1、 API PUBLu329 94 0732290 054397b 908 m AND MANAGEMENT 1 9 9 1 API PUBLu329 94 0732290 0543977 844 Generation and Management of Residual Materials Petroleum Refining Perf ormance 1991 Survey Health and Environmental Affairs Department API PUBLICATION NUMBER 329 PREPARED UNDER CONTRACT BY: GAIL LEVINE
2、 WENDALL CLARK SUMMATIONS WC CONSULTANTS WASHINGTON, D.C. HOPEWELL JUNCTION, N.Y. MAY 1994 American Petroleum Institute API PUBLlir329 94 0732290 0543978 780 = FOREWORD API PUBLICATIONS NECESSARILY ADDRESS PROBLEMS OF A GENERAL NATURE. WITH RESPECT TO PARTICULAR CIRCUMSTANCES, LOCAL, STATE, AND FEDE
3、RAL LAWS AND REGULATIONS SHOULD BE REVIEWED. API IS NOT UNDERTAKING TO MEET THE DUTIES OF EMPLOYERS, MANUFAC- TURERS, 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 LOC
4、AL, 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 METHOD, APPARATUS, OR PRODUCT COV- ERED BY LETTERS PATENT. NEITHER SHOULD ANYTHING CONTAINED IN ITY FOR INFRINGEMENT
5、OF LETTERS PATENT. THE PUBLICATION BE CONSTRUED AS INSURING ANYONE AGAINST LIABIL- Copyrighi Q 1994 American Petroleum Institute i API PUBL*327 94 = 0732270 O543779 bL W ACKNOWLEDGMENTS THE FOLLOWING PEOPLE ARE RECOGNIZED FOR THEIR CONTRIBUTIONS OF TIME AND EXPERTISE DURING THIS STUDY AND IN THE PRE
6、PARATION OF THIS REPORT API STAFF CONTACTs) Barbara Bush, Health and Environmental Affairs Department Genevieve Laffly Murphy, Manufacturing, Distribution 2) Interim Status (Part A filed) or 3) RCRA permit issued. The refineries were rather evenly distributed, with 38 that were only generators, 38 t
7、hat had received their permit, and 29 facilities that were in Interim Status. 3-4 API PUBL*329 94 0732290 0544001 761 m RESIDUAL GENERATION The total amount of residual materials generated in 1991 by the 183 US. petroleum refineries was estimated to be 14.8 million wet tons-the smallest quantity est
8、imated during the five years of this survey. As shown in Figure H, this was 2.9 million wet tons less than the 18.2 million wet tons generated in 1991 and substantially less than generated in 1987-1989. As the vertical variance bars on the estimates indicate, the difference between 1991 and 1990 was
9、 statistically significant (Le., the vertical bars do not overlap). The amount of residuals generated in 1991 and 1990 differed significantly from the quantities estimated for 1987-1 989, which, as shown by the overlap in the variance bars, were comparable. Figure H Residual Generation in the Petrol
10、eum Refining Industry: 1991 - 1987 *Oc 19 :;I, , , , , io 1991 1988 1989 1990 YEIR 9 1987 What happened in 1991? The greatest change was observed in the generation of Other Aqueous Residuals, a stream generated by only a few refiners, but one that has accounted for more than two thirds of the residu
11、als generated in each survey cycle. The amount of Other Aqueous Residuals generated in 1991 was over 2 million wet tons less than 1990. This reduction reflects movement by some refiners away from deep well injection of residuals, with concomitant changes in the pretreatment and handling of the dilut
12、e residuals that had been suitable for injection. In 1991, four refineries reduced their reliance on deep well injection and are planning total phase-out of this disposal technique. Another refinery obtained a “no-migration“ permit for their Class I well, having demonstrated that continued use of th
13、e well presents no environmental hazards, At the same time, the industry witnessed an increase in the amount of primary sludges generated, the newly listed “F wastesi under RCRA. Two hundred thousand additional wet tons of these materials were estimated as being generated in 1991. It is unclear whet
14、her this represents a true increase in generation, an artifact of the new classification and reporting requirement (e.g., the IF wastes“ were reported for the first time in 1991 as individual streams), or even a peak in generation that resulted from refiners making an effort to remove 3-5 API PUBL*3
15、29 94 H 0732290 0594002 bT8 Residual Category Aqueous residuals NOS RCRA F Wastes Remaining 27 Residual Streams Total these materials before more costly management practices are required when LDR requirements become effective. Comparing the differences in the quantities of API Separator Sludge and D
16、AF Float generated between 1990 and 1991 , with the quantities of Primary Sludge reported in 1991, however, make it clear that with few exceptions, refiners did not reclassify K-wastes as F-wastes. The exceptions included a refinery that had previously reported the residual from an Induced Air Flota
17、tion unit as DAF float and was now correcting their reporting to show that this material was a Primary Sludge. In another case, a refinery reported taking an API Separator out of service and replacing it with an IAF unit (again appropriately reported as a Primary sludge). 1991 1990 1989 1988 1987 9,
18、036 11,107 11,100 11,076 11,296 327 97 144 104* 79 5,482 6,902 5,067 4,864 4,769 14,845 18,106 16,311 16,044 16,144 The remaining 26 streams had an overall decrease of close to 1.4 millions wet tons, as illustrated in Table 2. Table 2 Estimate of Ali Residuals Generated by the US. Refining Industry:
19、 1991 (thousands of wet tons) *The quantities for 1987-1990 for Primaiy Sludge were based on the estimates for “Other Separator Sludges,“ a stream that was subsumed in 1991 by the Primary sludge streams. This pattern of an increase in one type of residual being offset by decreases in other streams i
20、s noted in Table 3, which presents the annual data for the 29 individual streams. Increased quantities were estimated for the two largest streams, spent caustics and biomass. For both of these streams, the 1991 quantities were the largest ever generated. Other streams with increases were relatively
21、low quantity streams: residual coke/carbon/charcoal, residual amines, oil contaminated water (not wastewater) and spent sulfite solution. The largest decrease was noted for ppnd sediments which plummeted from its 1990 peak of over one million wet tons to 372 thousand wet tons. This was a return to a
22、 level comparable to the pre-1990 high when many refiners reported closures of surface impoundments that created the spike in the generation curve. Although the quantity of Contaminated soils /solids also dropped from the peak in 1990, this stream remained the third largest. Refiners continued to re
23、port substantial one-time generation quantities of this stream: for 1991, over 400 thousand wet tons or 67 percent of the total amount of Contaminated soil/solids generated resulted from “abnormal“ events. Common knowledge of the industrys ongoing site remediation activities and construction to upda
24、te refining process units corroborates this generation pattern. 3-6 API PUBL+329 94 0732290 0544003 534 Table 3 Estimate of Residual Materials Generated by the U.S. Refining Industry: 1991 :housands of wet tons) Residual stream Spent Caustics Biomass Contam in ated so i Islso I id s DAF float Other
25、inorganic residuals NOS Pond sediments Other residuals NOS API separator sludge FCC catalyst or equivalent Primary sludge (F038) Slop oil emulsion solids Residual coke/carbon/charcoal Residual amines Primary sludge (F037) Nonleaded tank bottoms Spent acids Oil contaminated waters (not wastewaters) H
26、igh pHAow pH waters Other oily sludges/organic residuals NOS Other contaminated soils NOS Hydroprocessing catalysts Spent Streford solution Other spent catalysts NOS Residual oils/spent solvents TSD Leachate (F039) Residual sulfur Spent sulfite solution Heat exchanger bundle cleaning sludge Leaded t
27、ank bottoms Other separator sludges Total 1991 909 855 809 406 397 372 339 21 o 204 177 165 138 136 130 1 o9 88 67 54 54 37 32 25 23 21 20 19 9 3 1 NA 5,809 1990 889 782 920 553 451 1 ,O1 7 352 251 198 291 92 75 194 336 8 105 53 69 31 29 39 115 35 1 13 3 97 6,999 1989 71 6 642 512 496 440 31 3 325 4
28、1 9 182 272 129 51 161 8 29 91 47 53 36 42 33 31 52 8 2 4 114 5,508 1988 656 786 240 655 213 266 41 2 355 193 224 67 14 129 149 36 138 61 68 36 49 37 7 22 40 5 8 104 4,968 1987 675 757 165 652 325 337 203 400 173 208 43 13 21 6 126 28 144 38 82 40 35 33 4 17 42 3 9 79 4,868 The decreases in the RCRA
29、 “K wastes“ also contributed to the overall reduction in generation quantities. DAF float and slop oil emulsion solids both dropped by over 100 thousand wet tons, to 406 and 165 thousand wet tons, respectively. API separator sludge experienced a more modest decrease, but had already undergone some s
30、uccessive, substantial reductions. 3-7 API PUBL*329 94 O732290 0544004 470 M While the quantities of heat exchanger bundle cleaning sludge and leaded tank bottoms were quite small, they nonetheless represented reductions of one third or more. As will be discussed later in this report, many refinerie
31、s attributed these decreases to source reduction activities. Sizeable reductions were also observed for spent acids, nonleaded tank bottoms, other contaminated soils and residual oilskpent solvents, streams that have some similarities in reporting patterns, but more interesting differences. As shown
32、 in Table 4, nonleaded tank bottoms, other contaminated soils and residual oilskpent solvents were reported by at least 59 refineries, a relatively high rate for this survey. Spent acids, on the other hand, was only reported by 20 refineries. What is interesting is that the decrease for spent acids
33、and residual oilskpent solvents reflects a change in generation rate by a only a few of the refineries participating in the survey, while the reductions in the other two streams appears to reflect a more systematic change by the group of refiners reporting each of these streams. These frequency coun
34、ts provide corollary information to the estimated quantity of residuals by the population of refiners, suggesting that there are patterns of generation. From Table 4 it is clear that no individual stream is generated by all refiners in any year. Yet some streams are generated by individual refiners
35、every year, while other refiners generate these streams every other year, less frequently, or not at all. Because residual streams are generated periodically, no single year of data can provide a reliable snapshot of industry practices. Even with several years of data, effort must be exerted to cont
36、rol for this source of variability in the estimated quantity of residual material. 3-0 API PUBL+329 94 m 0732290 0544005 307 m Table 4 Number of Refineries Reporting Each Stream Residual stream Total number of refineries participating Contaminated soils/solids Other residuals NOS FCC catalyst or equ
37、ivalent API separator sludge Nonleaded tank bottoms Spent caustics Residual oils/spent solvents Other spent catalysts NOS Other inorganic residuals NOS Primary sludge (F037) Other contaminated soils NOS Hydroprocessing catalysts Residual cokekarbonkharcoal Biomass DAF float Heat exchanger bundle cle
38、aning sludge Other oily sludges/organic residuals NOS Residual sulfur Slop oil emulsion solids Residual amines Pond sediments Leaded tank bottoms Spent acids Other aqueous residues NOS Primary sludge (F038) Oil contaminated waters (not wastewaters) Spent Stretford solution High pH/low pH waters Spen
39、t sulfite solution TSD Leachate Other separator sludges 1991 113 90 83 76 76 69 69 65 63 62 59 59 57 55 45 44 43 43 43 32 32 25 20 20 14 14 10 6 4 3 3 NA 1990 103 87 85 79 85 72 66 56 57 65 56 52 50 44 50 51 42 37 35 27 34 27 24 11 10 7 11 1 19 1989 117 88 89 84 93 72 70 56 60 73 61 65 51 44 47 49 49 42 38 38 31 31 18 14 14 11 11 2 22 1988 115 77 85 86 94 75 77 61 60 73 71 60 47 45 50 48 47 47 43 36 29 37 23 12 10 13 12 1 20 1987 115 77 92 85 91 72 79 52 62 77 70 57 48 47 53 49 49 41 47 32 26 38 20 13 14 12 14 1 15 3-9
