1、 _- API PUBL*302 91 0732290 0528994 683 Waste Minimization in the Petroleum Industry a Compendium of Practices Health and Environmental Affairs PUBLICATION NUMBER 3020 NOVEMBER 1991 American Petroleum Institute API PUBL*:302 91 W 0732290 0528995 5LT Acknowledgemenlts This project was performed by th
2、e American Petroleum Institute (MI) through the combined efforts of consultants, company representatives, and API staff. Mittelhauser Corporation, in conjunction with the API Waste Minimization Task Force, developed the concept and assembled the bulk of the document. R.G. Mattson brought additional
3、marketing expertise to the project. Christina GrifJin of Delta Analytical, Inc and Alan J. Senzel assisted in the technical edit of the report. Rick Stalzer of BP America, Don Hitchcock of Texaco, and Joel Robbins of Amoco made substantial contributions to the technical details. Barbara Bush of APIs
4、 Health ancl Environmental Affairs Department served as Project Ofleer. The API Refining, Marketing, and Production Departments and Ofice of General Counsel provided essential review of the technical information which facilitated completion of the document. API PUBLX302 91 0732290 E1528996 456 FOREW
5、ORD 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
6、 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,
7、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. API makes no recommendations regarding the course of conduct that should be followed, and
8、the reader is in no way bound to the findings of this study. The reader should exercise independent judgment that suits individual needs and must negotiate independently with the suppliers of any technology. API makes no promises, claims, or recommendations as to the site specific applicability, per
9、formance, or economics of any technology described herein. The reader is cautioned regarding the interpretation of any references to “costs“ or “cost effectiveness“ as these references may not be applicable to his/her specific application. This guideline may be used by anyone desiring to dio so. Eve
10、ry effort has been made by the American Petroleum Institute to assure the accuracy and reliability of the material contained in it at the time in which it was written; however, the institute makes no representation, warranty, or guarantee in connection with the publication of this guideline and here
11、by expressly disclaims any liability or responsibility for loss or damage resulting from its use or for the violation of any federal, state or municipal regulation with which this guideline may conflict, nor does the institute undertake any duty to ensure its continued accu racy. API PUBL*302 91 073
12、2290 0528997 392 Preface The American Petroleum Institute (API) sponsored the preparation of this document, “Waste Minimization in the Petroleum Industry: A Compendium of Practices“, which summarizes many practices currently used in the exploration and production, refining, and marketing segments of
13、 the oil industry. Thirty-five industry respondents were surveyed to provide information on practices to minimize wa.ste volume or toxicity. Additional information has been developed from literature review of practices in the oil, chemical, and utility industries. The regulation of many of the strea
14、ms and practices contained in this report has been changing rapidly. Therefore, careful review of all federal, state, and local laws and regulations should be undertaken before implementation of any of the practices contained herein. The Compendium is intended to provide a summary of current practic
15、es and is not intended as a basis for regulatory compliance. API PUBL*302 91 0732290 0528998 229 Executive Summary In early 1988, the American Petroleum Institute undertook a project to develop this document, “Waste Minimization in the Petroleum Industry: A Compendium of Practices“ for the productio
16、n, refining, and marketing segments of the industry. The following pages demonstrate the petroleum industrys keen awareness of the importance of minimizing waste, a worldwide trend that represents the wave of the future for all industrial processes. This Compendium focuses primarily on widespread pr
17、actices tc reduce the volume and toxicity of solid and liquid wastes generated by a multitude of operations and maintenance activities within the oil industry. Increasing costs and potential liabilities for disposal of wastes are providing ever-increasing pressure to develop cost effective means to
18、minimize the amount of waste generated by every industrial facility. Indeed, minimization of waste has become an integral element of ali good industrial waste management programs. Waste minimization practices can generally be divided into three categories. First, eliminating as much waste as possibl
19、e at the source of generation is a primary factor in ameliorating waste management problems. Second, recycling waste can have considerable economic benefits; in some cases, waste containing oil can be recycled back to operating units for recovery and/or conversion into saleable products. Third, trea
20、tment of waste can reduce its volume or toxicity and thereby help avoid high disposal costs. Treatment processes frequently recover oil for recycling and product water for reuse or disposal with normal wastewater eff luent. This Compendium reviews and summarizes the current state of the art in minim
21、izing waste and reducing toxicity at oil industry facilities. Schematic diagrams of important processes are provided, and specific case histories with cost-benefit analyses are described in detail. Increasingly stringent federal, state, and municipal regulations have provided opportunities and econo
22、mic incentives for the petroleum industry to implement significant waste reduction programs. Large facilities must furnish biennial reports on their progress to the U.S. Environmental Protection Agency. Land disposal restrictions on listed refinery wastes require facilities to treat these wastes usi
23、ng Best Demonstrated Available Technology (BDAT) before placement on the land. Newly promulgated regulations are resulting in even more waste streams being characterized as hazardous. This Compendium is intended to help API members meet current and future challenges with regard to minimizing waste i
24、n the petroleum industry. Clearly, as the complexity and cost of hazardous waste management and disposal increase, waste minimization efforts will become top priorities for all facilities in our industry. API PUBLk302 91 m 0732290 0528999 165 m Table of Contents Foreward i Preface ii . Executive Sum
25、mary III Table of Contents iv List of Figures viii List of Case Studies ix 1 Introduction and Document Use . 1 1.1 Background 1 1.1.1 Questionnaire . 1 1.1.2 Literature Survey . 1 1.2 Using this Document . 1 2 Waste Minimization . 3 3 Exploration and Production Waste Minirnization . 5 3.1 Design and
26、 Planning Considerationis 5 3.2 Drilling and Workover Fluids . 6 3.2.1 Substitution of Drilling Fluid and Fluid Additives 7 3.2.2 Oil Separation and Removal from Drilling Fluids . 7 3.2.3 Removal of Solids from Drilling Fluid . 8 3.2.4 Segregation and Reuse lof Drilling and Wo r koverlcom plet ioin
27、FI u ids . 8 3.3 Oily Sludges from Production Activities 9 3.4 Solvents and Chemicals . 10 3.4.1 Amine Reclaiming . 10 11 3.4.3 Saltwater-Contaminated DEA . 11 3.4.4 Purge Streams from Sul. fur Removal . 12 3.4.4.1 Reclaiming/Recycling . 13 3.4.4.2 Conversion to Chelated Iron Processing1 13 3.5 Misc
28、ellaneous Used Materials . 13 3.5.1 Empty Drums 13 3.4.2 Triethylene Glycol Reclaiming API PUBL*302 91 W O732290 0529000 585 m 4 3.5.2 UsedOils Ref in in g Waste Min i mizat i on Practices . 4.1 Oily Sludges 4.1.1 Control of Solids into Wastewater System 4.1.1.1 Runoff Control . 4.1.1.2 Control of E
29、xchanger Bundle Cleaning Solids 4.1.1.3 Control of FCCU and Coke Fines . 4.1.1.4 Minimizing of Fine Solids Recycling . 4.1.2 Control of Surfactants in Wastewater System 4.1.3 Desalter Brine Treating . 4.1.4 Filtration 4.1.4.1 Belt Filter Press 4.1.4.2 Recessed Chamber Pressure Filter (Plate Filter)
30、. 4.1.4.3 Rotary Vacuum Filter 4.1.5 Centrifugation 4.1 51 Scroll Centrifuges 4.1.5.2 Disc Centrifuge 4.1.6 Thermal Treatment 4.1.7 Sludge Coking 4.1.7.1 Quench Water Injection 4.1.7.2 Coking Cycle Injection . 4.1.7.3 Blowdown Injection . 4.2 Tank Bottoms . 4.3 Fluid Catalytic Cracking Unit (FCCU) D
31、ecant Oil Sludge . 4.4 Purge Stream from Tail Gas Treating . 4.4.1 MDEA Conversion . 4.4.2 ADA and Vanadium Recovery Process . 4.5 Empty Drums . 4.6 Slop Oils . 4.7 Solvents . 4.8 Spent Caustics Caustic 4.8.1.1 Off-Site Recycling 4.8.1.2 On-Site Recycling 4.8.2 Recycling Sulfitic Caustic . 4.9 Spent
32、 Catalysts 4.9.1 Recycling to Metals Reclamation 4.9.2 Recvclina to Cement . 4.1.5.3 System Design 4.8.1 Recovery and Recycling of Phenols from 14 16 16 17 18 19 19 20 22 24 25 25 26 27 28 28 29 29 30 31 31 32 32 32 34 35 35 36 37 37 38 39 39 40 40 40 41 41 42 . API PUBL*302 91 = O732290 05290011 41
33、11 = 5 4.10 Spent Clay . 4.11 Sandblast Media 4.1 1.1 Abrasive Blast Media 4.1 1.2 Copper Slag Abrasive with Recycling . 4.1 1.3 Alumina Oxide Abrasive with Recycling . 4.12 HF Sludge Media 4.1 2.1 Neutralization and Filtration 4.1 2.2 Production of Fluorspair . 4.13 Cooling Tower Blowdown . 4.13.1
34、Minimizing the Quantity of Cooling Tower 4.13.2 Minimizing the Toxicity of Cooling Tower Blowdown Blowdown Miscellaneous Wastewater System Wastes 4.14.1 Replace Phenol Extraction . 4.14.2 Changing Coagulation Chemical . 4.1 4.3 Stormwater Diversion and Reuse 4.1 4 Marketing Waste Minimization Genera
35、l Procedures for all Marketing Facilities 5.2 Classification of Marketing Segmeni Facilities 5.1 5.3 Refined Product Storage and Distribution Terminals and BulkPlants . 5.3.1 Terminal and Bulk Plant Yard Areas . 5.3.1.1 Stormwater Runoff . 5.3.1.2 Filter Separators . 5.3.1.3 Air Eliminatoirs . 5.3.1
36、.5 Product Pump-off andlor Truck 5.3.1.6 Tank Car Unloading . 5.3.1.7 Empty Drum Storage 5.3.2.1 Antifreeze (See also Section 5.5.5) . 5.3.2.2 Solvents (See also Section 5.5.6) . 5.3.2.3 Used Oil (See also Section 5.5.4) . 5.3.2.4 Floor Cleaners (See also Section 5.3.2.5 Truck Washing (See also Sect
37、ion 5.3.2.6 Aluminum Brighteners . 5.3.3 Tank Basins . 5.3.3.2 Sample House . 5.3.1.4 Loading Racks . Unloading . 5.3.2 Truck Maintenance Bays 5.4.2) . 5.5.3) . 5.3.3.1 Tank Water Draining 42 42 43 43 44 44 44 44 45 45 47 47 48 48 49 81 81 82 82 82 83 83 83 84 84 85 85 85 86 86 86 86 87 87 88 88 89
38、API PUBL+302 91 O732290 0529002 358 5.3.3.3 Additive Injection Facilities . 89 5.3.3.4 Tank Cleaning . 90 5.3.4 Alcohols 91 5.3.5 Marine Docks 91 5.3.5.1 Dock Product Transfer Areas . 91 5.3.5.2 Sanitary Waste 92 5.3.5.3 Ballast Water 92 5.3.5.4 Package Storage . 92 93 5.4.1 Boiler Blowdown 95 5.4.2
39、 Floor Cleaning 95 5.4.3 UsedOil 96 5.4.4 Loading Rack Slab Washing . 96 5.4.5 Sludges from Separator and Sumps . 96 5.4.6 Slop Oil and Commingled Product 97 5.4.7 Lube and Grease Manufacturing 97 5.4.8 Solvents (See also Sections 5.3.2.2 and 5.5.6) . 98 5.4.9 Sampling and Laboratory Wastes . 98 and
40、 Truck Stops) 99 5.5.1 Underground Leaks and Product Spills 100 5.5.2 Underground Tank Water Bottoms . 101 5.5.3 Car Wash (See also Section 5.3.2.5) 101 5.5.4 Used Oil (See also Section 5.3.2.3) . 102 5.5.5 Antifreeze (See also Section 5.4.2.1) 102 5.5.6 Solvents (See also Sections 5.3.2.2 and 5.4.8
41、) . . 102 5.5.7 Tires 103 5.5.8 Batteries . 103 5.5.9 Oily Solid Waste (Filters, Sumps, Rags, 103 5.4 Complex Marketing Terminals . 5.5 Retail Facilities (Service Stations, Fast Lubes, C-Stores Empty Containers and Absorbent) . Bibliography 108 Appendix A Questionnaire and Instructions . A-1 Appendi
42、x B Letter of Transmittal for Production. Refining and Marketing . B-1 API PUBLX302 91 0732290 0529003 294 List of Figures Figure 4.1-1 : Figure 4.1 -2: Figure 4.1 -3: Figure 4.1-4: Figure 4.1 -5: Figure 4.1-6: Figure 4.1 -7: Figure 4.1 -8: Figure 4.1-9: Figure 4.1-10: Figure 4.1-1 1 : Figure 4.1-12
43、: Figure 4.1 -1 3: Figure 4.3-1 : Figure 4.4-1 : Figure 4.8-1 : Figure 4.8-2: Figure 4.1 3-1 : Figure C-4-4: Figure C-4-7: Figure (2-5-1 : Typical Refinery Solids Recyclle Loop 50 Integration of Sludge Treating Unit into Refinery Operation 51 Desalter Brine Treating Unit . 52 Belt Filter Block Press
44、 Flow Diagram 53 Plate Filter Press Block Flow Diagram . 54 55 Rotary Vacuum Filter Block Flow . 56 Operation of a Disc Centrifuge . 58 Thermal Treatment Block Flow Diagram 59 61 Cross Section Diagram Recessed Plate Filter Operation of a Horizontal Scroll1 Centrifuge . 57 Process Flow Diagram Quench
45、1 Water Injection 60 Process Flow Diagram Coking Cycle Injection . Process Flow Diagram Blowdown Injection . 62 Recovery Process Block Flow Diagram 64 A Simplified Schematic of a Cooling Tower . 67 Asphalt Waste Recycling 106 FCCU Decant Oil Catalyst Removal System Block Flow Diagram . 63 Phenol in
46、Gasoline 65 Phenolic Caustic Treatment . 66 Deoiling of Desalter Effluent 74 Sludge Coking Process 78 API PUBL+302 91 m 0732290 0529004 120 m List of Case Studies Case Study 3-1 : Case Study 4-1 : Case Study 4-2: Case Study 4-3: Case Study 4-4: Case Study 4-5: Case Study 4-6: Case Study 4-7: Case St
47、udy 4-8: Case Study 5-1 : Case Study 5-2: Filter Press . 15 Street Sweeper to Reduce Oily Sludges . 68 Reuse of FCC Fines 69 Alternative Sandblast Media and Recycle 70 Deoiling of Desalter Effluent 72 Screening of Solids from Exchanger Cleaning 75 Spent Jet Fuel Treater Clay Deoiling . 76 Sludge Cok
48、ing 77 Chemical Recovery Process 79 Asphalt Waste Recycling . 104 Recycling of Soap Dust Waste 107 . API PUBLr302 91 0732290 0529005 Ob7 1 Introduction and Document Use 1 .I Background Information from several sources was assembled to form this Compendium. A survey of API members was conducted using
49、 a questionnaire developed to gather practical information on actual practices. Additional information was obtained from literature sources such as technical papers from symposia and journals as weil as various trade associations. A bibliography of these documents is presented just before the appendices. Those who worked on the preparation of the Compendium drew upon first-hand knowledge regarding waste mi ni mization practices. The Compendium was prepared to present the information in a form suitable for quick reference by top management and field personnel alike. The w
