1、 API PUBL*303 92 D 0732290 051082b T25 , .- I l Generation and Management of Wastes and Secondary Materials Petroleum Refining Performance 1989 Survey 5 AMERICAN PETROLEUM INSTITUTE HEALTH AND ENVIRONMENTAL AFFAIRS DEPARTMENT JUNE 1992 FORWARD . API PUBLICATIONS NECESSARILY ADDRESS PROBLEMS OF A GEN
2、ERAL NATURE. WITH RESPECT TO PARTICULAR CIRCUMSTANCES, LOCAL, STATE AND FEDERAL LOWS AND REGULATIONS SHOULD BE REVIEWED. API IS NOT UNDERTAKING TO MEET DUTIES OF EMPLOYERS, MANUFACTURERS OR SUPPLIERS TO WARN AND PROPERLY TRAIN AND EQUIP THEIR EMPLOYEES, AND OTHERS EXPOSED, CONCERNING HEALTH AND SAFE
3、TY 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 PA
4、TENT. NEITHER SHOULD ANYTHING CONTAINED IN THE PUBLICATION BE CONSTRUED AS INSURING ANYONE AGAINST LIABILITY FOR INFRINGEMENT OF LETTERS PATENT. , , API PUBL*303 92 0732290 0530828 8T8 Ackno wiedgements APls . Pollution Prevention Task Force sponsored this survey, which was directed by Barbara L. Bu
5、sh, a Senior Regulatory Analyst in the Health and Environmental Affairs Department (HEA O). Other individuals who made significant contributions to the project include: Genevieve Laffly Murphy, in APls Refining Department, who served as liaison with the General Committee on Refining and the Committe
6、e on Refinery Environmental Control (CREC); Mark Hopkins from Chevron, the Chairman-of the Solid Waste Survey Workgroup that stewarded the project; Gail Levine from SUMhMTIONS, the,prime contractor for the project; Wendy Sams in APls Information Systems that developed the automated version of the qu
7、estionnaire; and Wendall Ciark, the expert consultant on refining practices. This core I group was assisted by/sfaff members from APls Statistics Department, the Office of General Counsel and the Editotial and Special Issues Department. I - - 1 , I . I - 1 I, I. . .- 4, API PUBLx303 92 M 0732270 05L
8、0829 734 . TABLE OF CONTENTS Executive Summary . :. . i Introduction ;. :. . 1 . _. -. , Methodology 3 -Data Collection . 3 Waste Minimization 5 Automated Questionnaire . a6 Survey Administration . 6 DataAnalysis . 7 Survey Design . 3 , Results 9 . *Response Rate 9 - Respondent Characteristics 9 Tot
9、al Waste Management Quantity . 12 Waste Generation 12 . Treatmerit Additives 15 Storage 15 Totat Quantity of Waste Managed . 16 Source Reduction . 18 21 Recycling . . 21 Treatment .: 1. 25 ., Waste Management . i. Land Treatment . . 29 Disposal . 31 I Waste Minimization Programs 34 Discussion 35 Was
10、te Generation . i. 35 Source Reduction . 38 . Waste Management . 39 . - I APPENDICES A - Questionnaire B - Statistical Procedures C - Summary of Source Reduction Activities E - Summary of Waste Management Practices for Individual Waste Streams L D -JYaste Management Summary Tables API PUBLa303 92 07
11、32290 0530830 456 i . TABLES 3 I 1 . Refining Waste Streams . 4 . . 2 - Estimated Wastes from the U.S. Refining Industry 14 3 . Number of Refineries Reporting Wastes . 15 I 4 . Top-five Waste Streams Removed from Storage 16 5 . Top-five Waste Streams Placed into Storage 16 6 . Estimated- Waste Quant
12、ities 17 I 7 . Summary of Source Reduction Achievements . 18 8 . Methods of Calculating Source Reduction Achievements . 19 . 9 . Summary of Source Reduction Activities . 20 10 . Incentives for Source Reduction Activities 21 22 I 11 . Summary of Recycling Practices 12 . Estimated Quantities of Recycl
13、ed Wastes 24 13 . Location of Recycling Activities . 25 14 . Summary of Treatment Methods . 26 15 . Estimated Quantities of Wastes Treated . 28 16 . Location of Treatment Activities 29 17 . Estimated Quantities of Land Treated Wastes ._ 30 * 18 . Summary of Disposal Practices . 31 19 . Estimated Qua
14、ntities of Wastes Eliminated by Disposal . 32 20 . Location of Disposal Activities 33 . 21 . Sources of Variability in Waste Generation Rates 1987-1989 . 37 22 . Barriers to Source Reduction . 38 / API PUBL*303 92 0732290 05L083L 392 I . B - Distribution of Respondents by Location 10 FIG UR ES A - N
15、umber of Respondents by Capacity Group . . 9 C - Distribution of Respondents by Complexity . 1 O D - Distribution of Respondents by Age 11 E - Distribution of Respondents by Sewer Type . 11 F - Waste Minimization Program Components 34 G - Wastes Generated: 1989 35 H - Wastes Generated: 1987-1 989 .
16、36 I -,Waste Management Practices: 1989 . 40 J - Waste Management -Practices: 1987-1 989 . 41 K - Management Practices for RCRA Hazardous Wastes 42 I / , . API PUBLX303 92 = 0732290 0510832 229 Eirecutive Summary 1989 Survey Each year, U.S. petroleum refineries process 650 million tons of crude oil
17、as they create fuels and othy petroleum products vital to the U.S. economy and way of life. Not much waste results - less than 1 percent of those 650 million tons. Still, that. amount ofwaste is a big number in its own right. This is the third annual survey of wastes generated by U.S. petroleum refi
18、neries - and how they handle those wastes. Conducted by the American Petroleum Institute, it is the only ongoing industry-wide effort of its kind. It is also the first to track “source reduction“ in refineries - preventing pollution by avoiding the creation of waste. For fhis survey, Generation and
19、Management of Wastes and Secondary Materials: Petroleum Refining Performance, API mailed questionnaires to 183 operating U. S. refineries. The 117 refineries that responded represent 74 percent of domestic refining capacity. This high response rate enabled API to develop industry-wide estimates with
20、 - a high degree of confidence and statistical accuracy. Wastes Generated U.S. refineries generated roughly 16.3 million wet tons of wastes and secondary materials in 1989 - about the same as in 1987 and 1988. The total includes non- hazardous and hazardous wastes (as classified under RCRA, the fede
21、ral Resource Conservation and Recovery Ad), byproducts, and other secbndary materials. The survey obtained information on 28 waste streams, grouped in six categories. As shown below, aqueous wastes constitute about two-thirds of the total. Four facilities (treated as outliers in the statistical anal
22、ysis) generate nearly ali of these wastes and dispose of them by injecting them into underground wells. In diminishing order of volume, the remaining wastes are oily sludges, chemicals, contaminated soils, “other,“ and spent catalysts. Types of Wastes Generated (millions of wet tons) Total Quantity
23、16.31 1 Wet Tons WS WarIn 11913 Al Other Waues Non-Aqueous Wastes 4.398 Wet Tons / 1659 con)unh.lsd sd( 747 API PUBLx303 92 0732290 0530833 365 - . 1 . With the exception of contaminated soil, the amount of each type of waste has remainedxabout the same since 1987. It appears that the amount of cont
24、aminated soil is on the risp - most likely, a result of new construction at refineries and stepped-up efforts to clean up and remediate contamination from past releases. . i Waste Management The U.S. Environmental Protection Agency has created a waste management hierarchy that reflects the growing e
25、mphasis on reducing the amount of waste generated rather than than treating and disposing of it. The ranking (in general order of preference) is source reduction, recycling, treatment, and disposal. Trends in handling petroleum refining wastes reflect the shift inemphasis in the waste management com
26、munity at large. Of the 11 7 refineries that participated in the 1989 survey, 55 reported progress in source -reduction. Their ctivities included technical and procedural modifications, in-process recycling, and improved housekeeping practices. Economic incentiyes such as lower treatment and disposa
27、l-costs were the main reasons they undertook such source reduction ,activities. Recycling of refinery wastes is also on the dse. Twenty-six percent of refineries wastes were recycled in, 1989, compared to 21 percent in 1987. In contrast, land farminsg has declined dramatically. It was used to dispos
28、e of 66 percent of refinery wastes in 1981 and 17 percent in 1987, but just 13 percent in 1989. As the illustration below shows, refineries use other waste management methods as well. In 1989, they eliminated 29 percent of their wastes through treatment and 32 percent through disposal - about the sa
29、me proportions as in 1987 and 1988. * - * Methods of Managing Wastes (millions of wet tons) RECYCLE 26% r- 13% OUTLIERSREMOVED / . 5.263 WETTONS !, , API PUBLX303 92 = 0732290 0530834 OT3 = 1 ., ImplicatYons APls waste management survey is a tool that quantifies the wastes petroleum progress, while
30、providing an overview of the industrys performance as a whole. Now that three successive years of data are available, it is also possible to compare the pxformance of individual refineries and the industry as a whole over time. Here, “within facility“ variations in amounts of wastes generated sugges
31、t that the industry- wide aggregated data give a false sense of stability. Annual variations in generation quantities for specific waste streams at individual refineries are up to seven times greater than those of the industry as a whole. If additional observations validate this trend, it could lend
32、 support to the view that site- specific factors merit consideration - espwially, in regulatory decisions. . refineries generate. It helps individual refineries assess their performance and monitor L 4 , , API PUBLr303 92 0732290 05L0835 T38 I . Introduction Four yearsago, API began chronicling the
33、generation and management of wastes and secondary materials in the petroleum refining industry. Recognizing that one-time data collection would provide a snapshot that could not be used to reliably assess progress, API committed to analyzing at least four consecutive years of data. In February 1991,
34、 the first two years of data were compiled and published in The Generation and Management of Wastes and Secondary Materials in the Petroleum Refining Industry 1987-7988 (API publication number 849-30000). This report on 1989 data continues the series. Data for 1990 are now being collected and will b
35、e published separately. The scope of the survey is broader than the Resource Conservation and Recovery Act (RCRAj regulatory definition of. solid waste. API has collected data on a variety of materials, including hazardous and non-haz,ardous wastes and secondary materials sometimes considered byprod
36、ucts or recyclable materials. The rationale for including both wastes and secondary materials in the survey is to characterize - and quantify - the non-fuel materials the refining industry generates and manages. Previous data collection efforts - by regulatory agencies and the industry itself - focu
37、sed only on certain wastes; the resulting lack of comprehensive information impaired advocacy efforts and slowed the planning of pollution prevention initiatives. The primary goal of the survey is to track the management of wastes and secondary materials from the point of generation. API has incorpo
38、rated an integrated waste management hierarchy in the data collection forms - classifying waste handling . practices as source reduction, recycling, treatment or disposal. This conceptual framework acknowledges that a range of practices is needed to handle wastes, and that some practices are more de
39、sirable than others. It may ,also help the industry and individal refineries assess progress over time both in reducing the amount of waste generated and in handling those that remain in an environmentally sound manner. The survey is an ambitious undertaking. In the area of waste - where conventiona
40、l wisdom holds that smaller is better - a large industry essentially asked, “How much?“ Petroleum refineries process some 15.7 million barrels of crude oil per per day - 5.7 billion barrels or 650 million tons per year. Even if the waste from each barrel is small, the sheer volume results in a large
41、 number. By amassing several years of da in an effort to create a reliable baseline, the industry risks being asked a second question, “How much less?“ Here, the variability inherent in refineries operating practices works against early detection of incremental progress in reducing wastes. One-time
42、events such as turnarounds or shutting down surface impoundments create peaks in waste volumes that can mask the progress better management practices and source reduction activities achieve. , API PUBL+303 92 0732290 0530836 974 = 7 , I Simply by conducting the survey, APIW.itec a third question, “W
43、hat does it mean?“ , While many quantitative observations can be explained - particularly where there are strong trends - the reasons why other numbers increase or decrease are more elysive. Though some may never be entirely clear, additional measures overiIn extended period of time may identify mor
44、e factors that influence generation rates .- and the magnitude of their effects. - Individual refineries have already reported that they find the survey a useful accounting tool for classifying and quantifying wastes. Having characterized their wastes, they may go on to compare themselves to the ind
45、ustry as a whole and target areas where change is needed. The aggregated survey data also provide a context for evaluating the impact-of new regulations and reporting requirements. Though it takes two to three years to amass the data, APls information is more current and cdmprehensive than reliable
46、estimates of the impact of proposed regulatory changes. any other waste management database. Thus, fhe survey can also provide more I / . T , -. *. I I t .* 2 I / 4 , . A Since the 1989 survey largely replicates the 1987-1 988 survey, the following discussion focuses on changes made to improve the q
47、uality of the data. For detailed information on general survey procedures, see The Generation and Management of Wastes and Secondary Materials in the Petroleum Refining Industry: 1987- 1988 (AP I publication number 849-30000). - This survey, like its predecessors, took a census approach. Using the D
48、epartment of Energys 1989 Petroleum Supply Annual and APls Entry and Exit in US. .f etroleum Refining, 1948-1989, the Institute updated its list of 176 operational refineries. The resulting population of 183 refineries used for the 1989 survey reflect the opening (under new ownership) of some refine
49、ries and the closing of others. Njnety-five companies owned the refineries; roughly a third were API members.? Data Collection - - The survey questionnaire had Wo parts: 12 short-answer questions about the age, size and complexity of the refinery, the types of source reduction activities performed, and “data sheets“ that captured quantitative information on generation of 28 types of wastes and secondary materials, and methods of managing them (see Appendix A). The 1
