1、API PUBL*33b 96 0732290 0560250 35T m. American Petroleum s documenting performance improvements; and communicating them to the public. The foundation of STEP is the API Environmental Mission and Guiding Ervironmental Principles. API ENVIRONMENTAL MiSSION AND GUIDING ENVIRONMENTAL PRINCIPLES The mem
2、bers of the American Petroleum Institute are dedicated to continuous efforts to improve the compatibility of our operations with the environment while economically developing energy resources and supplying high quality products-and services to consumers. The members recognize the importance of effic
3、iently meeting societys needs and our responsibility 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 and the public. To meet these responsibilities, APi members pled
4、ge to manage our businesses according to these principles: 9 To recognize and to respond to community concerns about our raw materials, products and operations. *:. To operate our plants and facilities, and to handleour raw materials and products in a manner that protects the environment, and the sa
5、fety and health of our employees and the public. +:e To make safety, health and environmental considerations a priority in our planning, and our development of new products and processes. e:* To advise promptly, appropriate officials, employees, customers and the public of information on significant
6、 industry-related safety, health and environmental hazards, and to recommend protective measures. *:. To counsel customers, transporters and others in the safe use, transportation and disposal of e:* To economically develop and produce natural resources and to conserve those resources by 9 To extend
7、 knowledge by conducting or supporting research on the safety, health and , our raw materials, products and waste materials. using energy efficiently. environmental effects of our raw materials, prgducts, processes and waste materials. 9 To commit to reduce overall emission and waste generation. *:.
8、 To work with others to resolve problems created by handling and disposal of hazardous substances from our operations. To participate with gqvernment and others in creating responsible laws, regulations and standards to safeguard the community, workplace and environment. 9 To promote these principle
9、s and practices by sharing experiences and offering assistance to others who produce, handle, use, transport or dispose d similar raw materials, petroleum products and wastes. API PUBLa33b b 0732290 05b0252 122 Management of Residual Materials: 1994 Pet role u m Ref i n i ng Perf or man ce Health an
10、d Environmental Affairs Department API PUBLICATION NUMBER 336 PREPARED UNDER CONTRACT BY: GAIL LEVINE SUMMATIONS DAVID RAMROTH WASHINGTON, D.C. DIANNA KOCUREK TISCHLER/KOCUREK ROUND ROCK, TEXAS SEPTEMBER 1996 American Petroleum Institute API PUBLX336 96 0732290 0560253 Ob9 = FOREWORD API PUBLICATION
11、S NECESSARILY ADDRESS PROBLEMS OF A GENERAL NATURE, WITH RESPECT TO PARTICULAR CIRCUMSTANCES, LOCAL, STATE, AND FEDERAL LAWS AND REGULATIONS SHOULD BE REVIEWED. MI IS NOT UNDERTAKING TO MEET THE DUTIES OF EMPLOYERS, MA“FAC- TURERS, OR SUPPLIERS TO WARN AND PKOPERLY TRAIN AND EQUIP THEIR EMPLOYEES, A
12、ND 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 MANU- FACTURE, SALE, OR USE OF ANY MET
13、HOD, APPAMWS, OR PRODUCT COV- ERED BY LETTERS PATENT. NEITHER SHOULD ANYTHING CONTAINED IN ITY FOR INFRINGEMENT OF LETERS PATENT. THE PUBLICATION BE CONSTRUED AS INSURING ANYONE AGAINST LIABIL- Copyright O 1996 American Petroleum institute iii API PUBL*336 96 = 0732290 0560254 TT5 m ACKNOWLEDGMENTS
14、THE FOLLOWING PEOPLE ARE RECOGNIZED FOR THEIR CONTRIBUTIONS OF TIME AND EXPERTISE DURING THIS STUDY AND IN THE PREPARATION OF THIS REPORT: API STAFF CONTACTS Bradley R. Jones, Health and Environmental Affairs Department ANNUAL REFINING SURVEY WORK GROUP Greg Bolner, Texaco James Metzger, Conoco, Inc
15、. Gary Robbins, Exxon Company, U.S.A Michael Fuson, Shell Oil Company Richard Lindstrom, Ashland Petroleum Company THEREFINERS At each refinery participating in the survey, one or more individuals assumed the responsibility to complete the survey questionnaire. Their efforts deserve special recognit
16、ion and thanks from the industry. Carol Gosnell (API) is recognized for her contribution to the cover art for this publication. iv API PUBLm33b 96 = 0732290 05b0255 931 M TABLE OF CONTENTS EXECUTIVESUMMARY . ES-1 INTRODUCTION . 1 METHODOLOGY . 1 DataCollectionForms . 2 DataAnalysis 3 RESULTS . 4 Res
17、ponse Rate 4 Respondent Characteristics 4 Residual Stream Profiles . 12 API Separator Sludge 13 DAF Float . 17 Slop Oil Emulsion Solids 19 Primary Sludges . 21 TankBottoms . 23 Pond Sediments . 25 Contaminated Soils 27 FCCU Catalysts . 29 Hydroprocessing Catalysts 31 Other Spent Catalysts 34 Biomass
18、 . 36 SpentCaustics 38 DISCUSSION . 42 APPENDICES Appendix A . Copy of the Questionnaire Appendix B . Description of Statistical Procedures Appendix C . Data Tables API PUBLx33b 96 W 0732290 05b0256 878 W FIGURES Figure 1 . Number of Respondents by Capacity Group 5 Figure 2 . Location of Participati
19、ng Refineries . 5 Figure 3 . Distribution of Respondents by NPDES Complexity Classification 6 Figure 4 . Distribution of Respondents by Refinery Age . 6 Figure 5 . Management of TC Wastewater 9 Figure 6 . Summary of Residual Generation: 1987 . 1994 . 12 12 Figure 8 . Managed Quantities of the API Se
20、parator Sludge Residual Stream: 1987 . 1994 . 13 Figure 9 . Management of the MI Separator Sludge Residual Stream . 14 Figure 10 . Managed Quantities of the DAF Float Residual Stream: 1987 . 1994 . 17 Figure 1 1 . Management of the DAF Float Residual Stream . 17 Figure 12 . Managed Quantities of the
21、 Slop Oil Emulsion Solids Residual Stream: 1987 . 1994 . 19 Figure 13 . Management of the Slop Oil Emulsion Solids Residual Stream . 19 Figure 14 . Managed Quantities of the Primary Sludge Residual Stream: 1987 . 1994 . 21 Figure 15 . Management of the Primary Sludge Residual Stream . 22 Figure 7 .
22、Residuals Managed in 1994 Figure 16 . Managed Quantities of Tank Bottoms: 1987 . 1994 . 23 Figure 17 . Management of Tank Bottoms 23 Figure 18 . Managed Quantities of Pond Sediments: 1987 . 1994 . 25 Figure 19 . Management of Pond Sediments . 25 Figure 20 . Managed Quantities of Contaminated Soils:
23、1987 . 1994 27 Figure 2 1 . Management of Contaminated Soils 28 Figure 22 . Managed Quantities of FCCU Catalysts: 1987 . 1994 . 29 Figure 23 . Management of FCCU Catalysts . 29 Figure 25 . Management of Hydroprocessing Catalysts . 31 Figure 24 . Managed Quantities of Hydroprocessing Catalysts: 1987
24、. 1994 31 Figure 26 . Managed Quantities of Other Spent Catalysts: 1987 . 1994 34 Figure 27 . Management of Other Spent Catalysts . 34 Figure 28 . Managed Quantities of Biomass: 1987 . 1994 . 36 Figure 29 . Management of Biomass . 36 Figure 30 . Managed Quantities of Spent Caustics: 1987 . 1994 38 F
25、igure 3 1 . Management of Spent Caustics . 38 Figure 32 . Summary of Residual Generation A987 . 1994 Figure 33 . Trends in Management Practices . 43 Figure 34 . Managed Quantities of All Residual Materials: 1993 . 43 . 44 API PUBLJ336 96 O732290 05b0257 704 TABLES Table 1 . Frequency of Reporting Wa
26、stewater System Components 7 Table 2 . Comparison of Wastewater Treatment Components by Capacity Class 8 Table 3 . Sources of Water Discharged by Refineries . 8 Table 4 . Water Quality Discharge Parameters 9 Table 5 . Responses to Pollution Prevention Question 11 Table 6 . Management Techniques Used
27、 for the NI Separator Sludge Residual Stream . 15 18 Table 7 . Management Techniques Used for the DAF Float Residual Stream Table 8 . Management Techniques Used for the Slop Oil Emulsion Solids Residual Stream 20 Table 9 . Management Techniques Used for the Primary Sludge Residual Stream 22 Table 1
28、O . Management Techniques Used for Tank Bottoms . 24 Table 11 . Management Techniques Used for Pond Sediments . 26 Table 12 . Source of Contaminated Soils 27 Table 13 . Management Techniques Used for Contaminated Soils 28 Table 14 . Management Techniques Used for FCCU Catalysts . 30 Table 15 . Manag
29、ement Techniques Used for Hydroprocessing Catalysts . 32 Table 16 . Management Techniques Used for Other Spent Catalysts . 35 Table 17 . Management Techniques Used for Biomass . 37 Table 18 . Management Techniques Used for Spent Sulfidic. Naphthenic and Cresylic Caustics . 39 Table 19 . Management T
30、echniques Used for Spent Caustics 41 API PUBLx336 96 E 0732290 0560258 640 E EXECUTIVE SUMMARY The petroleum refining industry managed 4.8 million wet tons of 15 key residual materials in 1994. This was comparable to the quantity for these streams reported in 1992, and is somewhat less than the high
31、 observed in 1990. A peak in the Primary Sludge residual stream (associated with the regulatory deadlines to close or retrofit surface impoundments) and an increase in Hydroprocessing Catalysts overwhelmed the reductions observed for Pond Sediments and Contaminated Soils, and contribute to making th
32、is last cycle the third largest documented by the American Petroleum Institutes (API) annual refining survey. Summary of Residual Generation: 1987 - 1994 (represents 15 residual streams) I 6000 5000 4000 E3000 1 v) U O v) E z 2000 - o 1000 i o “ 1 / I I l I I I 1 1987 1988 1989 1990 1991 1992 1993 1
33、994 Regarding the management of these streams, treatment continues to account for slightly more than 30 percent of the residuals. Since 1992, however, more material has been recycled than treated. Use of land treatment has diminished substantially and disposal, which peaked between 1990 and 1991, ha
34、s stabilized at a low level comparable to that observed in 1989. These findings were based on the data from 15 residual streams that were included in APIs refining survey. API substantially reduced the number of streams included in its 1994 survey in order to curtail the burden associated with parti
35、cipating in the study. The streams selected for continued study include the most closely regulated residuals and other high volume streams that are generated by the majority of refineries. The 15 streams represent approximately 80 percent of all residuals generated and are the most costly streams to
36、 manage. Refiners responded positively to these changes, reporting that the new, abbreviated forms were much easier to complete. This was reflected in the response rate for the study, which continued to represent more than 60 percent of the domestic refining capacity. Other modifications of the surv
37、ey questionnaire were undertaken to improve the utility of the data. For example, the spent caustic stream was broken out to differentiate the three types of caustics: sulfidic, APIs Petroleum Industry Environmental Performance (PIEP) report (API, 1996) lists 13 residuals. The numbers are comparable
38、, however, since the PIEP report treated three caustic streams as one stream. These streams represent approximately 80% of all residuals generated. ES- 1 API PUBL*336 96 = 0732290 0560259 587 10 5 O naphthenic and cresylic. This enabled a better comparison between Environmental Protection Agencys (E
39、PA) and MIS findings on the management of these materials. As noted in the report, both groups found that a substantial portion of the spent caustics are reclaimed, used as commercial feedstock, or reused as secondary materials in other manufacturing processes. -e , * -.* ., . . . *-.-*. a. I I l I
40、l I I Trends in Management Practices 40 1 35 30 - 25 2 20 S a Q) Treatment - Recycle Land Treatment -. - Disposal . . . . . . . . Other revisions included new questions on wastewater treatment systems and discharges and the inclusion of questions on the management costs for several of the streams. T
41、his information should expand the utility of the survey findings, enabling multi-media tracking of industry progress and practical experience with cost accounting strategies. A series of scatter plot charts summarizing the cost data are included following the discussions of API separator sludge, hyd
42、roprocessing catalysts, and spent sulfidic caustic. ES-2 API PUBLx33b b 0732290 05b02bO 2T9 INTRODUCTION For 1994, the American Petroleum Institute (API) substantially revised its annual refining survey. The scope of the survey was expanded from the single media (wastekesidual) approach by the inclu
43、sion of new questions on wastewater treatment systems and discharges. A series of questions on the management costs for select residual streams was added to the basic survey items on generation quantities and handling practices. To reduce the burden associated with completing the survey, API limited
44、 the number of residual streams included in the survey. Using criteria that included regulatory status, quantity generated, and the magnitude of management costs, the number of streams included in the 1994 survey was reduced from 30 to 15. Data reported in the Executive Summary represents only the 1
45、5 streams surveyed for years 1987-1994. These changes reflect APIs ongoing critical review of the survey effort and its commitment to implement modifications that will improve the quality and utility of data collected. The reductions in the scope of the survey were bom of necessity. Given the overar
46、ching economic considerations directing the streamlining of American industries in the 1990s, refiners view voluntary efforts critically. An important factor in their decision to participate in such efforts is the “value added to their operations from participation in an extemal effort. The addition
47、s to the 1994 survey are NIS attempt to increase the value of the survey. The inclusion of information on capital improvements to the wastewater system and on management costs will be used to create benchmarks that refiners can use to evaluate their performance and the efficiency of their operations
48、. The inclusion of these questions also reflects NIS desire to keep abreast of current environmental performance monitoring trends: multi-media tracking systems and mechanisms to support total cost accounting. The changes in the scope of the survey also have ramifications on the public reporting of
49、the industry- wide estimtes. Whereas the survey previously summarized all residuals generated by the industry, the 1994 effort provides a profile of some of the residuals. Accordingly, the format used in this report focuses on specific streams, in a section-by-section basis. The waste management hierarchy-which recognizes that prevention of waste by source reduction activities and recycling is preferred to treatment and disposal of wastes-has been retained, but is used now to structure the reporting on each of the residual streams. Despite these changes, the p
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