Escolar Documentos
Profissional Documentos
Cultura Documentos
IAPCA
tions along roadways that criss-cross ing wastes are the spent fluids or muds. bearing soil in and around related facil-
the country. The full-service station of In its Report to Congress, EPA used ities, drill cuttings, materials produced
the past has given way to the self-serve the API method for estimating the na- from a well, and accumulated material
station selling various staple items. In tional volume of drilling wastes. The from production separators, fluid
1987, there were 93,864 service stations API method estimates that 361 million treating vessels, storage vessels and
operating in the United States. In 1985, barrels of drilling muds and cuttings production impoundments? According
about 596,000 people were employed at were generated in 1985 from the drill- to the APT, the exporation and produc-
about 99,987 retail gasoline service sta- ing of 69,734 wells.‘ tion sector annually produces about 16
tiom2 In addition to drilling wastes, signifi- million barrels of other associated
The following discussion of the. cant volumes of water are produced wastes.5
wastes identified for each industry seg- along with the oil and gas during the Currently, the above wastes are con-
ment and their attendant treatment process of removing hydrocarbons sidered to be exempt from the hazard-
and disposal options provides an over- from subsurface reservoirs. Over time, ous waste provisions of RCRA. In the
view. Gas processing operations are not the ratio of produced water to oil and EPA Report to Congress, a partial list
specifically covered in this overview gas increases as the well matures. This of nonexempt wastes was included.
because these types of facilities rarely produced water occurs naturally in the These wastes included waste lubri-
generate any significant amount of hydrocarbon reservoir and/or enters cants, hydraulic fluids, motor oil, bat-
hazardous waste. Wastes generated are the reservoir from the injection of wa- teries, paint, solvents, off-specification
substantially similar to those discussed ter into a nearby well which is known as and unused materials intended for dis-
in the exploration and production sec- waterflooding or secondary recovery. posal, incinerator ash, pigging wastes
tion. This paper does not cover the The recovery technique, geology of the from transportation pipelines, sanitary
waste disposal practices associated formation and the maturity of the oil- wastes, trash, gray water, gas (SO, and
with spills of crude oil or petroleum field are the determining factors which NO,) and particulates from gas tur-
products. Generally, if the material control the quality of water expected to bines or other machinery, drums whose
spilled can be recovered and recycled be produced. Produced water volumes contents are not intended for use, spent
or reused, this will be preferred over calculated by EPA and API for 1985 iron sponge, glycol and other separa-
disposal. If allowed, contaminated soil were 11,671,641and 20,873,243 barrels, tion media, filters, spent catalysts,
is treated utilizing in-situ biodegrada- respectively.’ wastes from truck and drum cleaning
tion methoas, otherwise the soil is ex- Unlike drilling fluids and produced operations and spills from pipelines or
cavated and properly disposed of. waters, Congress elaborated on the other transport methods.’ Indeed,
these are the wastes which must be
tested for hazardous waste characteris-
Table I. Refining listed hazardous wastes projected disposal tics when they become destined for dis-
rates [(wet) tons/vrl.12 posal.
K048-DAF float 308,000 Waste Treatment and Disposal.
K049-Slop oil emulsion solids 144,000 Treatment and disposal of drilling
K050-Heat exchanger bundle cleaning solids 1,300 wastes take place either on or off the
K051-API separator sludge 393,000 drilling site. Onsite treatment and dis-
KO52-Leaded gasoline tank bottoms 5,000 posal methods include reserve pits,
851,300
landspreading, annular disposal, solid-
ification of reserve pit wastes, treat-
ment and discharge of liquid wastes to
Wastes from Exploration and “other associated wastes” term. Specif- surface water and closed treatment
Production Operations ically, “other associated wastes” refers systems.’ The most commonly used on-
to materials intrinsically derived from site disposal method involves deposit-
On December 29,1987, the US. EPA primary field operations associated ing the used drilling muds and rock
submitted its final “Report to Con- with the exploration, development or cuttings in earthen-walled reserve pits.
gress”’ following the completion of its production of crude oil or natural gas. Once drilling is completed, the pit(s) is
study of exploration and production These wastes include hydrocarbon- closed according to state and local reg-
wastes. Congress mandated this study
in 1980 when i t exempted these
wastes-which include drilling muds, Table 11. Refining non-listed wastes projected disposal rates
produced waters and other associated [(wet) tons/yr] .I2
wastes-from the hazardous waste pro-
visions of RCRA. In addition, EPA was Primary O/S/W separator sludges 69,000
instructed to make recommendations Secondary O/S/W separator sludgeb 6,600
as to whether this exemption should Bio-sludge 699,000
Cooling tower sludge 14,400
remain in effect. These recommenda- 31,000
HF alkylation sludge
tions must be made to Congress by FCC catalyst 131,000
June 30, 1988,’which,in turn, will de- Other spent catalyst 17,000
cide whether to allow the exemption to Stretford solution 38,000
continue or whether new laws need to Non-leaded tank bottoms 117.000
be enacted to regulate these wastes. Treating clays 12,000
Drilling wastes include fluids or 1.135.000
~, ,
“muds” used to drill a well, cuttings or a Sludges generated in separators other than API separators to in-
rock fragments extracted from the clude equalization tanks or lagoons, corregated plate interceptors
borehole and, occasionally, various ad- (CPIs), parallel plate interceptors (PPIs),
etc.
ditives and chemicals used in the recipe Float (other than DAF float) generated from secondary treatment
for drilling muds to meet downhole of refinery wastewater following separation in the primary oil/sol-
conditions. The largest volume of drill- iddwater separator (before biological treatment).
Tank bottoms, Desalter clean out sludges Cooling tower sludge Gravity separator Maintenance Laboratory Administrative
leaded gasoline Caustic solution phenolic sludge (API, CPI, PPI] wastes wastes office bldg.
Caustic solution sulphidic Lime sludge Asbestos Spent General refuse
Tank bottoms, HF acid (neutralized) I.A.F. and D.A.F. chemicals e.g.:
unleaded gasoline H2S04acid (spent) Anthracite filters sludge Refractory (liquid)
Clay (spent) brick Waste paper
Tank bottoms, Activated carbon (spent) Spent zeolite resins Biotreater sludge Spent
crude oil Amine filters Oil con- chemicals Domestic
Off specification sulfur Sand from filters Storm pond silt taminated (solid) waste
Tank bottoms, Furfural (spent) soil
distillates Glycol (spent) Ion exchange Sump sludge Used drums Used office
Coke fines regenerant Used drums supplies
Tank bottoms, Stretford solution
decant oil FCCU catalyst (spent) PCB wastes
FCCU dust
Tank bottoms, E.S.P. dust Demolition
bunker Poly unit catalyst (spent) scrap
H2 plant catalyst (spent)
Tank bottoms, Reformer catalyst (spent) Heat exchange
slop oil Hydrocracker catalyst (spent) cleanings,
(emulsion Hydrotreater catalyst (spent) solids and
solids) Merox catalyst (spent) liquids
Copper chloride (spent)
Asphalt waste Claus plant catalyst (spent)
HF acid soluble polymer
Flgure 1. Sources of petroleumrefinery wastes.
I
b
P
ulations and landowner agreements. has identified five as listed hazardous Waste Treatment and Disposal.
Closures usually involve allowing the wastes. These wastes include dissolved Most refineries use decanting through
water in the pit to either evaporate or air flotation (DAF) float (K048), slop gravity separation to treat their oily
be decanted and properly disposed of. oil emulsion solids (K049), heat ex- listed hazardous waste including DAF
After this step is accomplished the pit changer bundle cleaning solids (K050), float, slop oil emulsion solids and API
is backfilled and the drill site is revege- API separator sludge (K051) and lead- separator sludge. Slop oil emulsion sol-
tated. ed gasoline tank bottoms (K052L7 ids are normally heat treated prior to
Off-site treatment and disposal On November 12, 1980, EPA pro- decanting. Leaded tank bottoms are
methods include use of centralized dis- posed a change to the KO48 listing from usually allowed to weather to oxidize
posal pits, injection and treatment fa- DAF float to secondary (emulsified) the tetra-ethyl lead prior to disposal at
cilities, commercial landfarms, and re- oil/solids/water separator sludge and a an off-site commercial landfill. Heat
conditioners of drilling muds.’ These change to the KO51 listing from API exchanger bundle cleaning solids are
centralized-type operations are often separator sludge to primary oil/solids/ commonly routed from a concrete
established in conjunction with the de- water separation sludge.8 T h e U.S. cleaning pad in the process area to the
velopment of an extensive oil and gas EPA reopened the proposal on Febru- refinery wastewater treatment system.
field. ary 11, 1985 for further comments; When conducted in accordance with 40
The vast majority, nearly 90 percent, however, the KO48 and KO51 listings CFR 261.3(a) (2)(iv)(c), this practice is
of produced waters are injected under- remain ~ n c h a n g e d Currently,
.~ EPA is exempt from hazardous waste regula-
ground through approximately 168,000 revisiting its proposal. On April 13, tions as long as the waste stream is a
injection wells5 This injection of pro- 1988, a notice of data availability agd mixture of the refinery’s wastewater,
duced water is permitted either by the request for comments was published by which is subject to regulation under ei-
US.EPA’s underground injection con- EPA after receiving additional data ther Section 402 or 307(b) of the Clean
trol program or a comparable state pro- from API.’O Water Act.
gram which is US. EPA-approved. The basis for listing these five wastes The most common “disposal” prac-
Other methods of disposal include centers on two metal constituents, lead tice for most listed hazardous wastes in
evaporation pits and permitted dis- and hexavalent chromium.” The lead the API survey, previously mentioned,
charges i n t o coastal and offshore wa- mostly comes from the use of tetra- is land treatment or “landfarming” as
ters. Another practice with produced ethyl lead as an octane booster in gaso- it is commonly referred to in the indus-
water is reinjection into the same reser- line. Hexavalent chromium finds its try. Even though by definition (40 CFR
voir from which the water originated in way into these wastes in the blowdown 261.10 and 268.2) land treatment is
order to enhance the recovery of hydro- from cooling towers that use hexava- considered “land disposal,” the tech-
carbons. In some areas of the country, lant chromium compounds as a corro- nique uses biodegradation and immo-
low-salinity produced waters are used sion inhibitor. bilization to completely treat waste
for irrigation and for drinking water for The most current (1981) industry- constituents. Many refineries pretreat
livestock under the beneficial use per- wide estimates of listed hazardous their waste prior to landfarming to re-
mitting program of the Clean Water waste disposal rates, adjusted for tem- cover hydrocarbons for further pro-
Act. porary storage, are given in Table I. In cessing. Listed wastes which are usual-
Depending upon the type of other this same API survey, projected dis- ly landfarmed include API separator
associated waste involved, similar posal-rate estimates of non-listed sludge, DAF float and slop oil emulsion
methods are used in treating and dis- wastes were also made. These are given solids.
posing of these wastes. In general, these in Table 11. Even though the wastes in Other than minimal decanting, the
wastes are sold to reclaimers, land- Table I1 are not listed hazardous non-listed wastes are not generally
farmed, landfilled or injected into un- wastes, the survey testing summary of treated prior to disposal. For those re-
derground wells. Currently, the API these wastes revealed all of them failed fineries that do treat these wastes prior
through an.EPA request has undertak- one or more of the hazardous waste to disposal the methods include chemi-
en a thorough review of what wastes characteristics (i.e., EP toxicity, ignita- cal, thermal and biological methods,
should be considered “other associated bility, reactivity [sulfide] and corrosivity). weathering, thickening, centrifuging,
wastes” along with establishing a bet-
ter understanding of the waste man-
agement practices used by the industry
concerning these wastes. i I
K
Product
Treatment and disposal of nonex-
empt wastes depends on the hazardous
waste characteristic of the waste and
whether the material can be reused, re-
cycled or reclaimed. The majority of
i Rack Drive
l
these wastes are disposed of a t permit-
ted offsite commercial hazardous and/ slop Box Separator
or industrial waste facilities.
I
WASTE MANAGEMENT
and filtering. Accoiding to the API sur- This system has proven to be an effec- usually acceptable to dispose of spent
vey12 most of the non-listed wastes are tive means by which the terminal oper- antifreeze in municipal sanitary sew-
either landfarmed or landfilled a t off- ator effectively manages his or her ers. If empty used drums can be reused
site commercial facilities. Other dis- spent solvent. they are sent to a drum reconditioner,
posal methods k e d include deep well Other methods for disposing spent otherwise they are crushed and sent to
injection, metals reclamation, recycling solvent have included injecting it into a a municipal landfill. Used clay filters
into petroleum cokers and the use of crude stream pipeline going to a com- and other filters are allowed to drain to
nonhazardous sludges as road oil. pany-owned refinery, mixing it with recover the product and then discarded
fuel for industrial boilers and furnaces at a municipal landfill.
Wastes From Transpbrtation Facilltles and disposing of it at a commercial haz-
ardous waste disposal facilities. Waste Minimization Commitment
The transportation sector of the pe- Used oil from routine oil changes is
troleum industry generates the follow- also generated a t truck terminals. Used The petroleum industry is strongly
ing waste streams which on occasion oil is normally placed in the truck’s die- committed to voluntary rather than
exhibit one or more hazardous waste sel tanks or arrangements are made mandatory waste minimization pro-
characteristics. These wastes include with a recycler or re-refiner. grams. The 1984 RCRA amendments
tank bottom sludge and water from required the implementation of volun-
crude oil and product (Le., leaded and Wastes From Retail Marketing Facilities tary waste minimization programs. In
unleaded gasolines, jet fuels and diesel) many respects, the petroleum industry
storage tanks, oil/water separator Marketing facilities in the petroleum had already initiated practices and
sludge and solvent degreasers. Data on i n d u s t r y g e n e r a t e several waste process modifications to avoid the gen-
nationwide volumes associated with streams which may occasionally exhib- eration of wastes, examples of which
these waste streams are not available. it one or more hazardous waste charac- are described below.
teristics. These wastes include tank Congress has begun to review legisla-
Waste Treatment and Disposal. bottom sludge and water, separator tive proposals dealing with waste re-
Tank bottom sludge is normally gener- sludge, contaminated and off-specifi- duction in conjunction with this year’s
ated whe? a crude oil or product stor- cation product, used oil and other lu- RCRA reauthorization initiatives.
age terminal undergoes a tank clean bricants, used batteries, used tires, EPA believes further statutory author-
out and maintenance program. Separa- spent antifreeze, solvent degreasers, ity in this area is premature a t this
tor sludge is normally removed by vac- used drums and used clay filtration ele- time. To support EPA’s contention,
uum truck and handled in much the ments. Accurate data on nationwide the petroleum industry has undertaken
same manner as tank bottom sludge. volumes of these wastes are not avail- the task of developing its waste mini-
The sludge is usually disposed of a t a able. mization story.
commercial or company-owned land- Public interest groups that are advo-
farm, drummed and sent to a commer- Waste Treatment and Disposal. cating more regulation (e.g., manda-
cial landfill depending upon t h e The only treatment that is normally tory waste minimization programs)
sludge’s hazardous characteristic, andl found a t a marketing facility is an oil/ presume certain regulatory incentives
or it is treated using a filter press or water separator which is used in con- will spark industry to eliminate the
centrifuge. The filter press and centri- junction with the facility’s drainage majority of its wastes through source
fuge are usually mobile units which system. Tank bottom sludge and water reduction (Le., process modification,
come on site and are used to dewater is usually encountered when tanks are product reformulation, new product
the sludge and in the process recover oil cleaned, which is very rarely, and when design, input substitution and im-
or product which is recycled. The filter tanks are replaced. Depending upon its proved management practices) and on-
cake or centrifuged solids are drummed hazardous characteristic, tank bottom site recycling. The only problem with
rind sent to a landfill while the water is sludge a n d s e p a r a t o r sludge a r e this presumption is that it fails to take
treated a t a commercial, public, or drummed and sent to a commercial in- into account the extractive nature of
company-owned wastewater treatment dustrial or hazardous waste landfii. If the petroleum industry. This extrac-
plant or it is placed in on-site evapora- the rinse water tests nonhazardous it is tive nature makes it inherently diffi-
tion tanks. allowed to drain to the sanitary sewer cult to reduce the generation of wastes.
To a great extent tank water draws following approval from the local mu- As a part of the petroleum industry’s
are discharged to the secondary con- nicipality. If hazardous, the rinse water experiences, it is extremely important
tainment area around a tank’s perime- is disposed of a t a commercial hazard- that Congress, EPA, and public inter-
ter where it is allowed to evaporate and ous waste facility. est groups become aware of the indus-
percolate into the ground. Under the Used oil and other lubricants are try’s progress in waste minimization.
Waste Minimization Projects, a de- handled by recyclers or re-refiners un- Coupled with this progress, these same
scription of a unique system for han- der contractual arrangements. Con- groups need to understand the obsta-
dling tank water draws used by Conoco taminated and off-specification prod- cles encountered by the petroleum in-
Pipe Line Company is provided. uct is often reworked back into the dustry in reducing t h e volumes of
Solvent degreasers are a relatively manufacturing process. Used batteries waste it generates.
low-volume waste stream generated as are normally sent to regenerators un- These obstacles are given here as ex-
a result of parts and equipment clean- der contractual arrangements. Used planations rather than excuses as to
ing. Many terminal operators have tires are sent to a shredder, if available, why the petroleum industry’s waste
gone to a system where the solvent sup- for blending into asphalt or, for the minimizationlreduction programs will
plier retains ownership of the solvent. most part, they are disposed of a t the not realize significant reductions in
The solvent i s in a container which is nearest municipal landfill. Spent sol- waste volumes. It is for these reasons
replaced by the supplier on a periodic vents from parts cleaning are handled the industry’s programs emphasize re-
basis. The solvent supplier exchanges in much the same manner as discussed cycle and reuse practices in addition to
solvent containers and returns to his above. Spent antifreeze is often re- source reduction and innovative treat-
facility to reclaim the spent solvent. claimed for its glycol content. Also, it is ment technologies.
818 JAPCA
Most source reduction methods are though the amount of each product products is relatively low and to a large
often unique to specific products or processed from a barrel of oil can be extent controlled by international
production processes. Even so, these highly controlled, the fixed nature of competition, companies may be unable
methods can be grouped into four ma- these products cannot be controlled. to pass the cost of a major process
jor categories as was done is S.1429, the Some fuels are so chemically simple, change on to the consumer.
Hazardous Waste Reduction Act such as propane and butane, their com-
(1987).These categories included: position cannot be changed. Further, Management Practices
Substitution of raw materials; these products must meet stringent
product and regulatory specifications Improving management practices,
Reformulation or redesign of prod- such as limits on sulfur, nitrogen, sol- inventory control, materials handling,
ucts; ids, and specific ranges of octane, boil- training and employee awareness is one
Equipment, technology, process, or ing point, vapor pressure, and viscosi- area the industry has no particular ob-
procedure modifications; and ty. With these restrictions and the gen- stacles to overcome. However, the po-
Improvement in management, eral range of petroleum product tential level of further waste reduction
training, inventory control, materi- composition, the refining sector is left attributable to these practices is rela-
als handling, or other general opera- with limited flexibility in product rede- tively small. Considerable effort has al-
tional phases of industrial facilities. sign or reformulation. ready been expended by the industry
With the exception of the last category, toward improving these practices to
the extractive nature of the petroleum Process Modifications husband product losses.
industry raises significant obstacles, In summary, while source reduction
some of which are impossible to over- The nature of the petroleum indus- is an integral component of overall
come, to make significant reductions. try's products is such that they are waste minimization and management
These categories are characterized be- small in number but high in volume. strategies, the opportunities available
low in a petroleum industry context. The products are produced on a very to the petroleum industry are not as
low value-added basis and have com- great as in most other industries.
mercial lifetimes measured in decades. Therefore, the key elements of the pe-
.Raw Material Substitution These factors results in very large and troleum industry's waste minimization
capital intensive process equipment and management strategy focus on re-
The petroleum industry has no con- dedicated to achieve maximum effi- cycling/reuse and treatment.
trol over the basic composition of crude ciency. This proccss equipment is de-
oil which is determined by geological signed with expected lifetimes of years Waste Minimization Projects
forces. The production sector of the or decades. These products and process
business is faced with having to sepa- time scales make it extremely difficult At the national level the API, the
rate water produced with the crude oil to introduce process modifications National Petroleum Refiners Asspcia-
which typically increases as the well which could achieve source reduction. tion (NPRA) and the Petroleum Envi-
matures. This waste generation is be- Indeed, industry experience has shown ronmental Research Forum (PERF)
ing further compounded because older that modifying process units does not are aggressively promoting a variety of
domestic oilfields are not being re- lead to reduction in volumes of wastes waste minimization projects. To a great
placed by younger fields as rapidly as generated. There are insufficient eco- extent these organizations through
in the past. Much of the oily wastes nomic incentives for the refining sector specific committees are tasked with
generated during refining occur as a re- to launch massive capital intensive raising the level of awareness concern-
sult of the inherent lack of control over process modification or replacement of ing waste minimization within the pe-
the basic nature of feedstock crude oil, existing equipment projects to achieve troleum industry with industry repre-
the increased use of heavier crude marginal reductions in the amount of sentatives and government officials at
streams with lower gravities, and the wastes generated. In addition, because the federal, state and congressional lev-
associated removal of naturally occur- the marginal profitability of petroleum el.
ring contaminants in the crude oil.
Other wastes, such as filter media and
spent caustics, are generated as a result
of removing sulfur and nitrogen con-
taminants present in crude oil. In addi-
tion, the quality of crude oil feedstocks
is lower now than in past years, which
translates into higher amounts of sul-
fur and nitrogen compounds and other
impurities. These crudes require addi-
tional processing. Hence, greater
amounts of wastes will be generated.
On February 25, 1987, the API and Identifying opportunities for imple- cilities usually put these used oils in
the NPRA conducted a workshop with menting techniques or practices, their field crude oil tanks where the
the purpose of informing their mem- Conductng employee awareness ses- used oil ultimately makes its way to a
berships of the statutory and economic sions at the operator level, refinery for processing via the crude
incentives for waste minimization and Establishing employee incentive stream.
to provide information on opportuni- compensation programs (bonuses) Other practices which have been im-
ties and approaches for waste minimi- for waste minimization suggestions plemented and proven to be successful
zation.13 On March 23 and 24, 1988, which are implemented, and include using smaller reserve pits and
PERF convened the Refinery Waste produced water pits, recycling drilling
Minimization Conference with the pur- Funding research projects which muds in closed systems, segregating
pose of covering the overall role of may lead to effective recycling en- muds for disposal as nonhazardous
waste minimization in refining, source deavors. waste prior to entering a hydrocarbon
reduction opportunities and various re- zone, and solifying wastes in reserve
cycling approaches. Following is an overview of waste pits.’3
In addition, the API is documenting minimization projects in the petroleum
the scope and degree of success the pe- industry which have proven to be suc- Refining Projects
troleum industry is achieving in waste cessful. Some states’ rules and/or sta-
minimization. Under this effort a data tes’ interpretation of U S . EPA regula- In general, the opportunities for
base of petroleum industry generated tions may preclude the use of some of waste reduction in the refining area
wastes is being developed for the refin- the following waste minimization pro- currently reside in changing operator
ing and marketing sectors. A compen- jects. habits and practices rather than in pro-
dium of waste minimization practices cess modifications as discussed earlier.
and equipment now used in the petro- Indeed, the most promising area refin-
leum industry is also being prepared. Exploration and Production Projects ers are working on is waste segregation.
Finally, API is establishing contacts Most refinery hazardous waste comes
with other organizations, such as the The industry’s offshore operations from oily sludges found in combined
Chemical Manufacturers Association, are primarily faced with disposing of process/storm sewers. Steps are being
National Governors Association, Na- paint and spent solvent wastes and taken a t many refineries to prevent the
tional Association of Manufacturers, used nickel/cadmium batteries. Under mixing of relatively clean rainwater
Business Roundtable, etc., to further contractual arrangements the spent runoff with oily wastes. Where it is fea-
communicate the positions and prac- solvent is sent to a solvent reclaiming sible, separate stormwater and process
tices of industries involved with this company. Rather than having to land wastewater sewers are being installed.
iss.ue and increase overall awareness. dispose batteries, many operators are Refineries that have a coker can en-
At the individual company level a va- switching t o lead acid batteries which joy the petroleum coke exemption un-
riety of efforts are underway. These ef- are sent to battery regenerators when der 40 CFR 261.6(a)(3)(ix). This ex-
forts include: they no longer can be used. Onshore emption allows for refinery hazardous
Establishing corporate policy and painting projects are not on the order wastes that contain oil to be used as
goals for waste minimization, of magnitude of painting offshore plat- feedstock to a coker as long as the
forms; therefore, onshore operators wastes are generated a t the same facili-
Conducting waste minimization au- normally use contractors who contrac- ty a t which the coker is located and the
dits, tually agree to be responsible for their resulting coke does not exhibit a haz-
Developing company-wide waste paint wastes. ardous characteristic. The oily wastes
data bases on quantities of wastes Used lubricants, hydraulic fluids and that a coker can normally receive in-
generated, motor oils generated offshore are col- cludes DAF float (K048), slop oil emul-
Identifying various waste minimiza- lected and sent to a company’s shore- sion solids (K049), API separator
tion techniques presently being base where they are stored prior to sludge (K051), tank bottom sludge and
used, transporting to a recycler. Onshore fa- bio-sludge. The process modification is
relatively inexpensive and is currently
used in the industry by Mobil. The pro-
cess has been shown t o be extremely
\
1 \
effective for recycling the above listed
and non-listed hazardous wastes.
In the area of product substitution,
major efforts are under way to reduce
and eventually eliminate the use of
lead in gasoline as an octane enhancer.
To accomplish this federally mandated
lead phase-down, refineries are install-
ing technology process modifications
such as reformers and alkylation units,
along with using other octane en-
hancers, such as methyl-tertiary-butyl-
ether (MTBE). Although more acid
wastes are expected to be produced
from the alkylation unit; offsetting this
increase is the elimination of wastes
due t o tetra-ethyl lead production,
Flgure 4. Geodesic dome for external floating roof storage tank. leaded gasoline storage tank sludge
820 JAPCA
(K052) and the emission of lead into Another use of cat poly catalyst is was generally discharged from the dike,
the environment by way of combus- being researched by a university under often in combination with stormwater.
tion.14 a project funded by Conoco. This pro- This practice was, and still remains,
Phosphate-based corrosion inhibi- ject involves the use of cat poly catalyst common throughout a large segment of
tors are being substituted for chro- as a source of phosphorous fertilizer for the petroleum industry.
mate-based ones used in cooling water agronomic crops. The catalyst is being With the passage of RCRA in’ 1980,
systems at refineries. This substitution compared to the use of a commercially CPL discontinued this practice of dis-
eliminates the source of the hazardous available triple superphosphate fertil- posing t a n k bottom water t o t h e
characteristic (i.e., E P toxicity for izer (0-46-0). Initial results reveal there ground. This decision was based on the
chromium) often found in refinery is no significant difference in straw and above-mentioned analytical results.
wastewater treatment sludges. On grain yields between the two phospho- Having made this decision, CPL un-
March 29, 1988, EPA began the rule- rous sources. Nutrient uptake data re- dertook the design of a tank bottom
making process to prohibit the use of veal only small differences between the wastewater handling system along with
hexavalent chromium-based water two sources; however, they were of no a procedure for evaluating treatment
treatment chemicals in comfort cooling agronomic or environmental conse- and ultimate disposal options.
towers.l5 In the preamble of this pro- quence. Figure 2 describes the tank bottom
posed rule, EPA states that it is con- The AF’I has experimentally evaluat- wastewater handling system chosen by
tinuing its evaluation of the need for ed a number of technologies forcthe CPL. Most of these systems have been
listing chromium (hexavalent or total) treatment of listed petroleum refinery installed underground. This system
as a hazardous air pollutant and for oily wastes. The technologies studied has been installed at 35 of 50 terminals
subsequent national emission stan- were mechanical treatment (filtration), at a cost of around $40,000 per termi-
dards for hazardous air pollutants for solvent extraction, thermal treatment nal. The majority of the systems were
industrial cooling towers. Regulatory (drying), and pyrolysis. In several cases installed between 1982 and 1984.
initiatives like this will likely lead to the application of two treatment tech- T h e primary objective of CPL’s
eliminating the use of hexavalent chro- nologies in series was studied (e.g., fil- wastewater handling system is the col-
mium-based. chemicals in industrial tration followed by drying and drying lection of tank bottom water, its sepa-
process cooling towers. followed by fixation). Four of the tech- ration and analysis, and its subsequent
Sulfidic and phenolic caustics from nologies tested were effective in pro- preparation for disposal. The system
the refining industry are being used as ducing a residual of substantially re- consists of five major components: the
effective substitutes for other commer- duced hazard level as measured by con- collection system, the slop box, the sep-
cially available chemicals. Companies centrations of hazardous constituents arator, the sumps and the collection
use these caustics as feedstocks for the in the product solids. In addition, tank (Figure 2).
production of new chemical products. chemical fixation further reduces the As illustrated, the collection system
No regeneration, reclamation or mate- level of hazardous materials leached consists of a network of “hard-piped”-
rials extraction takes place in the pro- from the solids in the toxicity charac- pipelines which connects the storage ,
duction process nor are any of the ma- teristic leaching procedure (TCLP).16 tanks to the separator by way of a slop ’
terials land disposed or burned. When box. In general, the pipelines, separator
a refinery has to dispose of these caus- Transportation Projects and slop box are installed with cathodic
tics they usually fail one or more of the protection. The wastewater flow is con-
hazardous characteristics resulting in In the summer of 1980, Continental trolled by manual valves which are op-
having to handle the material as haz- Pipe Line Company (CPL), now known erated by terminal personnel. Some
ardous wastes. Depending upon the as Conoco Pipe Line Company, the op- terminals utilize a portable trailer in
strength of the caustics, refineries have erator of Conoco’s petroleum product lieu of “hard-piping” to transport the
found this to be an effective use of a storage terminals and pipelines, under- waste to the separator.
material that otherwise would be a haz- took an extensive investigation of the The collection system also connects
ardous waste if disposed of. wastewater generated at their product run-off waste material from the truck
A high volume refinery waste that terminals. The study involved analyz- rack loading area. The waste material
shows promise as an effective substi- ing tank bottom water from 45 tanks from this area generally consists of
tute for other commercially available around the country. The analyses in- small product spills, water used to
chemicals is spent catalyst, in particu- cluded traditional wastewater parame- wash down the rack and some storm-
lar, cat poly catalyst used in a refinery’s ters (e.g., BODS, COD, pH, etc.) and water.
catalytic polymerization unit. In its dry the four hazardous waste characteris- The function of the slop box is two-
state this spent catalyst is not a hazard- tics tests. fold. First, it provides a mechanism by
ous waste; however, when it becomes The wastewater found at the bottom which flow into the separator is equal-
wet the material will fail the corrosive of product storage tanks enters the ized. Second, it provides a mechanism
hazardous characteristic. One of Cono- tanks from two major sources (i.e., wa- by which large solid material that
CO’S refineries is currently using its cat ter entrained in pipeline deliveries to might be entrained in the water will fall
poly catalyst as a pozzolan material in the tanks and rainfall entering the out prior to entering the separator.
the manufacture of concrete. The con- tanks around tank roof seals). Results The oil/water separator is a high effi-
crete made a t this refinery has exceed- of the analytical phase of the study re- ciency vertical tube coalescing separa-
ed Conoco’s standards for strength; vealed that the raw tank bottom water tor. It is designed to remove all free
however, it is not used for structural sometimes exhibited the ignitability floating hydrocarbon and to lower oil
support. It is used for on-site roadbase, characteristic and the EP toxicity char- and grease levels to a level which would
utility/storage pads and non-loadbear- acteristic for lead, arsenic and barium. be acceptable at most publicly owned
ing walls. FCC equilibrium catalyst Historically, this wastewater was treatment works (POTW). The separa-
also exhibits possibilities as an effec- drained from the tanks and discharged tor has two discharge streams-the
tive alumina source and admixture in into the tank dike area. After careful wastewater effluent, and the separated
the cement manufacturing industry. inspection for free oil, the wastewater petroleum product. These streams are
822 JAPCA
Register,” Vol. 45, No. 220, 74893- American Petroleum Institute, Wash- 16. Evaluation of Treatment Technologies
74894, November 12,1980. ington, DC, December 1983. for Listed Petroleum Refinery Wastes,
9. Hazardous Waste Management Sys- 13. Reducing RCRA Impact Thru Waste American Petroleum Institute, in prep-
tem-Identification and Listing of Haz- Minimization, Workshop Proceedings aration, Washington, DC.
ardous Waste: Notice of Availability of prepared by M. B. Van Hook, American
Data and Request for Comment, Feder- Petroleum Institute and National Pe-
al Register, Vol. 50, No. 28, 56374638, troleum Refiners Association, Arling-
February 11,1985. ton, VA, 1987.
10. Hazardous Waste Management Sys- 14. Waste Minimization Issues and Op- Mr. Leemann is senior director,
tem-Identification and Listing of Haz- tions. EPA 530-SW-86-04. US. Envi- hazardous waste programs, a t Con-
ardous Waste: Notice of Availability of ronmental Protection Agency, Wash- OCO Inc., 600 N. Dairy-Ashford Road,
Data and Request for Comment, Feder- ington, DC, October 1986. Houston, T X 77079. This paper was
al Register, Vol. 53, No. 71, 12162- 15. Proposed Prohibition of Hexavalent submitted for peer review March 30,
12167, April 13, 1988. Chromium Chemicals in Comfort Cool- 1988; t h e revised manuscript was re-
11. 40 CFR 261, Appendix VII, Basis for ing Towers, Federal Register, Vol. 53, ceived May 4,1988.
Listing Hazardous Waste. No. 60, 10206-10221, Washington, DC,
12. The 1982 Refinery Solid Waste Survey, March 29,1988.
740 JAPCA