1、-_ API PUBLX333 95 D 0732290 0554309 bT3 W GENERATION AND MANAGEMENT OF RESIDUAL MXTERIALS Petroleum Refining Performance 1992-1993 , - API PUBL*333 95 0732290 0554330 315 Envimnmentul Purtnmhip . One of the most significant long-term trends affecting the future vitality of the petroleum industry is
2、 the publics concerns about the environment. Recognizing this trend, API member companies have developed a positive, forward-looking strategy called STEP: Strategies for Todays Environmental Partnership. This program aims to address -public concerns by improving our industrys environmental, health a
3、nd safety performance; documenting performance improvements; and communicating them to the public. The foundation of STEP is the API Environmental Mission and Guiding Environmental Principles. API ENVIRONMENTAL MISSION AND GUIDING ENVIRONMENTAL PRINCIPLES The members of the American Petroleum Instit
4、ute 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 efficiently meeting societys needs and our
5、 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 responsihilities, API members pledge to manage our businesses according
6、 to these principles: 9 To recognize and to respond to community concerns about our raw materials, products and operations. *:e To operate our plants and facilities, and to handle our raw materials and products in a manner that protects the environment, and the safety and health of our employees and
7、 the public. To make safety, health and environmental considerations a priority in our-planning, and our develpment of new products and processes. +:* To advise promptly, appropriate officials, employees, customers and the public of information on significant industry-related safety, health and envi
8、ronmental hazards, and to recommend protective measures. *:+ To counsel customers, transporters and others in the safe use, transportation and disposal of our raw materials, products and waste materials. 4. TO economically develop and produce natural resources and to conserve those resources by usin
9、g energy efficiently. e:+ To extend knowledge by condlicting or supporting research on the safety, health and environmental effects of our raw materials, products, processes and waste materials. *:e To commit to reduce overall emission and waste generation. e:+ To work with others to resolve problem
10、s created by handling and disposal of hazardous substances from our operations. e:+ To participate with government and others in creating responsible laws, regulations and standards to safeguard the community, workplace and environment. e:+ To promote these principles and practices by sharing experi
11、ences and offering assistance to others who produce, handle, use, transport or dispose of similar raw materials, petroleum products and wastes. API PUBL*333 95 0732270 0554333 251 = Generation and Management of Residual Materials Petroleum Refining Performance 1992 - 1993 Survey Health and Environme
12、ntal Affairs Department API PUBLICATION NUMBER 333 PREPAREDUNDERCONTRACTBY: GAIL L. LEVINE DAVID N. RAMROTH SUMMATIONS WASHINGTON, D.C. DIANNA KOCERUK TI SCHLE R/KOCERU K ROUND ROCK, TEXAS WENDALL CLARK WC CONSULTANTS HOPEWELL JUNCTION, NY FEBRUARY, 1995 FOREWORD API publications necessarily address
13、 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 duties of employers, manufacturers, or suppliers to warn and properly train and equip their employees, and others exposed, concern
14、ing 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 c
15、overed by letter patent. Neither should anything contained in the publication be construed as insuring anyone against liability for infringement of letters patent. Copyright Q 1995 American Petroleum Institute API PUBL*333 95 O732290 0554313 024 = ACKNOWLEDGMENTS The following people are recognized
16、for their contributions of time and expertise during this study and the preparation of this report: API STAFF Barbara Bush, Health and Environmental Affairs Department Tim Sampson, Manufacturing, Distribution this increased to over one half of the quantity reported in 1993. These spikes in generatio
17、n are consistent with timing of variances EPA had provided to land ban requirements. Similar spikes in generation have been noted for other residuals streams, such as Contaminated soilskolids, Other inorganic residuals, Residual oildspent solvents, Pond sediments, and Other residuals NOS. Refiners h
18、ave indicated that these reflect capital improvements (Le., closure of units, construction and remediation activities). Such events occur infrequently, and as reported in the survey, are considered “one-time“ incidences. The quantities of these residuals associated with these abnormal events are sub
19、stantial, accounting for the increases in residuals noted since 1989, as well as the variability observed in residual generation between 1990 and 1993. 1990 1941 1992 1993 Generation of Residual Materials ES-2 API PUBLt333 95 rn 0732290 0554320 264 w The pattern observed for TC wastewaters, however,
20、 was successive reductions, rather than increases in generation. The largest quantity was reported in 1991, followed by an 11 percent reduction for 1992, and a 24 percent drop by 1993 (based on the 41 refineries that provided TC data in all three survey cycles). The pie charts presented below illust
21、rate the reduced reliance on surface impoundments to manage TC materials that has occurred over time. Management of TC Wastewaters 6% 1991 159 million wet tons 1992 141 million wet Ions 1993 121 million wet tons ES-3 API PUBLX333 95 = 0732290 0554321 LTO INTRODUCTION This report presents information
22、 on the generation and management of residual material in the petroleum refining industry during 1992 and 1993. This study differs from previous survey cycles and respective reports in that two years of data were collected and analyzed simultaneously. The American Petroleum Institute (API) employed
23、this strategy for several reasons. First, collection of the 1992 data had been delayed to avoid conflict with the refiners completion of the Environmental Protection Agencys (EPA) survey conducted under the authority of Section 3007 of the Resource Conservation and Recovery Act (RCRA). This mandator
24、y survey went to the field in September 1993-exactly when API had planned to send out the forms for collection of its own 1992 data. Recognizing that completion of EPAs 142 page questionnaire would require a substantial manpower effort, API opted to delay administration of its survey. API, however,
25、was concerned that a delay in collecting the 1992 data could undermine the utility of these data within the refining industry. Refiners had already expressed concern that the three year lag time in publishing the data made it less useful to them. For example, because the 1991 data were published in
26、1994, information on the first year of land disposal restrictions was released when refiners already had three years of experience with the prohibitions. Thus, while APIs survey reports are viewed as the most comprehensive and current source of data on industry practices by those outside the industr
27、y, to some intimately involved in day-to-day refining operations, the information was too dated to assist in timely management decisions. After discussing the issue with company representatives on APIs General Refining Committee and the Committee on Refining Environmental Controls (CREC), agreement
28、was reached that the 1992 and 1993 data should be collected simultaneously, but the time required to analyze and report results should be reduced substantially. The refiners would therefore shoulder an increased reporting burden, while API, the respective committees involved in the survey, and the c
29、ontractor would be obligated to expedite handling and review of the survey data. This report represents the accomplishment of these goals. The survey materials were mailed to refineries in March, 1994, less than one year ago. Publication of this report with 1993 data represents a substantial reducti
30、on in the lag time to publication. The refiners part in this collaborative effort is noteworthy for it represents the efforts of front line workers in a time when corporate downsizing already made their jobs more demanding. Between 1992 and 1994 when the data was collected, the number of employees i
31、n refining dropped from 121.8 thousand to 108.5 thousand-an 1 1 percent reduction (U.S. Department of Labor, Employment Hours and Earnings, August 1993, June 1994). This reflects the closing of 22 refineries between 1991 and 1993 and reductions in staff at the remaining 161 operating refineries. At
32、the same time, manufacturing increased, from 593 to 618 billion barrels. 1 API PUBL*333 95 = 0732290 0554322 O37 = METHODOLOGY The survey procedures used for the 1992 and 1993 cycles were the same as previously employed. The census design was based on the listings of operating refineries in the Depa
33、rtment of Energys Petroleum Supply Annual for 7992 and 7993. Survey materials were mailed in March 1994. The six week interval originally adopted for form completion was extended to almost seven months to maximize the response rate. Contact was maintained with all refineries during the field adminis
34、tration, with follow-up calls placed to refineries to encourage participation and through a “HELP-line“ staffed by a refining expert. The sections that follow provide more detail on the data collection forms and the estimation procedures used in the study. Data Collection Forms The questionnaire was
35、 provided in both hard copy form and on an automated disk, written using Clipper, a commercially available compiler for dBase. A copy of the data collection form is presented in Appendix A. The survey questionnaire had two sections. The first included nine short-answer questions that focused on refi
36、nery characteristics such as age, size, complexity of processing, and sewer configuration. The second section of the questionnaire was a series of one-page “data sheets“ that collect empirical information on: 1) the quantities of residual materials generated; 2) how they were managed (according to t
37、he waste management hierarchy steps of recycling, treatment, and disposal); and 3) the amount of materials that were reduced as a result of pollution prevention activities. There were 30 of these data sheets for each year, one for each of the residual streams identified in Table I. (Refer to Appendi
38、x A for an example of a data sheet ). The data sheets were virtually the same as used in the 1991 cycle of the survey. The two page format was retained, wherein codes for the management techniques and pollution prevention activities were printed on the back of the preceding page in a different color
39、. The only modifications made to the forms were clarifications of various instructions, such as the inclusionary criteria for several streams (Le., Residual oils and spent. solvents, Spent acids, and High pH/low pH waters), and the selection of the most appropriate code for pollution prevention acti
40、vities. These revisions were considered to be minor since edit checks had previously been performed on these same data elements. 2 API PUBLm333 95 0732290 0554323 T3 Table 1 Refining Residual Streams Category Aqueous residuals Chemicalslinorganic residuais Contaminated soils/solids Oily sludges/othe
41、r organic residuals Spent catalysts Other residuals Constituents Biomass High pHAow pH waters Oil contaminated waters (not wastewaters)* Spent Streford solution Spent sulfide solution TSD Leachate (F039)* Other aqueous residues NOS* Spent acids Spent caustics Residual amines Other inorganic residual
42、s NOS* Contaminated soils/solids Heat exchanger bundle cleaning sludge* Residual coke/carbon/charcoal Residual sulfur Other contaminated solids NOS* API separator sludge* DAF float“ Leaded tank bottoms* Nonleaded tank bottoms Pond sediments Primary sludge (F037)* Primary sludge (F038)* Slop oil emul
43、sion solids* Residual oils/spent solvents Other oilv sludaes/oraanic resiLJals NOS* Fluid cracking catalyst H yd rop rocessing catalyst Other sDent catalvsts NOS“ Other wastes NOS* * Does not include NPDES or POW wastewaters. “* Not otherwise specified. * RCRA-listed hazardous wastes for petroleum r
44、efining. API has used an equation on each data sheet as a quality control measure: the “inputs“ of residual materials must balance the “outputs.“ Inputs include the quantities of residual material Generated plus Treatment Additives and the Net Removed from Storage (.e., the total amount of material
45、removed from storage minus the amount placed into storage) and constitute the “Total Quantity Managed.“ As depicted in the equation below, this is balanced by the quantities of the residual recycled, treated, or disposed. 3 API PUBL*333 95 0732290 0554324 90T Quantity Generated + Treatment Additives
46、 + Net From Storage = Total Quantity Managed Total Quantity Managed = Quantity Recycled + Quantity Treated + Quantity Disposed Each data sheet also contains a section to capture information on pollution prevention activities that have been performed. In addition to indicating the quantity of waste r
47、educed, respondents are asked to classify the pollution prevention activity according to the codes displayed below and to then briefly describe the activity performed. POLLUTION PREVENTION CODES 1 = Equipment or Technology Modifications 2 = Procedure Modifications 3 = Reformulation or Design of Prod
48、ucts 4 = Substitution of Raw Materials 5 = Improved Housekeeping, Training, or Inventory Control 6 = In refining process units (e.g., crude unit; coker; desalter) 7 = Recovering oil (I dewatering) by filter pressing/centrifugation 8 = Other recycle 9 = Reuse/reclamation 10 = Other IN-PROCESS RECYCLE
49、 OUT-OF-PROCESS RECYCLE Data Analysis The data verification and estimation procedures used were similar to those used previously. Data Verification included 28 automated consistency checks for the variables on each data sheet, as well as final range checks across respondents and comparisons with the data previously submitted by the respective refinery. In all cases, any questionable data were verified by direct contact with the facilities to ensure their accuracy. For each survey cycle, regression analysis has been used to estima
