (Hl added) our lnltlol pollutant loadfng fs rlnply ho* mass of pollutant I n the rofl/cd a&d + I+' Note that W i g i s the total That is, M i includes the surface area r a s s of pollutant i n both the vapor and t h e liquid The equations presented herein allow the calculatim of t h e rates of biodegradation and a i r emission Irm landfarms numerical integration in order to be solved The exact quatiofis r q u i r e However, accurate correlations have been developed and presented t o estimate these rates These equations allow easy calculation of the fraction of pollutant lost to the air, the fraction of po1lutant lost by biodegradation, and the fraction of pollutant remaining i n the soil at any time after the soil is tilled Wethod o f solution has been outlined for the reapplication o f pollutant and retilling of the soil `,,-`-`,,`,,`,`,,` - Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS 185 Not for Resale `,,-`-`,,`,,`,`,,` - 0699.50C3P Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale 1220 L Street, Northwest Washington, D.C 20005 202-682-8000 h tfp://w ww.api.org `,,-`-`,,`,,`,`,,` - American Petroleum Institute Order No 144650 Copyright American Petroleum Institute Provided by IHS under license with API No reproduction or networking permitted without license from IHS Not for Resale