2008 Sector Performance Report - US Environmental Protection ...

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energy technologies, and improving methods for tracking GHG emissions. Water Use and Discharges Petroleum refiners use 1-2 billion gallons of water daily, principally for process cooling systems. 30 Because they use relatively large volumes of water, refineries are often located near water sources (e.g., beside riverbanks and other shoreline locations). Refinery operations generate process wastewater as well as surface water runoff. Wastewater characteristics and quantities differ among facilities and are driven by individual petroleum refining configurations. Processes to refine heavy crude, for example, tend to generate significant amounts of ammonia and suspended solids. In 2005, 121 refineries reported water discharges of TRI chemicals totaling 17.7 million pounds. This was a 52% increase in reported absolute pounds since 1996, and a 42% increase overall, when normalized by crude oil inputs to refineries. Nitrate compounds, reported by 62 facilities, and ammonia accounted for almost all (97%) of the reported discharges. 31 Wastewater from petroleum refining typically requires multiple steps to remove contaminants, recover product, and recycle process fluids prior to discharge. Refiners often lessen discharge quantities, treatment burdens, and associated costs by separating the various waste streams of cooling and process water, sanitation and sewage, stormwater, and other streams. In addition to being regulated for direct discharges and discharges to Publicly Owned Treatment Works, refineries with materials exposed to precipitation are regulated for stormwater runoff, sometimes under a general permit that provides sectorspecific limits on pollutants such as zinc, nickel, lead, ammonia, nitrates, and total suspended solids. Waste Generation and Management Wastes from petroleum refining operations can be generated from process-related functions or other activities, such as pollution prevention (e.g., control devices) or remediation of contamination. Refineries also generate wastes from handling petroleum products and treating wastewater. Typical refinery wastes are sludges, spent caustics, spent process catalysts, filter clay, and incinerator ash. Hazardous Waste Management In 2005, the sector reported generating 5.1 million tons of hazardous waste. The hazardous waste management method most utilized in refining was disposal, which accounted for 84% of wastes managed in 2005. Waste Management Reported to TRI In 2005, refineries reported a total of 1 billion absolute pounds of chemicals released, disposed, or managed through treatment, energy recovery, or recycling. This was a 22% decrease in the reported amount of waste managed since 1996, when normalized by crude oil inputs to refineries. Figure 3 shows how this waste was managed. In 2005, 54% was treated, 23% was recovered for energy use, and 17% was recycled, while 6% of TRI-reported waste was disposed or released. Energy recovery appeared to be the principal waste management method early in the decade; treatment was the predominant management method in recent years, accounting for 54% of the total pounds of TRI chemicals managed in 2005. Flaring is presently a major means of onsite treatment at many petroleum refineries; the industry is addressing associated GHG emissions under API’s Climate Challenge. In 2005, refineries reported that 6.3 million lbs. of TRI chemicals were disposed to land or transferred to offsite locations for disposal. Ammonia, zinc, and nickel disposals accounted for almost half of the total pounds disposed, as shown in Table 8. Most petroleum refinery TRI hazardous waste disposals utilized underground injection, although 43% relied upon landfill disposal. 32 Table 8 Top TRI Disposals 2005 Chemical Absolute Pounds Reported 1 Number of Facilities Reporting 2 Ammonia 1,337,000 3 29 Asbestos (Friable) 730,000 2 Benzene 107,000 98 Ethylbenzene 22,000 100 Lead 187,000 111 Molybdenum Trioxide 440,000 32 Nickel 817,000 64 Toluene 127,000 101 Xylene (Mixed Isomers) 105,000 104 Zinc 826,000 32 Percentage of Sector Total 74% 4 81% 5 Notes: 1. Total sector disposals: 6.3 million lbs. 2. 163 total TRI reporters in the sector. 3. Red indicates that the chemical is one of the top five chemicals reported in the given category. 4. Chemicals in this list represent 74% of the sector’s disposals. 5. 81% of facilities reported disposals of one or more chemicals in this list. Source: U.S. Environmental Protection Agency 88 Oil & Gas 2008 SECTOR PERFORMANCE REPORT
Figure 3 TRI Waste Management 1996–2005 600,000,000 Disposal or Other Releases 22% Treatment 22% 1996 total: 1.3 billion lbs Energy Recovery Recycling 56% 2005 total: 1 billion lbs 22% 30% 500,000,000 Normalized lbs 400,000,000 300,000,000 200,000,000 100,000,000 0 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 Notes: 1. Normalized by annual crude oil inputs into refineries. 2. Disposal or other releases include air releases, water discharges, and land disposals. Sources: U.S. Environmental Protection Agency, U.S. Department of Energy Additional Environmental Management Activities for E&P and Refining Several Oil & Gas sector environmental initiatives include both E&P and refining operations. For instance, EPA’s Natural Gas STAR program engages all segments of the natural gas industry—production, gathering, processing, transmission, and distribution—to identify and implement technologies and practices to reduce emissions of CH 4 . Natural Gas STAR identifies best management practices (BMPs) selected through a collaborative process involving EPA and natural gas industry advisers. The BMPs identify areas of operation where emissions can be reduced cost effectively. In 1999, Natural Gas STAR producer partners reported saving 17.4 Bcf of CH 4 , representing emissions that were prevented and natural gas that was retained in the system to be sold. EPA expanded the program in 2000 to include companies that gather and process natural gas. In 2005, partners reported more than 33.2 Bcf of CH 4 emissions reductions. 33 The American Exploration & Production Council (AXPC) is an official endorser of the Natural Gas STAR program, in which 16 AXPC member companies actively participate. Implementing Natural Gas STAR–recommended technologies and management practices, these AXPC member companies collectively reduced CH 4 emissions by 103 Bcf, representing savings of $720 million. Marathon’s Multi- Media Environmental Management Approach Marathon Petroleum Company–Louisiana Refinery Division in Garyville, LA, is the last petroleum refinery built in the United States (1976) and the only refinery in EPA’s Performance Track program. 34 In 2005, Marathon-Garyville announced plans for a major expansion to add 185,000 barrels per stream day of crude oil capacity. During the permitting process, Marathon agreed to reduce N0 x emissions beyond Best Achievable Control Technology requirements and to impose CO limits below burner manufacturer specifications. Marathon also installed four realtime ambient air monitoring stations and plans to upgrade the wastewater treatment system to ensure no additional NPDES permit allocations will be necessary. Marathon already has an onsite wastewater treatment plant that uses water from the adjacent Mississippi River and returns it to the river cleaner than it was when withdrawn. 35 2008 SECTOR PERFORMANCE REPORT Oil & Gas 89
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2008 Sector Performance rePort
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table of Contents i Preface 1 Execu
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Key to our work is collaboration wi
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Energy Use The eight sectors for wh
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Sector Data Side by Side The follow
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TRI Air Emissions Across Sectors 19
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TRI Waste Management Across Sectors
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This report relies upon a variety o
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TABLE 3 Economic Activity Data for
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Presentation of TRI Air Emissions D
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Presentation 500,000,000 of TRI Was
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Cement Manufacturing 1 AT A GLANCE
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equires 32% more energy per ton of
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Summing the Toxicity Scores for all
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l t , r t i t i Figure 3 Cement Kil
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ChemiCal manufaCturing 1 AT A GLANC
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Chemical facilities purchase electr
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conservatively assumes that chemica
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Balanced Water Use at BASF Supply U
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Waste Management Reported to TRI In
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Colleges & universities 1 AT A GLAN
Page 44 and 45: Criteria Air Pollutants Most CAP em
Page 46 and 47: Construction 1 AT A GLANCE 1996-200
Page 48 and 49: Figure 1 Fuel Use for Energy 2002 E
Page 50 and 51: Figure 4 Trends in Construction and
Page 52 and 53: Food & Beverage Manufacturing 1 AT
Page 54 and 55: Figure 2 Air Emissions Reported to
Page 56 and 57: associations, or government agencie
Page 58 and 59: disposed or released to air or wate
Page 60 and 61: Forest Products 1 AT A GLANCE 1996-
Page 62 and 63: 2002 the manufacture of wood produc
Page 64 and 65: emission controls to the pulping, p
Page 66 and 67: Water discharges became a major foc
Page 68 and 69: Iron & Steel 1 AT A GLANCE 1996-200
Page 70 and 71: ton of steel shipped improved over
Page 72 and 73: existing, high-toxicity weighting f
Page 74 and 75: water that has been reused. Typical
Page 76 and 77: Metal Casting 1 AT A GLANCE 1996-20
Page 78 and 79: using a cupola furnace can dehumidi
Page 80 and 81: Table 1 presents the top TRI-report
Page 82 and 83: Waste Management Reported to TRI hi
Page 84 and 85: Oil & Gas AT A GLANCE 1996-2005 1,2
Page 86 and 87: equipment helps recover the gas. In
Page 88 and 89: The most widely used EOR technique
Page 90 and 91: Petroleum refining Latest Environme
Page 92 and 93: Figure 2 Al TRI HA s Air Emissions
Page 96 and 97: Paint & Coatings 1 AT A GLANCE 1996
Page 98 and 99: Figure 1 Air Emissions Reported to
Page 100 and 101: Owned Treatment Works, but may also
Page 102 and 103: Ports 1 AT A GLANCE 2005: 360 publi
Page 104 and 105: Increasing Use of Solar Power The P
Page 106 and 107: developing retrofit and replacement
Page 108 and 109: “invasive” if they are capable
Page 110 and 111: shipbuilding & ship repair 1 AT A G
Page 112 and 113: of marine coatings. CAPs and GHGs a
Page 114 and 115: Table 1 Top TRI Air Emissions 2005
Page 116 and 117: Shipyards’ stormwater runoff is t
Page 118 and 119: data Sources, Methodologies, and CO
Page 120 and 121: Facilities described above must rep
Page 122 and 123: Data Processing RSEI calculates tox
Page 124 and 125: • Section 6.2: Transfers to other
Page 126 and 127: Cement Manufacturing 1. Facilities:
Page 128 and 129: 12. Charles Heizenroth, EPA, person
Page 130 and 131: Forest Products 1. Facilities: Cens
Page 132 and 133: 40. Includes direct discharges to w
Page 134 and 135: Public Data Release (PDR) (includes
Page 136: Advancing Port Sustainability, Janu
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