Assessment In Industrial Hazardous Waste Management Petroleum Re-refining Industry

    SW-144c

|                          Prepublication issue for EPA libraries
                          and State Solid Waste Management Agencies
                     ASSESSMENT OF INDUSTRIAL HAZARDOUS WASTE MANAGEMENT

                                PETROLEUM RE-REFINING INDUSTRY
                    This final report (SW-144o)  describes work performed
                        for the Federal solid waste management program
                      and is reproduced as received from the consultant
                              Copies will  be available from the
                           National  Technical  Information Service
                                 U.S.  Department of Commerce
                                Springfield, Virginia  22161

                                 AJ o 7


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                            U.S.  ENVIRONMENTAL PROTECTION AGENCY

                                            1977

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This report as submitted by the grantee or contractor has been
technically reviewed by the U.S. Environmental Protection Agency (EPA).
Publication does not signify that the contents necessarily reflect the
views and policies of EPA, nor does mention of commercial products
constitute endorsement by the U.S. Government.

An environmental protection publication (SW-144c) in the solid waste
management series.

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                   ACKNOWLEDGMENTS
This report is the result of a study of potentially
hazardous wastes generated by the petroleum rerefining
industry.  Included is information relating to
quantities of wastes produced, current treatment and
disposal technology, and costs of treatment and
disposal as well as potential improved process methods.

We are grateful for the invaluable suggestions, advice,
and assistance of Mr. Matthew A. Straus, Dr. Shelly J.
Williamson, and Mr. Timothy Fields, Jr., of the
Hazardous Waste Management Division, Office of Solid
Waste, U.S. Environmental Protection Agency.

This study could not have been accomplished without
the cooperation and assistance of all but two of the
commercial rerefiners in the U.S.  Particular apprec-
iation is due Mr. Belton R. Williams of the Motor Oils
Refining Company, Mr. H. B.. Robertson of the Jackson
Oil Company, Mr. A. L. Warden of the Warden Oil Company,
Mr. William Judd and Mr. E. E. Fisher of the Texas
American Oil Company, and Mr. Lester R. Schurr of
Berks Associates as well as Mr. Duane H. Ekedahl of
the Association of Petroleum Rerefiners.

A very special acknowledgment mus.t be made to Sally B.
Swain who, cheerfully, prepared the several drafts of
this report.
                                                            f..

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                   TABLE OF CONTENTS


                                                 Page

List of Tables                                   vii

List of Figures                                   xi
1.0  Introduction ...............    1

2.0  Executive Summary  .  ...........    3

     2.1  Introduction  ............    3
     2.2  Purpose of Study  ..........    5
     2.3  Methodology .............    6
     2.4  Industry Characterization ......    7
     2.5  Waste Characterization  .......    9
     2.6  Treatment & Disposal Technology ...   18
     2.7  Cost Analysis ............   21

3.0  Characterization of the Petroleum
     Rere fining Industry  ...........   22

     3.1  Introduction  ..... . ......   22
     3.2  History of Waste Oil  ........   23
     3.3  Overview of Reclaiming, Reprocessing,
          & Rerefining Industries ....."..   26

          3.3.1  Recycling, Reclaiming &
                 Rerefinin  ..........   27

     3.4  Sources & Quantities of Waste Oils. .   29
     3.5  Refined Oil Products  ........   32
     3.6  Industry Characteristics  ......   32

4.0  Waste Characterization ......... .   40
     4.1  Introduction.  ............   40
     4.2  Rerefining Process Description  ...   41

          4.2.1  Pretreatment .........   41
          4.2.2  Distillation .........   43
          4.2.3  post Treatment ........   44
          4.2.4  General Processing ......   45

     4.3  Criteria for Determination of
          Potentially Hazardous Wastes   ....   49
     4.4  Waste Analysis Data .........   52
     4.5  Waste Stream Description  ......   63
     4.6  Waste Quantities for 1975 ......   70
                     IV

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                                                Page

     4.7  Rationale for Extrapolation of Waste
          Quantities for 1977 & 1983	   73
     4.8  Waste Quantifies Projected for 1977
          & 1983	   80

          4.8.1  Projections 1977	   80
          4.8.2  Projection, Petroleum
                 Rerefining Wastes 1983. ...   87

     4.9  Future Process Changes in
          Rerefining 	 .....   90

5.0  Waste Treatment & Disposal Technology . .   94

     5.1  Introduction	   94
     5.2  Hazardous Waste Management
          Overview 	 .....   95

          5.2.1  Sludge & Clay Waste
                 Management	   95
          5.2.2  Process Waters Waste
                 Management	   99

     5.3  Alternative Treatment & Disposal
          Methods	104

          5.3.1  Introduction	104
          5.3.2  Sludge Burning	106
          5.3.3  Chemical Fixation 	  106
          5.3.4  Clay Reclaiming	107
          5.3.5  Waste Water Recycle 	  107
          5.3.6  Large Scale Operations,
                 Alternatives  	  108

     5.4  Levels I, II, & III Technologies for
          Oil Rerefining Hazardous Wastes  . .  109
6.0  Cost Analysis	117
     6.1  Introduction	117
     6.2  Techniques fo Assumptions Used  . . .  118
     6.3  Industry Disposal Costs  	  120

References	123

Appendices
 A   List of Commercial Rerefiners ......  126
 B   Data Questionnaire,  Petroleum Rerefining
     Wastes Study	128
 C   Composition of Some Lubricating Oil
     Additives	132

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                                            Page
D   U.S. EPA Regional Offices	     133
E   Glossary	     134
F   Explanation of Waste Oil Generation
    Factors	     148
                 VI

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                      LIST OF TABLES
Table                                              Page

  1   Waste Oil Generation 1975,  1971 ......    24
  2   Waste Lube Oil Recycling Methods  	    28
  3   Sales of Lubricating & Industrial Oils &
      Greases 1967,  1&69,  1971, 1973, & 1975  .  .    30
  4   Rerefineries,  Distribution of Plants by EPA
      Regions, Employees & Age	    34
  5   Rerefineries,  Distribution of Plants by
      Quantities, Processes,  & Products Produced.    36
  6   Petroleum Rerefiners Production & Capacity
      vs. Industry Totals	    39
  7   Criteria for Determining Hazardous Wastes
      from Petroleum Rerefining 	    50
  8   Acid Sludge Analysis	    53
  9   Acid Sludge Analyses, Composite 	    55
 10   Physical Characteristics of Acid Sludge .  .    56
 11   Analysis of Rerefining Caustic/Silicate
      Sludge 1973	    57
 12   Analysis of Petroleum Rerefining Spent
      Contact Clays 	    58
 13   Laboratory Analysis  of Acid & Caustic
      Sludge  	'	    60
 14   Lead Material Balance for Waste Crankcase
      Oil Acid/Clay Rerefining  	    61
 15   Analysis of Spent Clay from Clay-Only
      Rerefining Process  	    62
 16   Metals & Phosphorus  Content of 10 Used
      Lubricating Oils	    65
 17   Process Water (Steam Stripping) from the
      Acid/Clay Oil Rerefining Process, 1976  .  .    69

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                                                 Page

13   Annual GeneraLic;! of Sludge & Speat  Clay
     from Petrolaur Re.r«fining in 1975 by EPA
     Regions ,.».,,....«.*.....   71

• y   Total Potentially Hazardous Substances
     Generated by U.S. Petroleum Rerefining
     Industry,  1975  . „	   72

20   Distribution by &PA  Regions of Metals &
     Other Substances in  Acid Sludge for  1975.  .   74

21   Quantity Distribution of Metals & Other
     Substances in Caustic & Other Sludge,
     1975		75

22   Lead & Oily Constituents of Spent Clay
     Generated in the Petroleum Rerefining
     Industry in 1975	76

23   Estimated 1977 Production of Product &
     Generation of Wastes by the Petroleum
     Rerefining Industry  .	   81

24   Total Potentially Hazardous Constituents
     in Wastes Generated  by the Petroleum
     Rerefining Industry  in 1977 ........   83

25   Total Potentially Hazardous Constituents
     in Acid Sludge Generated by the Petroleum
     Rerefining Industry  in 1977	84

26   Lead & Oily Constituents in Caustic  & Other
     Sludge Generated by  the Petroleum Rerefining
     Industry in 1977  .,	85

27   Lead & Oils in Spent Clay Generated  by the
     Petroleum Rerefining Industry in 1977 ...   86

28   Estimated Production of Rerefined Oil &
     Potentially Hazardous Wastes Generated by
     the Petroleum Rerefining Industry in 1983  .   88

29   Total Potentially Hazardous Constituents
     Generated by the Petroleum Rerefining
     Industry in 1983	89
                    VTIl

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                   LIST OF FIGURES
Figure                                           Page

   1   Flow Diagram, Current Waste Oil
       Pverefining Practice	    42

   2   Flow Diagram, Current Petroleum
       Rerefining Processes - Clay Only, Acid
       Pretreatment, Caustic Pretreattnent  . .    46

   3   Rerefining by Caustic/Solvent/Clay
       Process	    48
                    XI

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1.0  Introduction

     Resource recovery has  become  a matter  of  great
     importance in worldwide  public awareness.  Wastes
     from manufacturing  sources  generated in tremendous
     quantities are  often a threat to  our environment and,
     when not recycled,  irretrievably  deplete  our  finite
     resources.

     This study addresses potentially  hazardous wastes
     generated by the  petroleum-rerefining  industry.  However,
     the underlying  resource  recovery  potential is present.
     There is little argument today against the preference
     for rerefining  of waste  lubricating oils  as opposed  to
     their use as fuel.   Rerefining has been practiced since
     1915.  Civilian and military  aircraft  engine  oils were
     rerefined until 1949.  29,000,000 hours of engine flight tin:
     was accumulated using  rerefined.oils.  1,174,810
     gallons, representing  25 percent  of total lubricating
     oil demand,  was used by  the U.S.  Air Force in 1949.

     A potential shortage of  lubricating oils  is predicted
     by most authorities.  The effect  on transportation
     vehicles is readily apparent. However, the effect on
     industry, which uses petroleum oils for many  other
     purposes, as well as lubrication, could be even more
     severe.

     However, use of waste  oils  as fuel, processed to remove
     contaminants which  cause air  pollution, is certainly

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                                                         2
preferable to dumping of raw waste oils on land or
into sewers or open drains.

Thus, potentially hazardous wastes are generated in
the rerefining of waste oils for lubricating use as
well as the processing of waste oils for use as
environmentally acceptable fuel.  These wastes contain
potentially hazardous contaminants such as heavy metals,
phenols and potentially carcinogenic aromatic hydro-
carbons .

This study report attempts to qualify and quantify the
potentially hazardous wastes generated by the petroleum
rerefining industry in the United States.  It further
surveys the industry characteristics as well as the
treatment and disposal technology and costs for its
wastes.  Projected production of rerefined oil and
generation of wastes, using the best data available,
have been made for 1977 and 1983.

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2.0  Executive Summary

     2.1  Introduction
          This report  is  the  result- of a  study commissioned by
          the U.S.  Environmental Protection Agency  (EPA) to
          assess  "Industrial  Hazardous Waste Management
          Practices in the Petroleum Rerefining Industry"
          (SIC 2992).   This industry study is one of a series
          sponsored by the Office of Solid Waste, Hazardous
          Waste Management Division.  The studies were conducted
          for information purposes  only and not in  response to
          a Congressional regulatory mandate.  The  studies
          serve to  provide EPA with:  (1) an initial data base
          concerning current  and projected types and quantities
          of industrial wastes and  applicable disposal methods
          and costs;   (2) a data base for technical assistance
          activities;   and  (3) a background for guidelines
          development  activities.

          The definition  of "potentially  hazardous  waste" in
          this study was  developed  based  upon contractor
          investigations  and  professional judgment. This
          definition does not necessarily reflect EPA policy
          since such a definition,  especially in a  regulatory
          context,  must be broadly  applicable to widely differing
          types of waste  streams.   Obviously, the presence of
          a toxic substance should  not be the major determinant
          of hazardousness  if there were  mechanisms to represent
          or illustrate actual effects of wastes in specified

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environments.  Thus, the reader is cautioned that the
data presented in this report constitute only the
contractor's assessment of the hazardous waste manage-
ment problem in this industry.

It has been estimated that 1.1 billion gallons of
waste oil were generated in 1972.    Using the same
waste oil factors, it is estimated from 1975 sales
data that 1.26 billion gallons were generated in 1975.
The components of these estimates  are presented below.

Waste Oil Generation (U.S. 1972, 1975)   (Gallons-106)
                               1972         1975
Automotive lube oils            616          673
Industrial and aviation oils    394          458
Other industrial oils            87          113
Lube oils purchased by U.S.      18           16
                      Total   1,115        1,260

These wastes can present significant environmental
hazards from unacceptable disposal methods, such as:
1.  Uncontrolled burning, as a fuel, with consequent
    emission of lead and other heavy metals.
2.  Uncontrolled dumping on land with consequent con-
    tamination of ground water by  leaching and contam-
    ination of surface water by run-off.
3.  Dumping in waterways, which can result in danger
    to fresh water and marine organisms, and affect
    recreational and drinking water quality,
4.  Road oiling which can result in undesirable

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         environmental effects via runoff into surface
         waters and absorption into the  soil  and plant
         life.

     High fuel prices in recent years  have had the  effect
     of diverting a major quantity of  waste oil from
     rerefining to some form of energy use, such as a  fuel.

     Oil rerefining produces lubricating oils which have
     a higher economic value than fuel oils.   Shortages of
     lubricating oil products are projected by most
                 2
     authorities.   One significant problem affecting  the
     industry is the generation and disposal  of process
     wastes which concentrate the hazardous materials
     contained in waste oils.

2.2  Purpose of the Study
     This study has been conducted to:
     1.  Provide a characterization of the current  petroleum
         rerefining industry.
     2.  Determine the quantity and character of potentially
         hazardous wastes currently generated by the
         petroleum rerefining industry and projections of
         1977 and 1983 quantities.
     3.  Investigate current treatment and disposal tech-
         nology and present  and improved technologies  with
         acceptable health and environmental  protection.

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     4.  Estimate typical costs  for three technology
         levels:
         Level I.    Most prevalent current  technology
         Level II.    Best current  technology
         Level III.   Technology  necessary to provide
                     adequate  health and environmental
                     protection

2.3  Methodology
     The study has been segmented  into  four  basic  sections:
         Industry Characterization (Section  3.0)
         Waste Characterization  (Section 4.0)
         Treatment and Disposal  Technology (Section 5.0)
         Cost Analysis (Section  6.0)

     No previous  in-depth studies  have  been  conducted of
     petroleum rerefining industry wastes;  however,  past
     studies sponsored by the  U.S.  Environmental Protection
                                        3 4
     Agency have  discussed these wastes.  f

     Each of the  commercial rerefiners,  as well as those
     former rerefiners still active in  used  oil recycling
     in some other manner,  was interviewed by telephone or
     during plant visits.  (See  Appendix A)   The survey
     form used for these interviews is  shown in Appendix B.

     The author developed this questionnaire to gain as
     much current information  about the petroleum  rerefining
     industry as  possible.   It is  the source of much of
     the data presented in this  report.   Few rerefiners
     keep detailed records  of  waste quantities.  However,
     cross checking  using the  quantity  of waste oil received,

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     rerefined oil produced and use  of clay  established
     reasonably accurate numbers.  Where notable  incon-
     sistencies were indicated the author  used his best
     judgment and information from other sources  to
     reconcile the data.  A review of the  literature,
     private communications and the  author's knowledge
     and experience have been employed to  obtain  the best
     possible information and data.   These allowed for
     reasonable and viable conclusions and estimates of
     current and potential petroleum rerefining waste
     generation, treatment and disposal technology and
     costs,  and potential environmental hazards.

2.4  Industry Characterization
     Petroleum oil rerefining produces lubricating.oil  base
     stocks  which are used in motor  oils,  gear oils,
     transmission fluids, hydraulic  oils,  and  various
     industrial oil products.

     The industry has 27 active rerefiners as  of  September
     1976.  This is a decline of 10% from  1975 (30 rere-
     finers), and an 82% reduction from 1960 (150 rerefin-
     ers) .

     Three firms which were rerefining in  1975 are using
     portions of their plants for production of fuel and
     certain industrial oils.  These plants  are considered
     to be inactive but potentially  available  for rerefining.
     Production, approximately 44.4% of total  capacity
     (including the six known inactive rerefiners, as well
     as the 27 active rerefiners), has declined from an

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                                                       8
estimated 300 million gallons in 1960 to 51 million
gallons in 1975.  At least eight rerefiners, with a
current total production of 12 million gallons per
year, are contemplating withdrawal from rerefining.
However, twelve rerefiners show a production increase
versus 1975, totaling 9 million gallons annually,
while eleven show decreases for the same period of
nearly 5 million gallons per year.

The decline in industry production and number of
facilities since 1974 has been largely due to a
shortage of waste oil which, with little or no proces-
sing, has been diverted to fuel use,  and problems in
disposing of wastes from the rerefining process.

With few exceptions, the rerefining operations are
small, old and often family run.  The largest plant
is responsible for approximately 20% of the 1975
U.S. production, with 10 million gallons of rerefined
oil.  Data on plant age, size, and production are
presented below.
 (Gallons)        PLAtfT AGE                  EMPLOYEES
Production   <5     5-30    31-50      <10    10-20   21-30
0-999
1000-1999
2000-3999
4000-5999
6000-10000
0
1
0
0
0
7
8
5
1
1
3
0
0
1
0
7
3
0
0
0
3
5
3
2
1
0
1
2
0
0

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     The twenty seven rerefiners are operating in 19
     states.  California has four facilities  (15%),  Texas
     has three (11%), and Minnesota and Wisconsin have
     two each (7.4%).  The remaining sixteen  each have
     only one rerefiner.  The rerefineries  are located
     in or near large cities, because of availability of
     the product and markets.

     The more profitable rerefiners either  handle a  major
     quantity (over 30% of production)  of industrial oil
     (including railroad oil),  or engage in related
     activities,  such as packaging and/or sales of virgin
     oils and anti-freeze.  Fifteen percent of the rere-
     finers have a significant proportion (over 30%) of
     industrial oil production.

2.5  Waste Characterization
     The criteria used in this study for determining the
     potentially hazardous nature of petroleum rerefining
     industry wastes are based on the proposed Interim
     Primary Drinking Water Standards  established by the
     U.S. Environmental Protection Agency,  since leaching
     of toxic materials to a drinking water source is
     possible.

     Rerefining consists of three basic processes:
     1.  Pretreatment, which removes unwanted constituents
         using heat and chemicals.
     2.  Distillation, usually with bleaching clay mixed

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                                                       10
    with the pretreated waste oil, which removes low
    boiling fractions and some of the undesirable
    constituents.
3.  Post treatment, which removes the spent clay by
    filtration.  It can include acid neutralization
    or other finishing processes or a separate clay
    contact treatment.

Twenty rerefiners (74.1%) use a sulfuric acid pre-
treatment;  two (7.4%) use sodium hydroxide (caustic
soda) alone or mixed with sodium silicate and sur-
factants.  These processes produce either acid or
caustic sludges.  Four rerefiners (14.8%) use little
or no pretreatment, but use as much as four times
more than the average amount of clay during distil-
lation.  One rerefiner uses an unknown proprietary
process which, purportedly, is neither acid or caustic.

All rerefiners distill by heating an oil/clay mixture
to 550-650 F to remove light ends and certain con-
stituents not removed by pretreatment.  Light ends,
or distillate, is similar to kerosene or home heating
oil, and is largely consumed within the facility as
fuel.  The clay removes color bodies and other undesir-
able constituents not removed by pretreatment or dis-
tillation.  Where only clay is used, after little or
no pretreatment, most of the undesirable constituents
are found in the clay rather than the pretreatment
sludge.  Since live steam is introduced to the oil/clay
during distillation,  the waste produced in this process

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                                                       11
is water containing metals,  phenols,  and sulfur
compounds, among others.

The post treatment, currently employed by all rere-
finers, removes the spent  clay from the oil by
filtration, and thus produces the spent clay waste.

The oil (base stock) is blended with virgin oil,  if
necessary for required viscosity, and additives
suitable for the product  end use, such as motor oil.

Acid sludge is a black, tar-like, acid material with
a strong sulfuric acid odor reflecting its high acid
content.  It contains most of the metals, polar
compounds  (original additives, or compounds formed
during use), and solids.   Metals found in the sludge
include lead, zinc, chromium, copper, iron and alum-
inum, among others.  Since the waste oil is dehydrated
before acid pretreatment, it contains little or no
water.

Sludge from caustic (sodium hydroxide) pretreatment
may contain as much as 20% water as produced, but is
usually disposed in an essentially dry state, since
the water separates in storage and is removed before
disposal.  It is somewhat emulsifiable and can be
made more fluid by neutralizing with acid and/or
diluting with waste oil or rerefinery distillate.  The
pH ranges from alkaline  (pH 10.0) to close to neutral,
or approximately pH 7.  It contains the same metals
as acid sludge, as well as the original additives and

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                                                      12
compounds, such as oxidized petroleum fractions,
formed during use.  There is some evidence to indicate
that there is a lower degree of aromatic hydrocarbon
        6
removal.

Spent clay, a grey-tan powder in its original state,
is black and oil compacted, ranging from very oily
and greasy to slightly oily after contact with the
oil during distillation.  Common and low cost solvents
can remove much of the adsorbed oil and other con-
taminants.  The spent clay contains lead and other
heavy metals, phenols, oils, and other compounds.

Solid waste from process water treatment is negligible,
and is included in the sludge.  No separate record
of this sludge is kept by rerefiners.

There are four sources of wastewater in the rerefining
operation:
1.  Water contained in the raw waste which settles
    during storage.
2.  Ground water run-off, which may contain oil from
    spills and leakage.
3.  Process cooling water.
4.  Steam stripping water, which is that resulting
    from live steam introduced during  distillation.

The most significant of these, from the potentially
hazardous waste standpoint,  is the steam stripping

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                                                          13
process water which contains small, but troublesome,
quantities of lead, zinc, and phenols, for example.  It
also contains quantities of hexane solubles (oils,
polymers and polar compounds) considerably higher than
levels specified by the U.S. Environmental Protection
Agency.

The 27 rerefiners using acid, caustic, or other pre-
treatments,produced in their wastes the following 1975
estimated amounts of some of the substances considered
to be hazardous in the environment.
Hazardous
Substances
SuIfuric Acid
Lead *
Arsenic
Zinc
Cadmium
Chromium
Oil, Polymers,
Polar Compounds
& Asphalt
    ACID SLUDGE
Generation  Typical
(Metric     Analysis
tons/yr)     (PPM)
  CAUSTIC SLUDGE
Generation  Typical
(Metric     Analysis
tons/yr)     (PPM)
9,913.0
660.9
1.5
69.4
0.3
1.3
27.0 (%)
19,000
45
2,100
9
28
0
163.6
0.4
12.3
0.1
0.2
0 (
27,500
45
1,500
7.5
18
11,896.0    57.3 (%)   2,699
                33.0 (%)
   * It should be noted that the lead content of waste oil
     is being reduced with the increased use of low and
     no-lead gasoline.

No specific investigations have been made of the potential
carcinogenic properties of rerefining wastes by EPA,
National Institute of Occupational Safety & Health  (NIOSH),

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                                                          14
or Occupational Safety & Health Administration  (OSHA).
However, it has been stated that virgin lubricating
oil contains polynuclear aromatics which have been
                              7
determined to be carcinogenic.   Used oils show a higher
                                                 7
percentage of such constituents than virgin oils.   Since
the rerefining process removes many of these constituents
                   Q
from the waste oil,  it is logical to assume that the
rerefining wastes are potentially carcinogenic.  Further
waste oil analyses, including polynuclear aromatics, by
National Bureau of Standards (NBS), as mandated by the
Energy Conservation Act of 1975, should increase knowledge
in this area and provide a data base for a more complete
investigation.  It may also offer further data supporting
this assumption regarding the carcinogenic properties
of rerefining wastes.

Other potentially carcinogenic agents may also be present.
Recent findings indicate high levels of nitrosamines in
metalworking fluids.  These materials may well become
constituents of industrial oily waste and, hence, con-
stituents of the waste oil.  It is also indicated that
these carcinogenic compounds could be found in used motor
oils since both nitrogen and amiine compounds are found
                                                       9
in motor oils, with possible formation of nitrosamines.
Further research needs to be done in this area.  There
may well be other toxic©logical, carcinogenic and
mutagenic hazards not previously addressed.

Sludges derived from rerefining of industrial oils,
including diesel engine oils, vary,  depending  on the

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                                                          15
source.  The lead content of used diesel engine oil is
very low, approximately 13% of that found in used gasoline
oils.  Metalworking oils may contain substantial amounts
of iron, aluminum, copper, tin,  and chromium,  as well as
fatty oils, soaps and emulsifiers,  corrosion and rust
inhibitors, sulfur, chlorine, and phosphorus compounds.

The hazardous properties of spent clay are of a consider-
ably lower order of magnitude.  There has been much less
investigation of spent clay than of acid sludge.  However,
lead content in spent clay is reported as only 8% of
that found in acid sludge.    Excluding four rerefiners
using clay only or other processes with no acid or caustic
pretreatment, the amount of lead in the clay is estimated
at 76.5 metric tons annually.  Rerefiners using the clay-
only process contribute an estimated 139.8 metric tons
of lead.

The other metals, such as zinc,  removed by the clay-only
process are present in the clay in proportion equal to
that found in the waste oil.    The undesirable polar
compounds and polymers will also be found in the spent
clay.

The rerefining industry reports production of 51 million
gallons of rerefined oil for 1975 with the following
waste generation:
  Waste Type                Metric tons/yr (dry weight)
  Acid sludge                         33,045
  Caustic & other sludge              8,180 *
  Spent clay                         15,700
  * Caustic sludge contains water as produced but is usually
   substantially water-free at disposal since the water
   separates in storage.

-------
                                                          16
It is difficult to project the waste stream quantities
for 1977 and 1983, because of the steady decline of the
rerefining industry since 1960, and because of the
uncertainty of its survival.  Five current major factors
indicate continuing decline.  These are as follows:
1.  Waste disposal problems, such as unavailability of
    disposal facilities or increased costs of trans-
    portation and/or disposal.
2.  High waste oil feed stock prices due to use of un-
    processed oil as fuel.
3.  Reduced virgin oil prices.
4.  Age of company owners with little successor management
5.  Financial inability to make potential process changes
    for efficiency, and environmentally adequate handling
    of waste requiring large capital investment.

However, four factors could provide a favorable climate
for increased production of rerefined oils in 1977 and
1983.  These are:
1.  Governmental action in control of burning of raw waste
    oil.
2.  Favorable legislative action on re-imposed excise
    taxes on virgin oils.
3.  Removal of the Federal Trade Commission labelling
    requirement for rerefined oils.
4.  Improved market prices for lubricating oils.

-------
                                                          17
While a decline in the number of currently active

rerefiners is probable, new and larger rerefineries
with improved technology could be in operation in the

near future.

With the above factors in mind, the following rerefined

oil production and waste quantities are projected for
1977 and 1983.
Year
1977
1983
Production
Gallons
(106)
68.9
183.3
Increase
over 1975
Gallons
(105)
18.0 (26%)
132.6 (35%)
Sludge
generation
Metric tons
(103 dry wgt)
54.2
91.6
Increase
over 1975
Metric tons
(103 dry wgt)
12.9 (31%)
50.4 (103%)
      Production
      Gallons
Year  (106)
Clay
generation
Metric tons
(103 dry wgt)
1977
1983
68.9
183.3
20.0
52.5
Increase
over 1975
Metric tons
(10  dry wgt)

 4.4  (28%)
36.8  (234%)
It is estimated that the use of low lead and unleaded
gasoline will reduce the lead content of sludge and spent
clay by 70% by 1983.  The lead concentration is expected

to be approximately 2,000 PPM in waste motor oil,  6,000 PPM

in rerefining sludge generated by current processes, and
8,500 PPM in sludge or bottoms generated by improved
technology.


It is also possible to project a near complete disappearance

-------
                                                               18
     of the rerefining industry by  1983  if no governmental
     action is taken to eliminate uncontrolled burning of
     raw waste oil and road oiling,  and  if current tax and
     labelling restrictions on waste oil continued.  Waste
     oil generated and recovered would then be used as fuel,
     with or without processing.

2.6  Treatment and Disposal Technology
     The levels of treatment and disposal technology for the
     petroleum rerefining industry  are defined as follows:

     Level I    The use of off-site or on-site landfills
                without treatment of wastes such as acid
                neutralization or use  of fixative materials.
     Level II   The use of landfills with some form of waste
                treatment to reduce leaching of hazardous
                substances.
     Level III  The use of either chemically secure landfills
                with or without treatment of waste;  or use of
                sanitary landfills  after environmentally
                adequate treatment  of  waste to prevent leaching
                of potentially hazardous substances.

     Sixteen, or 80%,  of the rerefiners  having acid sludge
     use Level I disposal practices, which are disposed in
     environmentally inadequate landfills, on-site landfills,
     or use on roads.   Thirteen rerefiners use commercial or
     municipal landfills, two use on-site landfills, and one
     spreads the sludge on roads.   Off-site landfill and road

-------
                                                          19
oiling disposal account for 74.2% (24,525 metric tons)
of the total acid sludge generated.   There are 2,670
metric tons, or approximately 9% of the total acid sludge
generated, disposed in on-site landfills.

Level II technology,  the best disposal practice currently
employed, is practiced by four rerefiners (20%) which
utilize acid pretreatment.   This technology includes
treatment of wastes by mixing with a neutralizing agent,
and/or fixative materials.   These rerefiners generate a
total of 5,850 metric tons, or approximately 19% of the
total acid sludge produced annually.  Three rerefiners
use off-site landfills and one treats and disposes of
the waste on-site.

Total caustic and "other" sludge generated totals 8,180
metric tons.  About 1,440 metric tons, or 17.6% of this
sludge, is applied on roads.  An equal quantity is mixed
with waste oil and heavy virgin fuel and burned as a
fuel.  The remainder, 5,300 metric tons, or 64.8% of the
total caustic and "other" sludge generated, is used as
an asphalt extender and plasticizer.  These three methods,
respectively, dispose of 12.8%, 3.5%, and 3.5% of total
sludge generated.  Therefore, if it is assumed that the
sludge which is used as fuel and that used in asphalt
products are products of rerefining rather than waste,
then the 1,440 metric tons used for road oiling becomes
the total quantity of caustic and other sludge requiring
disposal.

-------
                                                          20
Road oiling is considered to be a Level I technology
disposal method.

Only four rerefiners utilize sludge treatment methods
which qualify as best current practice (Level II).
Current leaching tests on one neutralizing and fixating
process are currently being conducted under EPA sponsor-
ship.  Should these tests show satisfactory results, the
processes, and others similar, would qualify as Level III
technology when done prior to landfilling.

Road oiling, using either acid or caustic sludge, is
environmentally unacceptable unless it can be demon-
strated that suitable methods for fixation of hazardous
substances can be, or are, possible.

The rerefining industry generated 15,700 metric tons
of spent clay in 1975.  Twenty five, or 92.6%, of all
rerefiners use Level I technology for disposal of 14,235
metric tons per year.  Nineteen use off-site landfills
(11,930 tons), two dispose of the clay via use on roads
(1,097 tons), and four use on-site landfills (1,208 tons).

Two rerefiners use Level II technology for disposal of
spent clay.  That is, the clay is mixed with a fixative
and deposited in a landfill.  Here again, the environmental
adequacy of these methods must be determined by leaching
tests.
/
At this time, the only Level III technology is deposition
of the sludge and spent clay wastes in secure landfills
from which hazardous substances cannot leach.

-------
                                                                21
     The following is a summary of petroleum rerefining waste
     types and quantities vs. disposal technology levels  in
                   Waste Disposal Technology Level
                        metric tons/yr (dry wgt)
     Waste Type        Level I      Level II      Level III
     Acid sludge        27,195        5,850           0
     Caustic, other
      sludge*            1,440            0           0
     Spent clay         14»,235        1,465           0
   *A significant amount of caustic and other sludge generated is reused
    as either a 'fuel  or a product.
2.7  Cost Analysis
     Petroleum rerefining waste disposal costs vary widely.
     Since the major proportion of the waste is disposed  in
     off-site landfills, transportation cost is a significant
     factor.

     Few rerefiners separate contributory waste disposal  costs,
     such as, plant labor, equipment amortization,  and percentage
     of overhead.  Landfill charges and transportation costs
     are available, and other costs have been imputed with
     the agreement of the individual rerefiner.

     The following summary shows the range of costs and average
     cost per metric ton  (dry weight) of each Waste type  and
     the total current industry costs for waste disposal  for
     each technology level:

-------
                                                              22
            Petroleum Rerefining Waste  Disposal Costs
                  ($/Metric  ton, dry weight)
Tech- Sludge
nology Acid &
Levels Caustic Average Cl
I
II
III
*
$3-31.00 $10.74 $1-
5-15.00 7.82 3.
0 0
Author's estimate based
$0.45 "for r ere fined oil
§21
15.
Average
00 $6.20
50-15.

0
6
.68
0
Total
on bulk
" without
Estimated
Total Industry
Industry Sales *
Cost 103
$534,
73,

$607,
price per
additives .
489
209
0
698 22,950
gallon of
3.0  Characterization of the Petroleum Rerefining Industry

     3.1  Introduction
          The petroleum rerefining industry is  composed of
          small operations  with a maximum of 25 and an average
          of 11 employees.   Seventy percent of  the production
          of the industry is less than 2  million gallons per
          year.  In most cases,  the equipment has been
          designed and fabricated by the  operator,  often from
          second hand material.   Despite  the fact that the
          facilities do not compare in the technical sophisti-
          cation or efficiency associated with  the typical
          manufacturing process  industries,  the product (lubri-
          cating oil) is, or can be,  of high quality.   Tradi-
          tionally, marginal profits have prevented capital
          investment on a large  scale.

-------
                                                        23
     The major volume of waste  oil  processed is provided
     by used motor oil sources,  i.e.,  service stations,
     garages, car dealers,  and  truck,  bus,  and automobile
     fleets (See Table 1).   The oil products composing
     the wastes are automotive  lubricants,  motor  oils,
     gear oils, and transmission fluids.   Some firms
     process small amounts  of industrial  oils from
     manufacturing plants.   Four rerefiners, in industrial
     areas, handle relatively substantial quantities
     (30% or more) of the industrial oils and produce
     cutting and hydraulic  oils.  Several factors,  such
     as unfavorable governmental action,  waste disposal
     problems, high feed stock  cost, and  marketing problems,
     have caused a continuing decline  of  rerefined oil
     production.

3.2  History of Waste Oil Rerefining
     Recycling of automotive waste  oils has been  practiced
     since 1915.  The subject was addressed by W. H. Herschel
     and A. H. Anderson of  the  National Bureau of Standards
            12
     in 1922.   Production  of rerefined oils increased
     steadily until I960 when the industry produced an
     estimated 300 million  gallons. Use  of rerefined oils
     by aircraft industry was a positive  factor in aiding
     the growth of the industry. Military aircraft used
     substantial quantities of  rerefined  oils before,
     during, and after World War II with a peak usage of
     1,147,810 gallons in 1949.     Increasing use of jet
     engine aircraft using synthetic lubricants virtually

-------
                               TABLE 1


                   WASTE OIL GENERATION-l975, 1971

                            (gallons 10 )
                                                          24



Sales
AutoFsotive Lube Oils
Service Stations
Garages, Auto Supply
Stores
New car dealers
Retail sales for
commercial engines
Auto fleet & other lube
oil uses
Factory fills (auto &
farm equipment)
Discount stores
Commercial engine fleets
Total
Industrial & Aviation Lube
Hydraulic & circulating •
system oils
Metal working oils
Railroad engine oils
Gas engine oils
Aviation & other
Total
Other Industrial Oils
Process Oils
Electrical Oils
Refrigeration Oils
Total
Lube Oils Purchased by U.S
GRAND TOTALS
1975
239

90
103

95

151

54
250
225
1,207
Oils

314
145
58
60
147
724

340
62
11
413
. 32
2,376
1971
270

60
102

90

136

60
168
200
1,086


325
150
60
62
137
734

310
57
10
377
37
2,234
Waste *
Oil
Factor
.63

.63
.90

.63

.50

.90
.22
.50



.42
.70
.53
.90
.50


.10
.90
.50

.50



Oil
1975
150

57
93

60

75

49
55
112
651


132
101
31
54
73
391

34
56
6
96
16
1,154
1971
170

38
92

57

68

54
37
100
616


137
105
32
56
64
394

31
51
5
87
18
1,115
*  Waste oil factor indicates the percentage of oil available
   for recycling as opposed to that lost in use or discarded to
   the environment.

** National estimates by the American Petroleum Institute and
   other petrolevia industry sources range from 400 to 730 for
   1971.  No estimates from such sources are available for 1975


Source:  See Appendix

-------
                                                     25
eliminated this market.   Military oil specifications
since 1964 have banned the use of rerefined oils in
government owned and operated vehicles.

The decline of the industry is the result of the
following factors:
     1.  Reduced yield and higher operating costs
         due to increased additive content.
     2.  Aggressive and negative marketing activity
         and governmental lobbying by virgin oil
         producers.
     3.  Governmental action in removing excise taxes
         from virgin oils in the Excise  Tax Reduction
         Bill of 1965, which eliminated  the compet-
         itive price advantage of non-taxed rerefined
         oil.
     4.  The Federal Trade Commission (FTC)  labelling
         requirement.  (Trade Regulation Rule relating
         to Deceptive Advertising and Labelling of
         Previously Used Lubricating Oil;  effective
         September 1, 1965) .- requiring  the legend
         "Made from Previously Used Oil" on the con-
         tainer.
     5.  Problems in disposal of wastes, such as State,
         municipal and commercial landfill operators'
         refusal to accept rerefining wastes or sharply
         increased charges for those that are accepted.
         In several cases, rerefiners have been forced

-------
                                                          26
              to use landfills as far distant  as 450 miles
              with subsequent increased transportation
              charges.
          6.   An increase in waste oil feed stock prices
              by 400-600 percent from 1974.   It is esti-
              mated that over 90% of the recoverable waste
              oil is being used as fuel with little or no
              processing to remove sulfur,  metals, and
              o ther c ont aminant s.
          7.   Current reduced prices on virgin lubricating
              oils;  i.e., from approximately  $0.50/galIon
              to as low as $0.34/gallon.

     At this  time there are twenty-seven rerefiners
     operating with an annual production of approximately
     50.8 million gallons vs. 150 rerefiners with an
     annual production of 300 million gallons  in 1960.

3.3  Overview of Reclaiming,  Reprocessing,  and Rerefining
     Industries

     Waste automotive oils contain water,  solids, and
     additives, such as detergents,  blended with the
     original oil;  compounds, such as petroleum oxidates
     and resins, formed during use;   and metals, such as
     lead, iron, and copper from gasoline and  engine parts
     wear.  It is necessary to remove all of these materials
     to produce a high quality lubricating oil base stock.

     Waste industrial oils also contain extraneous materials,

-------
                                                     27
although they differ.   Fatty oils,  sulfur and
chlorine compounds,  rust and oxidation inhibitors,
and soaps and emulsifiers,  as well  as metals, are
                               14
found in industrial  waste oils.

3.3.1  Used Oil Recycling Processes
       Three processes of oil recycling can be
       defined;  1)  reclaiming,   2) reprocessing,
       and 3) rerefining.  (See Table 2)

       Reclaiming removes water,  solids, and a degree
       of polar and  other compounds.   Heat (100 -150 F),
       gravity, or centrifugal separation, screening,
       coarse filtration, and possible use of demulsi-
       fiers are employed.   This simple process pro-
       duces cleaner oils primarily for fuel use.
       Some of the oil is used as a parting agent on
       concrete forms.

       Reprocessing  uses higher temperatures (150°-210°F)
       with chemicals such as sodium hydroxide (caustic
       soda), sodium silicate, and, possibly,^special
       surfactants to assist in demulsification and
       solids settling.  The higher temperature also
       removes gasoline and other low boiling hydro-
       carbons.  This process removes the solids, water,
       a large percentage of original additives, and
       compounds formed or introduced during use.
       Products are clean fuels, parting agents, and

-------
RECLAIMING

  Removes

  Process
  Products
                       TABLE 2

           WASTE LUBE OIL RECYCLING METHODS



          Water, solids
          Heat   100°-180°F.
          Separatory screening
          Demulsification
          Gravity settling or centrifugation
          Fuel
          Parting agents, e.g.
                                                            28
                                  concrete forms
REPROCESSING
  Removes   Water, solids
            Additives blended with original oil
            Compounds formed during use
Process   Heat
                   150°-200°F.
  Products
REREFINING

  Removes
          Chemical treatment,  acid,  caustic,  sodium silicate
          Surfactants (demulsification,  solids settling)
          Gravity settling or  centrifugation
          Separatory screening
          Filtration
          Fuel
          Non-critical lubricants
          Parting agents
          Water,  solids
          Original additives
          Compounds formed during use
          Light ends (low boiling fractions)
          Color bodies and soluble high boiling compounds

Process   Chemical pretreatment (similar to reprocessing)
          Distillation   550°-650°F.
  Products
          Clay contact
          Filtration
          Distillate fuel
          Lubricating oils
          Motor oils
          Hydraulic oils
          Machining oils
          Process oils

-------
                                                           29
            certain non-critical  lubricants.   There is
            little quality control  practiced  in reprocessing
            operations.

            Rerefining usually consists  of a  pretreatment
            similar to,  but more  intensive than that used
            in reprocessing;  higher temperatures  (550  -650  F)
            is required  for distillation and  clay  contact
            followed by  filtration  (post treatment). The
            process produces lubricating oil  base  stocks
            and a distillate fuel fraction.

            There is little information  available  on
            reclaiming and reprocessing  activities and
            volume.  In  general,  these are small operations
            employing simple technology  with  somewhat less
            than impressive equipment.  A very inexact
            estimate supposes 70  reprocessors in the U.S.
            with an annual production of 100  to 200 million
            gallons.  It is reasonable to assume a 10%
            sludge and tank bottoms generation or  40,000
            to 80,000 metric tons (dry weight).

3.4  Sources and Quantities of Waste Oils
     Waste oils used by  rerefiners, and  most  of that handled
     by reprocessors, are generated by lubricating oil  users.
     These are reported  by the U.S. Bureau of Census as
     automotive, aviation, industrial lubricating, and
     industrial oils. Table 3 shows a total  increase in
     sales of lubricating and industrial oils and  greases

-------
                                                          30
                          TABLE 3


    SALES OF LUBRICATING AND INDUSTRIAL OILS AND GREASES1
              1967, 1969, 1971, 1973 and 1975



                                    YEAR

Product           1975     1973     1971     1969     1967
                                      gal.)
 lubricating &
 industrial:
 (gal. 10b)

 Automotive 	 1,250.7  1,272.5  1,126.6  1,147.3  1,132.6
 Aviation	    20.8     21.9     22.0     28.5     37.4
         Total   1,271.5  Ir294.4  1,148.6  1,175.8  1,170.0
Industrial:

 Lubricating -—  996.3  1,184.2  1,027.0  1,087.5    985.6
 Other 	590.3    699.7    538.4    533.1    464.7
         Total   1,586.6  1,883.9  1,585.4  1,620.6  1,450.3

-------
                                                      31
of 283.5 million gallons between 1965 and 1975.  The
1965 sales was 2,574.6 million compared with 2,858.1
million in 1975.  It is noteworthy that industrial
oil sales rose at a greater rate than automotive
oils, i.e., 191.4 million gallons vs. 92.1 million
gallons.  This indicates longer oil change periods
which, in turn, has decreased the yields and increased
processing problems of rerefiners.  The Waste Oil
Study, Report to Congress, April 1974, estimates
generation of 1.1 billion gallons per year of re-
coverable waste oils.  The 1975 generation of waste
oil has been estimated using the same waste oil factors.
Table 1 shows sources and quantities of waste oil
generated in 1972 and 1975.

It is estimated that recoverable waste automotive
lube oils totaled 616 million gallons in 1972.
Industrial and aviation oils, other industrial oils,
and U.S. lube oil purchases account for 394 million,
87 million, and 18 million gallons per year respectively.
The 1975 generation of recoverable waste oil is esti-
mated at 1,260 million gallons.  Automotive lube oils
accounted for 673'million gallons while industrial
oils, aviation oils, and other industrial oils generated
571 million gallons.  U.S. Government agencies con-
                                        4
tributed 16 million gallons of used oil.

-------
                                                           32
3.5  Rerefincd Oil Products
     Products in the automotive market include motor oils,
     transmission fluids,  and railroad car journal oils.
     The major industrial  oils are hydraulic  oils, machine
     oils,  and metal cutting oils.  The latter usually do
     not require the degree of intensive pretreatment and
     high temperature clay in-situ distillation necessary
     for hydraulic and motor oils.  Only four rerefiners
     process comparatively high percentages of industrial
     oils.   They are located in the industrial areas of
     the midwest.

     All products, unless  sold as blending stock oils to
     others, contain additives such as detergents and
     dispersants, oxidation inhibitors,  and pour point
     depressants.  Industrial oils contain such additives
     as fatty oils, sulfur and chlorine compounds, and
     rust and oxidation inhibitors to meet specifications
     and operating requirements (Refer to Appendix C).

3.6  Industry Characterization
     The twenty-seven active rerefiners are located in
     nine of the ten EPA Regions.  There is no rerefiner
     in Region I (New England).  Sixteen are  found in
     Regions IV, V and VI, with four in Region EC, two
     each in Regions II and III,  and one each in Regions  VII,
     VIII and X.  Only nineteen of the states have one or
     more rerefiners located within their boundaries.
     California has four;   Texas has three;  Minnesota

-------
                                                      33
and Wisconsin each have two.  The remaining sixteen
rerefiners are located in sixteen states.  Table 4
shows the geographical distribution by EPA Regions
as well as the range of the number of employees and
the age range of the plants.

Appendix A lists the twenty-seven active rerefiners
as well as six inactive rerefiners (those who dis-
continued rerefining, but use their plants for
production of fuels and some industrial oils).  The
rerefining capacity is therefore, inactive and not
fully utilized and, if conditions warranted, could be
reactivated for lube oil rerefining.

The number of rerefinery employees range from four
to twenty-five with two plants having five or fewer
employees.  The other twenty-five rerefiners employ
from six to twenty-five employees.

Every attempt was made to show only employees directly
involved in the refining operation to give a more
comparative picture.  Thus, employees involved in
packaging, i.e., filling of one quart to five gallon
containers, were not included since many rerefiners
do not package their own products.  In most cases,
those who do operate packaging equipment also do
custom work for other firms.  Several rerefiners also
distribute virgin oil products.

Several rerefiners preferred to report lower ages than

-------
                                         34


























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-------
                                                      35
that which would be shown if the inception date
were shown.  The rationale for this is that improve-
ments or updated replacements and capacity increases
have, in effect, established newer plants.  The data
reflect this preference,  but it should be noted that
several of the rerefiners commenced operations at
much earlier dates than those shown.  Plant age,  as
reported, varies from three years to forty-six years.

Table 5 shows the industry capacity, processes used,
and product distribution by EPA Regions.   The 1975
production was 46% of reported capacity.   Some plants
operate on a seven-day/twenty-four hour basis while
others vary from five days/one shift per day to
five days/three shifts per day.

Two factors account for the current lower than
capacity operations of the rerefining industry.
First, inadequate and high priced waste oil feed
stock, and second, a softening market with subsequent
reduction in prices for virgin oils.  A great percent-
age, possibly as high as 60% in 1975, of the estimated
recoverable waste oil is being used as fuel with
collectors, reclaimers, and reprocessors receiving
from $0.15/gallons for unprocessed waste oil to $0.28
for reprocessed oil.  In late 1973 rerefiners were
paying $0.03 to $0.05 per gallon for waste oil delivered
to their plants.  During the oil shortage period of
1974 prices on virgin oils more than doubled, allowing

-------
36


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                                                      37
the rerefiners to raise their prices on base rerefined
oils (oils less additives) from an average of
$0.22/gallon to $0.50/gallon, and, in some cases
higher for bulk loads.  However,  prices for similar
virgin oils dropped to around $0.42/gallon and in
August 1976 were reported to be as low as $0.34/gallon.
The result is that the rerefiners are caught in a
financial squeeze which has drastically reduced, if
not eliminated, profits.

Twenty rerefiners (74%) use the acid pretreatment
process, two (7.4%) use caustic (sodium hydroxide)
and five use clay-only or other processes.  One of
the latter uses an undisclosed proprietary process
and is categorized in the "other" process type.

All twenty-seven of the rerefiners produce automotive
oils;  twenty-five* in seven EPA Regions, produce
some quantity of industrial oils, although only four
(15%) process substantial quantities (more than 30%
of the production).  All rerefiners report sales of
fuels, usually the excess of plant requirements. Most
of the fuel sold is that produced by the distillation
process* but an unknown amount may be sales of either
raw waste oil or that which results from reprocessing.

The industry can be characterized as one with small
operations as measured by the number of employees,
the volume of production, and the sales volume.  The
largest has a total number of employees of twenty-five
(no packaging facilities and only two waste oil collection

-------
                                                       38
trucks) and, with 10 million gallons/year production,
accounts for nearly 20% of the total industry production.
Two other rerefiners produce 20% of the total.  Five re-
refiners account for over 27% of the total industry pro-
duction;  thus, eight, or 30% of the rerefiners, account
for over 66% of the total annual U.S. production.  Ten
rerefiners (37%) produce less than 10% of total annual
production.  The rerefineries, with few exceptions, are
owner operated facilities.  The industry has attracted
few younger and technically qualified persons.

Profits have traditionally been marginal since prices
are keyed to those charged for virgin oils.  The exper-
ience of 1975 is typical in that virgin oil prices are
being reduced due to oversupply.  What is not typical  is
the competition for, and increased prices of, the raw
waste oil diverted to fuels.  The costs of environmental
controls and waste disposal are adding significantly
to the operating costs.

The annual production per employee ratio reflects pro-
duction volume and, usually, reflects full scale operation
(seven twenty-four hour days per week) vs. five days per
week operation.  The ratio ranges from 28,000 gallons
per year to 500,000 gallons per year.

Table 6 lists active rerefiners in order of production
volume and the percentage of total industry production.
The capacity and percentage of industry capacity is also
shown for each rerefiner.

The rerefineries, with few exceptions, have been

-------
                                                       39
                         TABLE 6
                          (1975)
              PETROLEUM REREFINERS PRODUCTION
              AND CAPACITY VS INDUSTRY TOTALS
                        3
                     (10  gallons/yr)
Rere finer
1
2
3
4
5
6
7
8
9
LO
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
Production
10,000
5,500
4,200
3,500
3,500
2,500
2,400
2,100
1,800
1,800
1,600
1,500
1,200
1,200
1,150
1,000
1,000
850
800
700
650
425
420
360
285
225
200
% of Total
Industry
Production
19.6
10.8
8.2
6.9
6.9
4.9
4.7
4.1
3.5
3.5
3.1
2.9
2.3
2.3
2.2
1.9
1.9
1.6
1.6
1.4
1.9
0.8
0.8
0.7
0.6
0.5
0.4
Capacity
12,000
7,500
6,000
10,000
4,000
5,000
3,600
7,200
2,000
3,600
2,500
4,800
3,000
2,500
1,500
2,000
3,800
2,000
3,000
2,800
1,500
600
2,500
1,800
1,000
750
250
% of Total
Industry
Capacity
12.3
8.0
6.2
10.3
4.1
5.1
3.7
7.4
2.0
3.7
2.6
4.9
3.1
2.6
1.5
2.0
3.9
2.0
3.1
2.9
1.5
0.6
2.6
1.8
1.0
0.8
0.3
Total
50,865
100.0
97,200
100.0

-------
                                                                40
          owner-built  in an incremental  fashion,  often with
          second-hand  equipment  installed and modified by
          rerefinery employees.   While much  ingenuity  and,
          often,  innovative methods  have been employed,  the
          typical rerefinery does not have the  efficiency factor
          common  to the chemical or  petroleum process  industries.
4.0  Waste Characterization
     4.1  Introduction
          Rerefining generates  three waste  streams  -  sludge,
          spent clay,  and process water.

          Wastes from rerefining are similar to  those produced
          by virgin oil  acid/clay refining.   However,  the  acid
          sludge from virgin oil refining did not contain  the
          metals,  particularly  lead, found  in rerefining sludge.
          This prevents  rerefiners  from using a  high  tempera-
          ture acid recovery system x\rith subsequent use of the
          acidless low-metal content sludge  as fuel.

          Spent clay,  currently used in oil  refining,  is reclaimed
          by burning the petroleum  constituents  adsorbed by the
          clay.

          No economically or technically feasible method has
          been discovered for reclaiming the acid sludge pro-
          duced by 74% of the rerefining industry.  The use of
          caustic  pretreatment  sludge  as an  asphalt extender/
          plasticizer and the absence  of acid and other more
          desirable characteristics point toward reclamation

-------
                                                           41
     possibilities for this  sludge.   The volume  of spent
     clay produced by a rerefiner is  currently too small
     to permit economical  reclamation and  reuse  of the
     spent clay,  although  those  using a clay-only  process
     could achieve quantities  sufficient to  amortize  the
     capital investment.

4.2  Rerefining Process Description
     Figure 1 shows a petroleum  rerefining general flow
     diagram and average mass  balance.  The  three  major
     process areas are shown:  pretreatment,  distillation,
     and post-treatment.   The  figure  is applicable to any
     rerefining process.

     4.2.1  Pretreatment
            Pretreatment currently practiced includes mixing
            of waste oil with  sulfuric acid  or sodium
            hydroxide.  The  latter process may also include
            use of sodium  silicate and/or  surfactants.
            Patents have been  issued  for processes which
            extract the sludge constituents  with solvents.
            It is understood that other proprietary methods
            using neither  acid,  caustic, nor solvent  are in
            the developmental  stage.   None of these processes
            are being used commercially at this  time.

            Acid pretreatment  has three steps;   dehydration
            of the waste oil;  mixing of acid and  oil at
            90°F to 110°F;  and  settling and removal  of
            sludge.  Caustic pretreatment, practiced  by two
            rerefiners varies  somewhat in  details  but basically^

-------
                                   FIGURE 1

             FLOW DIAGRAM - CURRENT WASTE OIL REREFINING PRACTICE
                                     42
Waste Stream
 Sludge.     -^	
 (200 gallons)

 Constituents
   Water
   Solids - carbon, metals,
            silica
   Resins, tars
   Additives
   Sulfuric acid
   Caustic soda, sodium
            silicate
'process
Flow

Waste Oil
1,000 gallons
                                                        Process
Pretreatment
        1)  Dehydration
            350-550 F
        2)  Contact with acid
        3)  Contact with:
            Caustic soda,
            Sodium silicate,
            Surfactants

         Temperatures
          100-180  F
                                 1'retreated Oil
                                   (800 gal.)
                                 Clay (320 Ibs)
 Process Water
   Distillate
   Mercaptans
   Phenols
   Organic acids
   Metal compounds
   (600-1,000 gallong)
 Spent Clay
 Oil
 Polar Compounds
   e.g. Additives, Oxidates
 Metals
 Clay (450 Ibs)
Distillation
 Partial I/clay
 550-650°F
-^Distillate
    (fuel)
   (140 gal)


  _ Steam
                                  Oil/Clay
                                  (660 gal)

                                   	I
Post Treat
                                 Lube Oil (650 gal)
Heat   _
550-650°F
               Filtration of
                Spent Clay

               Secondary Steam
                Strip
               Neutralization

-------
                                                      43
       consists of mixing, raw (not  completely dehydrated)
       waste oil and sodium hydroxide,  or a mixture of
       sodium hydroxide (caustic  soda)  and sodium
       silicate.  Surfactants to  improve settling rate
       and quality may be used.   The sludges from each
       process contain mcst of the  same undesirable
       constituents of the waste  oil but are quite
       different in physical characteristics.  The
       caustic sludge, of course, does  not contain acid.
4.2.2  Distillation
       Today's commercial rerefiners use a partial
       distillation of the pretreated oil with clay
       in-situ (0.3 to 0.5 Ibs/gal).  The oil  is  heated
       to 550°F to 650°F.  Distillate,  or light ends
       (low boiling fractions),  are removed as a
       vapor and condensed.  The distillate is similar
       to kerosene and contains  some undesirable
       constituents which were not removed by  pretreat-
       ment.    Live steam is introduced to the oil/clay
       mixture to produce better clay contact  and to
       assist in removing light  ends and constituents,
       such as mercaptans, which have an affinity for
       water.  The distil Late/steam vapor is condensed
       and the resulting mixture separates readily
       yielding distillate and steam stripping process
       water.  Ammonia, sodium hydroxide, sodium carbonate,
       and/or organic amine compc-jnds are added to the
       vapor stream prior to condensation to reduce

-------
                                                      44
       equipment corrosion,  improve odor,  and produce
       a better distillate.

       The clay-only process eliminates the pretreatment
       step.   The raw waste  oil with approximately
       1.5 Ibs/gallon of clay is distilled directly
       at the usual 550°;? to 650°F temperatures.   All
       of the undesirable constituents which usually
       form the sludge ace adsorbed by the clay.

       Total vacuum distillation (to date  only conducted
       in laboratory or pilot plant operations) uses
       temperatures in the 945 F range with high
       vacuum.    This vaporizes the lube  fraction,
       which is the residual of partial distillation,
       and leaves bottoms (sludge) as a residual.

4.2.3  Post Treatment
       Post treatment in current rerefining practice
       consists of removal of spent clay from the
       oil/clay residual after partial distillation.
       Other forms of pout treatment are secondary
       neutralization of the oil and secondary steam
       stripping to improve  the odor and neutralization
       number by removal of  trace acidic compounds.

       Research has been done on hydrotreating of  the
       lube fraction from total vacuum distillation
       with good laboratory results.     Most virgin
       lube oils today a::e contacted  with hydrogen

-------
                                                       45
       (hydrotreating)  to  remove  sulfur, nitrogen,
       and other unwanted  constituents, rather than
       clay contact.  This would  eliminate  the spent
       clay disposal  problem.  However, a much larger
       volume of through-put,  than  any rerefiner  now
       has, would be  necessary to make the  process
       economically viable.

       Hydrotreating  is not now being used  commercially,
       although one company is installing equipment
       for this process method as well as for total
       vacuum distillation.

4.2.4  General Processitg
       Figure 2 is a  three part  flow diagram applicable
       to acid, caustic, or the clay-only process.  The
       pretreatment section shows a heater  utilized to
       raise the temperature of the waste oil to  150 F-
       200 p for caustic pretreatment (dash line) or
       350 F-550 F for  dehydration  prior to acid  pre-
       treatment (solid line). After either caustic
       or acid pretreatment and removal of  the sludge
       the oil in either case is  mixed with clay  and
       moves to a second heater to  raise the oil  temper-
       ature to 550 F-650  F for removal of  light  ends
       by distillation.

       In the clay-only process  (dotted line) waste
       oil bypasses pretreatment, clay  is added  and the
       oil/clay mixture is heated to approximately 650 F,

-------
                                               47
The clay addition step on the flow diagram
for the three processes is substantially the
same and one solid line is shown.

Figure 3 shows a flow diagram of a caustic/
solvent/ciay proces:..  The solvent is plant
produced distillate and acts primarily as a
viscosity reducer rather than an extractant.  In
other respects the process is similar to that
used by other reref:'.ners.

Since waste motor oils contain from 3% to 18%
bottoms, sediment, ,ind water (BS&W) and have an
original oil additive content of 8% to 15%, the
average sludge loss is approximately 20%.  Yield
of lube oil is between 55% and 65% of the un-
treated waste oil.  The distillate, or light ends,
yield is approximataly 15%-25%.  Appendix C
shows the compos iti3n and function of some
lubricating oil additives which, with compounds
formed during use aid metals from engine wear,
become the rerefiniig sludge.

Some rerefiners, using acid pretreatment, dehydrate
the oil at temperatures in the 500°F-550°F range.
This, not only removes the water in the raw waste
oili but, also, removes most of the light ends
(distillate).  This reduces the amount of acid
required for pretreatment but does not appreciably
alter the nature of the sludge.

-------
                                                           49
4.3  Criteria for Determination of Potentially Hazardous
     Wastes
     Leaching of potentially hazardous  constituents  of
     rerefining wastes  can contaminate  drinking water
     sources as well as affect  recreational waters.  There-
     fore,  the Interim  Primary  Drinking Water  Standards
     established March  1976 by  the U.S. Environmental
     Protection Agency   have been selected as  a criteria
     for determination  of petroleum rerefining hazardous
     wastes.  The author has also included hexane  solubles
     (oil,  polymers  and polar compounds)  and phenol  standards
     established by  the Water Quality Standards of the State
                1 6
     of Illinois,   since the Federal Standards are not
     specific for these constituents.   Since hazardous
     constituents are contained..in the  raw waste oil the
     adverse effects of contamination of  ground water  must
     also be considered.

     Table  7 lists the  drinking water standards established
     by the U.S. Environmental  Protection Agency and State
     of Illinois.

     The highest concentration  of undesirable  contaminants
     in acid sludge is, of course, the  oil (hexane soluble
     or equivalent)  at  over 57% including polymers,  polar
     compounds, and asphaltenes, as well  as petroleum  oil
     (See Table 8).   Acid content is reported  to range from
     27.0%  to 47.5%.8

     The metals found in acid sludge in the highest  average

-------
                                                          50
                           TABLE 7
             CRITERIA FOR DETERMINING HAZARDOUS
              WASTES FROM PETROLEUM REREFINING
A.  Interim Primary Drinking Water Standards          5
    Maximum Contaminant Levels for Inorganic Chemicals
    Contaminant                             Level  (Mg/L)
    Arsenic   				   0.05
    Barium	   1.0
    Cadmium   		-		   0.010
    Chromium  	   0.05
    Cyanide	   0.2
    Lead      	   0.05
    Mercury   	   0.002
    Nitrate (as N) 			  10.0
    Selenium  	   0.01
    Silver    —		   0.05
            ~'~"J1                                          l""" 1C
B.  Derived from State of Illinois Water Quality Standards
    Constituent                             Level  (Mg/L)
    BOD Si Suspended Solids, general	  30
    Oil (hexane solubles or equivalent 	  15.0
    pH  --	--			  5-10
    Phenols  	   0.3
    Total suspended solids  	  15.0

-------
                                                      51
concentration are lead, 20,000 PPM,  calcium,  1,000 PPM,
zinc, 1,500 PPM, and phosphorus,  1,100 PPM;   materials
such as chromium, arsenic,  cadmium,  and even mercury
have been reported in addition to iron, aluminum,
manganese, nickel, and others.

Caustic sludge does not contain sulfuric acid,  but
does contain the polymers,  polar compounds,  asphaltenes,
and petroleum oil as well as metals  in the same con-
centration range.

In the rerefining process which does not pretreat  the
oil, but uses much larger amounts of activated clay,
the sludge constituents are adsorbed by the clay.

Potentially carcinogenic materials such as polynuclear
aromatics (PNA's) and nitrosamines,  in rerefining
wastes have been given little attention.  Neither  the
Occupational Safety and Health Agency  (OSHA)  nor the
National Institute for Occupational Safety and Health
(NIOSN) have conducted specific investigations of this
area.

However, it is possible to draw certain conclusions
                                      7
from published data.  Irwin and Liroff  discuss and
cite references pertaining to the potential toxicity
and carcinogenicity of improperly disposed used oil.
They state that polycyclical aromatic hydrocarbons are
carcinogenic and that the content of these compounds
are higher in used oil than in virgin oil.

-------
                                                           52
             o
     Putscher  shous  a total  content  of  57.3% of  lube oil
     (naphthenes,  paraffins,  aromatics), polymers, other
     polar compounds,  and asphaltenes, and other  residues
     in acid sludge (See Table  8).  Some of  these are poly-
                                                    l fi
     cyclical aromatics, for  example.  Whisman, et.al   have
     demonstrated that used motor oils contain 12.8% mono-
     aromatics,  3.52% diaromatics,  and 61.57% polyaromatics.
     Irwin and Liroff also mention  that  cadmium found in
     petroleum rerefining slydge is suspected of  having
                          7
     carcinogenic effects.   They also state that carcin-
     ogens found in oil are known to  affect  DNA.   While
     the authors state that the DNA experiments did  not
     consider used oils, data from  other sources  indicate
     the need for further study in  this  area.

     Petroleum rerefining removes and concentrates many of
     the constituents in the  oil which could be considered
     carcinogenic. Therefore,  more detailed study of this
     potential hazard should  be investigated.

4.4  Waste Analysis Data
     Each of the process steps  produces  waste streams.  Pre-
     treatment sludge quantities include tank bottoms which
     contain mainly water and solids.  The water  may contain
     phenols and other water  soluble  or  dispersible  com-
     pounds.  Solids  include  metals such as  lead  and zinc.
     Dehydration,as a pretre&tment  step,produces  a process
     water containing phenols and mercaptans,  among  others,
     particularly when higher temperatures and steam

-------
                                                      53

                         TABLE 8
                 ACID SLUDGE ANALYSIS8
Soluble in Water                      wt.  %
    Ash		   4.2
    Acid (H2S04) 		  27.0
Insoluble in Water
    Ash - —	-	-		   8.4
    Acids	   1.6
    Volatiles (150°C. @ 1 mm Hg) 	   0.8
    Lube Oil (naphthenes, 	  15.5
       paraffins, arcmatics)
    Polymers 	  15.6
    Other Polar Compounds --.	   1.8
    Asphaltenes and Other Residues     24.4
                                       99.3

-------
                                                      54
are used to remove light ends before the major
distillation step.  Unfortunately, there is limited
data available pertaining to this process waste water.

Table 9 shows analytical data on two acid pretreatment
sludges.  One acid sludge analysis is that from
processing of diesel lube oil, the other from oils
used in gasoline engines.  Variances indicate the
differences in additives used in each type of oil and
the use of non-leaded fuel in diesel engines.

Table 10 not only shows the high density (10 Ibs/gal)
of acid sludge but it,s high viscosity.  As a compar-
ison, an SAE 20 motor oil would have a viscosity at
100°F of 250 to 300 contrasted with the sludge
viscosity of 475,000 <| 105°F.  Table 11 shows an
analysis of sludge derived from a caustic/silicate
pretreatment.  The 27,500 parts per million (PPM) of
lead is in a similar range to that found in acid
sludge (20,000 tPM).  Differences in the data can be
explained by differences in sampling, raw waste oil
makeup, and analytical procedures.  The higher silicon
content reflects the use of sodium silicate.  The BTU/lb
value indicates a substantial heat value approximately
equal to distillate fuels used in homes and smaller
commercial boilers.

Little detailed analytical work has been performed on
petroleum rerefining spent clay.  Table 12 shows an
oil content of 19%.  "his is composed of polar materials,

-------
                                                        55

                         TABLE 9
                 ACID SLUDGE ANALYSES
                       COMPOSITE
Weight %

% Acid
Ash Sulfate
Sulfur
4
Diesel
47.5
4.45
14.9
4
Stock
40.8
11.26
14.1
Stock17
NA
NA
NA
Sulfur calculated from
  % acid assuming H0S04    '15.5         13.3        NA
Elemental Analysis,  ppm
Cu
Al
Fe
Si
Pb
Ag
Zn
Ba
Cr
Ca
Na
P
B
Ni
Sn
Mg
Cd
Mo
Mm
As
Be
Co
Sr
V
40
40
500
800
1,000
14
200
400
190
12,600
200
1,000
40
10
35
70
9
18
63
45
0.1
0.8
2.7
18
40
140
1,100
1,400
20,000
0
2,100
1,300
50
6,400
4,000
4,300
50
30
30
1,000
NA
NA
NA
NA
NA
NA
NA
NA
190
560
2,200
NA
10,000
0.8
- 2,100
740
28
NA
NA
1,700
18
8
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA - Not available

-------
                                                    56

                     TABLE 10
                                             4
     PHYSICAL CHARACTERISTICS OF ACID SLUDGE
Physical Characteristics
Density, Ibs/gal.                    10.0
Viscosity, SSU
           75°F.                  4,000,000
          105°F.                    457,000
          125°F.                    150,600
pH                                    0.1

-------
                                                   57


                    TABLE 11


ANALYSIS OF REREFINING CAUSTIC/SILICATE SLUDGE 18
                      1973
Element
Fe
Pb
Cu
Cr
Al
Ni
Ag
Sn
Si
B
Na
P
Zn
Ca
Be
S
PPM
350
27,500
48
18
24
1
1
70
6,250
10
1,000
1,100
1,500
1,000
3,000
0.14%
            BTU/lb        18,333

-------
                                                       58

                         TABLE 12
            ANALYSIS OF PETROLEUM REREFINING

                  SPENT CONTACT CLAYS
Physical
Characteristic          Average            Range


BTU/lb.                  6000            1000 - 9250

Particle size,
  sieve no.               170              30 - 300

Volatile solids,
  wt. %                    14               0 - 55

Ash, wt. %                 53               0-99.8

Oil, wt. %                 19               1 - 45

pH                         5.6            3.5-7.5

Water, wt. %                8 .              0-36

-------
                                                      59
not removed by pretreatment,  as well as lube oil.

Table 13 gives results of more recent work (1975)
sponsored by EPA.    It compares five samples of acid
sludge and one of caustic sludge to an acid sludge
generated by laboratory bench scale acid pretreatment
rerefining of waste oil supplied by the rerefiner
using a caustic pretreatment.  The only metal analyzed
was lead and it is noteworthy that the laboratory acid
pretreatment reduced the lead content of the oil from
0.66% (6600 PPM) to 0.05% (500 PPM).  Table 14,
(derived from the same program) shows lead content
of 5.6% of that found in the original oil (0.66%)
despite losses in analytical procedure.  With the
exception of the small amount of lead found in the
distillate it is most likely that 95% of the lead was
removed by the pretreatraent.

Steam was not used during distillation, which probably
would show a somewhat higher percentage of lead in the
distillate.

It is noteworthy that the Diamond Head waste oil shows
a lead content of 0.66%.  Earlier reports indicated
an average of approximately 1.0% (10,000 FPM) in waste
motor oils (crankcase oil).  The reduction in lead
indicates the increased use of low lead and no lead
gasolines.

Table 15 provides analytical data on spent clay from

-------
                                                            60
                             TABLE 14

          LEAD MATERIAL BALANCE FOR WASTE CRANKCASE OIL

                    ACID/CLAY REREFINING 10
           Raw        Acid                      Rerefined
	Waste Oil  Sludge  Distillate  Clay  Oil	Total


Pb% Total   100.0 *    71.2      0.02     5.63   1.22      77.07

Pb Content
(Ibs) per
100 gal.      5.016     3.57     0.001    0.28   O.OU      3.87
raw waste
oil **
*  Lead content of raw waste oil equals 0.66% (6,600 PPM)
** Raw waste oil averages 7.6 Ibs/gal.


Note:  twenty three (23%) ?b loss due to unremovable resins in
       distillation flask and volutilization during analytical
       ashing.  Best estimate is that greatest loss occurred
       in sludge rather than clay.  Lead in distillate/neutral
       and rerefined oil should be reasonably accurate and
       indicative of commercial practice.

-------
                                                                                          61
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                                                        62





                       TABLE 15







ANALYSIS OF SPENT CLAY FROM CLAY-ONLY REREFINING PROCESS
Physical/Chemical

ADB (Apparent Bui
Benzene Soluble -
Loss on ignition
Loss of ignition
(after benzene
Metals
Aluminum
Barium
Calcium
Chromium
Copper
Iron
Lead
Magnesium
Manganese
Nickel
Silicon
Tin
Zinc
Characteristics



ft*»o°r ...........
850°C
solubles removal} —
%
2.34
0.42
0.40
0.013
0.012
0.85
3.95
1.02
0.012
0.006
15.58
0.001
0.43
Quantity
-„— - 7452
..... *S4 1V»c/ft
..... 32 4f>
--— - 46 8t>
..... 29 Vi>

PPM
23,400
4.200
4,000
1,300
1,200
8,500
39,500
10,200
1,200
60
150,580
10
4,300

-------
                                                           63
     a clay-only process  and verifies  the  contention  that
     the process is effective in  removing  unwanted  con-
     stituents (sludge)  from the  waste oil.  The  benzene
     solubles are additives  that  are compounds  formed during
     use.  The high metals content,  such as  aluminum,  mag-
     nesium,  manganese,  and  silicon, among others,  reflects
     those naturally occurring in the  clay.  The  lead
     content  includes that usually found in  the sludge and
     the clay from processes using pretreatment.

4.5  Waste Stream Data
     Petroleum oil rerefining generates three major waste
     streams:  sludge, spent clay, and process  water,  all
     of which contain hazardous substances.

     Sludge is predominantly composed  of the product  of
     acid or caustic pretreatment.  However, it may contain
     storage tank bottoms, the interface invert emulsion
     found in the condensed  light ends/stripping  steam
     separation, and waste water  treatment sludge.  A major
     portion of the lead found in waste motor oil is  trapped
     in the sludge.  Other metals will be  found in  quantities
     proportionate to their  concentration  in the  raw  waste
     oil.  Based on designation of hazardous substances as
                                                       19
     established by the Environmental  Protection  Agency,
     potentially hazardous levels are  identified  for  the
     following materials which may be  found  in  rerefining
     wastes:

-------
                                                       64
     Sulfuric acid           Lead compounds
     Ammonia                jagrcAjryj^ojapQiiiids-	->
     Arsenic compounds*    C^Naphthene compounds--^
     Cadmium compounds       Phosphorus compounds
     Chromium compounds      Nickel compounds
     Copper compounds        Zinc compounds
     Cresol                  Oils
     Iron compounds
     * Not all arsenic and other listed compounds are
       hazardous, but since we do not know the form of
       arsenic compounds, these and others are listed
       as possibilities for further study.

If acid is not used in pretreatment, sludge (or bottoms),
which must be generated by any rerefining method,
constitutes a hazardous waste based on heavy metals
concentration and presence of aromatic hydrocarbons.

Sludge from sulfuric acid pretreatment is a black tar-
like material.  Its highly viscous nature, plus the
fact that it is not soluble in common or inexpensive
solvents, makes separation of the acid and solids
difficult.  Even when the acid is removed, there appears
to be no economically feasible method of resource
recovery for the material.  The portion remaining after
acid and solvent removal contains approximately one
                                                       g
third each of petroleum oil, polymers, and asphaltenes.
However, another study of rerefining acid sludge
indicates that it cannot be used as an asphalt replacement,
                           20
at least for road building.

Table 16 shows an analysis of ten used lubricating oils.
Variations in lead, for example, are probably explained
by sampling procedure, water and solvent dilution,

-------
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                                                      66
varying ratios of oil from gasoline engines, and
the low lead content used in diesel engines.  These
1975 analyses show the effect of decreased lead
content in low-leaded gasolines.

Caustic pretreatment sludge is a black viscous material
which varies from free flowing to weakly gelatinous
and from neutral to alkaline.  It may contain up to
30% water, most of which settles out, particularly
if a small amount of acid is used to neutralize the
excess sodium hydroxide and break the gel structure.
This sludge is soluble in common solvents including
refinery produced distillates and waste oil itself.
It is also emulsifiable.

These sludges have been grouped under the column
heading, "caustic sludge",  since the solvent used in
the one pretreatment is used for dilution before
centrifuging rather than as an extractive solvent.
The "caustic/silicate" designation is used to differ-
entiate it from the "caustic/solvent" and to account
for a larger .percentage of silicon, which was found
on analysis.  The other metals are found in quantities
similar to those in acid treated sludge.  It should be
noted that differences in various metals between acid
and caustic pretreatment analytical data used in this
report are not particularly significant since sampling
procedures vary, and the makeup of the waste oil varies
to some extent based on area and source, e.g., diesel
engine oil vs. gasoline engine oil.  Diesel engine oil
-------
                                                      67
has very little lead since unleaded fuel  is  used.

Spent clay is a black,  oil-compacted material with
varying percentages of oil.  These variations are  due
more to filtration practice and equipment than to  basic
process methods.  There is very little analytical  data
available for spent clay.   In that used after pretreat-
ment Sahagian reports that 5.6% of the lead  in the
waste oil is found in spent clay.     It is probable
that other metals are present in the same proportion
as found in the raw waste  oil although the reactivity
factors of some metals or  compounds must  be  considered.
                                                4
The oil portion, reported  to be 1-45% of the clay
probably contains a major  portion of polymers and  other
polar compounds not removed at the pretreatment step.
Before storage, the clay contains no water.   However,
the usual storage practice in open containers or in
piles allows for water addition.

The clay-only process,  which uses approximately four
times the amount of clay than that used with pretreated
oil, contains all of the sludge constituents of the
waste oil.  If the waste oil contains 0.66%  lead,  it
would be expected that there is 3.63% lead in the  clay
when used at a dosage of 1.5 pounds per gallon. Analyses
done in 1973 by one rerefiner are shown in Table 15.
There was 3.95% lead shown, which indicates  that the
waste oil had approximately 0.8% lead which  is within
expected limits.  Leaching tests   show the  following
-------
                                                      68
percentage examples of some metals leached from
spent and unused clays based on amounts released:
                    From               From
     Metals         Spent Clay         Fresh Clay
     Iron             1.43   %           1.08   %
     Barium           0.215              0.263
     Calcium         19.0               11.4
     Magnesium       29.7               12.6
     Zinc             0.217              0.025

Analytical data on steam stripping process water is
also limited.  Table 17 lists hexane solubles, total
solids, and metals found in untreated and treated
process water.  The treatment process includes
neutralization and coagulation.  The water treatment
processes a water acceptable for municipal sewage
systems.  However, the lead content (4 PPM) of the
untreated water must be compared with the Federal
Interim Drinking Standards of 0.05 PPM.  Hexane
solubles of 200 P?M" and BOD of 220 on treated water
can be compared with the State of Illinois Water
Quality Standards of 15.0 mg/L (milligrams per liter «
PPM) and 30 mg/L.  This indicates a need for concern
in the case of most rerefiners who do not treat their
water to any great degree.

The second water generated that is of potential hazard
is the run-off containing oil or sludge resulting from
spills or leaks and possible leaching of spent clay in
temporary storage areas.  The oil portion of this water
will, of course, contain the potentially hazardous
constituents found in raw waste oil,  sludge,  and <51ay.
-------
                                                      69
                    TABLE 17
         PROCESS WATER (STEAM STRIPPING)
FROM THE ACID/CLAY OIL REREFINING PROCESS - 1976
22
Constituent
Hexane
Total Solids
BOD
Sodium
Zinc
Copper
Aluminum
Barium
Nickel
Chromium
Calcium
Iron
Silicon
Tin
Lead
Phosphorus
Boron
Magnesium
Vanadium
Molybdenum
Manganese
Cadmium
Titanium
Mercury
Untreated (PPM
200
NA
NA
0
3
0
0
0
0
0
150
13
8
0
4
0
2
37
0
0
0
0
0
NA
Treated (PPM
25
20
220
75
0
0
2
0
0
0
75
1
1
0
0
0
1
23
0
0
0
0
0
0.0002
Spectographis Results
-------
                                                           70
4.6  Waste Quantities  for 1975
     Table 18 shows the total quantity  of acid sludge,
     caustic, other sludge,  and clay  generated by  the
     rerefining industry in  1975,  distributed by EPA Regions.
     Sludges which are reclaimed are  included in the totals
     of waste generated, but subtracted to show the
     quantities that must be disposed of by rerefiners.
     All quantities are shown as dry  weight even though  the
     caustic sludge may contain small amounts of water after
     settling or water removal  on-site  by the rerefiners.
     Neither the acid  sludge nor the  spent clay contain
     water except  the  negligible amount from  rain  or air
     borne moisture during storage in open containers.   Most
     of the water  originally present  in the caustic sludge
     separates by  gravity leaving  only  a negligible amount
     in the sludge. No determination of this quantity has
     been made for this report.

     Table 19 shows total estimated quantities of  metals,
     acid, oil,  polymers,  and polar compounds considered
     to be hazardous substances generated by  the industry
     in 1975.  The largest quantity of  potentially hazardous
     waste is that under "oils", 17,736 metric tons.  This
     material is a mixture of petroleum oils, additives
     originally blended with the oil, and compounds formed
     during use.  The  latter category includes oxidized
                   i                               *
   .  and polymerized petroleum  compounds as well as reaction
     products resulting from gasoline blow-by.  Acid, the
     second highest constituent  at 9,913 metric tons is  the
                                                              s
-------
                    TABLE 18
   ANNUAL GENERATION OF SLUDGE AND SPENT CLAY
FROM  PETROLEUM REREFINING IN 1975 BY EPA REGIONS

         (metric tons/year - dry weight)
                                                        71
SLUDGE SLUDGE
EPA
Regions
I
II
III
IV
V
VI
VII
VIII
IX
X
Total
Total
Sludge
Total
Clay
Total
Waste
Acid
0
2,340
0
5,395
11,713
8,675
720
600
2,692
910
33,045
41,225
15,700
56,925
7, Total Caustic, 7, Total
Sludge Other Sludge
0
5.7 2,880 7.0
5,300 12.8
13.1 0
28.4 0
21.0 0
1.7 0
1.5 0
6.5 0
7.2 0
80.1 8,180 19.8



SPENT CLAY

0
1,368
745
2,976
5,427
3,657
180
600
657
90
15,700



% Total

8.7
4.7
19.0
34.6
23.3
1.1
3.8
4.2
0.6
100.00



-------
                                       TABLE 19
                   TOTAL POTENTIALLY HAZARDOUS SUBSTANCES GENERATED
                     BY U.S. PETROLEUM REREFINING DJDUSTRY-1975
                            (metric tons/year - dry weight)
                                                                          72
EPA
Regions Acid
I
II
III
IV
V
VI
VII
VIII
EC
X
Total

713

1,615
3,509
2,597
218
178
812
267
9,913
0
.7
0
.8
.2
.2
.1
.4
.8
.7
.0
Constituents
Oils*

2,068
1,898
2,537
5,302
3,854
295
336
1,100
345
17,736
0
.3
.0
.2
.1
.4
.1
.0
.4
.0
.5
As
. 0
0.12
0.3.7
0.24
0.53
0.39
0.03
0.03
0.12
0.04
1.87
Ba
0
5.2
5.3
5.4
11.7
8.7
0.7
0.6
2.7
0.9
41.2
Cd
0
0.02
0.06
0.05
0.12
0.08
0.01
0.01
0.03
0.01
0.39
Cr
0
0.26
0.26
0.22
0.46
0.34
0.03
0.03
0.11
0.04
1.38
Cu
0
0.38
1.0
0.65
1.41
1.04
0.09
0.07
0.32
0.11
4.97
Pb
0
112.2
110.2
168.5
278.1
238.5
15.5
15.3
57.2
18.3
1,013.6
Zn
0
4.7
17.2
11.3
24.6
18.2
1.5
1.3
5.6
1.9
86.3
*0ils:  includes polymers, polar compounds, asphalt and petroleum oils,
-------
                                                           73
     unreacted sulfuric  acid used  in pretreatment.  As
     would be expected,  lead at  1,013 metric tons is  the
     metal found in  the  largest  quantity.

     Table 20 shows  a  distribution by EPA Regions of  most
     of the metals,  those  considered hazardous  as well  as
     others not considered hazardous.  Acid, oils, polymers,
     polar compounds,  and  asphalt  found in  acid sludge  are
     also listed.  Table 21  shows  metals and oils found in
     caustic and other sludges.  The caustic sludge,  of
     course, contains  no acid  and  usually has very little
     unreacted sodium  hydroxide  or sodium silicate since
     any excess would  be removed from the sludge with the
     water separated during  storage.  The less  viscous  and
     tarry consistency of  the  caustic sludge, as compared
     with acid sludge, also  permits better  separation of
     petroleum oil.  Therefore,  the caustic sludge contains
     an average of 33  percent  oil  as opposed to 36 percent
     in acid sludge.  These  metals and other substances
     are not distributed by  EPA  Regions since they occur
     only in Region  III.  Table  22 shows lead and oils
     contained in spent  clay.  Data on other metals in  spent
     cj.ay from acid  or caustic pretreated oil are skimpy
     and too uncertain to  extrapolate.  However, it is
     reasonable to assume  that such metals  as copper,
     chromium, and zinc  are  found  in the waste.

4.7  Rationale for Extrapolation of Waste Quantities  for
     1977 and 1983
     The difficulties  in making  projections for the rerefining
-------
                                                                                                                 74
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                                                         75

                          TABLE 21


              QUANTITY DISTRIBUTION OF METALS
     AND OTHER SUBSTANCES IN CAUSTIC AND OTHER SLUDGE *
                            1975
                                    Total U.S. Metric
Constituent              PPM        Tons/yr - dry weight
Arsenic
Barium
Cadmium
Chromium
Copper
Lead
Silver
Zinc
45
1,000
8
18
48
20,000
1
1,500
0.37
8.2
0.06
0.15
0.39
163.60
0.008
12.29
   Aluminum                24              0.196
   Boron                   10              0.08
   Calcium              1,000              8.18
   Iron                   350              2.86
   Nickel                  15              0.127
   Phosphorus           1,100              8.998
   Silicon              1,500             12.27
   Sodium               4,000             32.72
   Tin                     70              0.573

   Oil Polymers,
   Polar Compounds
   & Asphalt             33%              2,699
   Caustic and other sludges generated only in Regions II
   and III.
-------
76

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                                                       77
industry are formidable.   The steady decline of the
industry since I960 (82%) has been discussed in
earlier sections.  The industry,  despite a reduction
of 10% in the number of operating rerefiners in 1975
showed an increase in production  of 4.7% or 9.1
million gallons over the previous year.   This increase
was effected by 44% of the rerefiners while 41% showed
decreased production of 4.8 million gallons.  The 1977
extrapolation is based on an anticipated 30% increase
in 1977 (20.9 million gallons) by the rerefiners
showing 1975 increases.  Some rerefiners who showed
decreased production and those who contemplate
cessation of rerefining are estimated at a reduction
of 2.9 million gallons.  Total net increases projected
are 18 million gallons or 35.4%.   One new rerefiner
anticipates production of 10 million gallons in 1977
and one anticipates an increase of 2 million gallons
increase.  Waste generation in the former case is
difficult to establish, since no  production experience
is available and the form of pretreatment has not been
decided.  It is expected that a lower order of magnitude
of sludge and bottoms will be generated and a 12% sludge
generation has been estimated vs. the average of the
more traditional process methods.  Since the afore-
mentioned plant will hydrotreat instead of using clay
there will be no spent clay generation.   The rerefinery
which anticipates an annual 2 million increase has
reduced sludge generation and, with a new proprietary
method, expects to reduce the percentage of sludge
-------
                                                      78
even more.  Therefore, a 10% factor for estimating
sludge generation has been used in this case.   Clay
generation will increase in the same traditional
proportion of 0.4 pounds per gallon of waste oil
rerefined.  The other existing rerefiners expected to
increase production of oil will generate sludge and
clay at the current rate.

The lead content of petroleum rerefining sludge in
1977 is estimated at 75% of the 1975 level,  reflecting
the increased use of no lead and low lead gasoline.
The estimate for lead content for sludge generated in
1983 is based on a projected reduction of 75% of the
1975 level.  Possible changes of regulations affecting
the lead content of gasoline by governmental agencies
may have an effect on these projections.

Projections for 1983 indicate that only 13 of the
present rerefiners will be in operation, of which 12
will increase production to 150% of the present pro-
duction levels.  One rerefinery plans to increase
production by 100% to 20 million gallons.  Five new
rerefiners will produce a total of 75 million gallons.
Total production is projected at 193 million gallons.

The increase in production is predicated on two
primary considerations:  1) favorable governmental
action in restricting uncontrolled burning of  waste
oil, and  2) shortages of lubricating oil with increased
-------
                                                      79
prices for virgin oils.   Other factors which would
have beneficial effects  are reimposition of the Federal
Excise Tax, which gave the rerefiners a competitive
edge prior to 1965 and deletion of the restriction
against use of rerefined oil in military oil specifi-
cations.  Improved rerefining methods, primarily
elimination of acid pretreatment,  increased utili-
zation of sludge, or bottoms, clay reclamation, or
use of hydrotreating in  larger operations,  will further
the growth of the industry with potential reduction
in hazardous waste disposal problems.  Increased use
of non-leaded gasoline along with  the elimination of
acid use will greatly reduce the environmental impact
of disposal methods currently presented by these
substances.

The projections for sludge and clay generation assume
that the wastes can be utilized as fuel by the new
and larger rerefineries  or converted to useful products.
Putscher shows that over fifty percent of acid sludge
consists of organic substances. This portion is
comprised of approximately thirty  three percent each
of lubricating oil, polymers, and  asphalt.   Large scale
rerefining offers possibilities for processing the
waste for by-product recovery.  Clay regeneration and
reuse has been practiced by virgin oil refiners and,
here again, large scale production would allow economical
reclamation of the spent clay.  However, it has been
shown that wastes are generated at lower levels than
-------
                                                      78
even more.  Therefore, a 10% factor for estimating
sludge generation has been used in this case.  Clay
generation will Increase in the same traditional
proportion of 0.4 pounds per gallon of waste oil
rerefined.  The other existing rerefiners expected to
increase production of oil will generate sludge and
clay at the current rate.

The lead content of petroleum rerefining sludge in
1977 is estimated at 75% of the 1975 level,  reflecting
the increased use of no lead and low lead gasoline.
The estimate for lead content for sludge generated in
1983 is based on a projected reduction of 75% of the
1975 level.  Possible changes of regulations affecting
the lead content of gasoline by governmental agencies
may have an effect on these projections.

Projections for 1983 indicate that only 13 of the
present rerefiners will be in operation, of which 12
will increase production to 150% of the present pro-
duction levels.  One rerefinery plans to increase
production by 100% to 20 million gallons.  Five new
rerefiners will produce a total of 75 million gallons.
Total production is projected at 193 million gallons*

The increase in production is predicated on two
primary considerations:  1) favorable governmental
action in restricting uncontrolled burning of waste
oil, and  2) shortages of lubricating oil with increased
-------
                                                      79
prices for virgin oils.   Other factors which would
have beneficial effects  are reimposition of the Federal
Excise Tax, which gave the rerefiners a competitive
edge prior to 1965 and deletion of the restriction
against use of rerefined oil in military oil specifi-
cations.  Improved rerefining methods, primarily
elimination of acid pretreatment,  increased utili-
zation of sludge, or bottoms, clay reclamation, or
use of hydrotreating in  larger operations,  will further
the growth of the industry with potential reduction
in hazardous waste disposal problems.  Increased use
of non-leaded gasoline along with  the elimination of
acid use will greatly reduce the environmental impact
of disposal methods currently presented by these
substances.

The projections for sludge and clay generation assume
that the wastes can be utilized as fuel by the new
and larger rerefineries  or converted to useful products.
Putscher shox^s that over fifty percent of acid sludge
consists of organic substances. This portion is
comprised of approximately thirty  three percent each
of lubricating oil, polymers, and  asphalt.   Large scale
rerefining offers possibilities for processing the
waste for by-product recovery.  Clay regeneration and
reuse has been practiced by virgin oil refiners and,
here again, large scale  production would allow economical
reclamation of the spent clay.  However, it has been
shown that wastes are generated at lower levels than
-------
                                                           80
     those resulting from current operations based on
     expectations of improved pretreatment  methods.   It
     is assumed that the five new plants will use clay
     in initial operations and switch to hydrotreating
     at levels of 30 million gallons  per year;  therefore,
     eliminating the generation of spent clay by these
     rerefiners.  While this could occur before 1983,
     the 1983 projections do not include this adjustment,
     since it is expected that these  new plants will  begin
     operations using clay and if,  and when,  sufficient
     volumes are achieved(30 million  or  more gallons  per
     year) will switch to hydrotreating.

     For the purposes of this study the  potential effect
     of synthetic lubricants now being test marketed  has
     not been considered.  Widespread use of these could '•'••
     have a dramatic effect on the rerefining industry,
     including new technology for rerefining these fluids.
              •^
4.8  Waste Quantities Projected for 1977 and 1983
     4.8.1  Projections of Petroleum  Rerefining Wastes in 1977
            Table 23 shows projected  total  production and
            generation of oil rerefining wastes for 1977
            by EPA Regions and the national total.  Table 23
            estimates are based on an increase in production
            of rerefined oils by a factor of approximately
            1.35.   However,  acid sludge  increases by  a
            factor of 1.17.   These projections reflect the
            greater use of non-acid pretreatments.  The  oils,
-------
                                   TABLE 23
                     ESTIMATED 1977 PRODUCTION OF PRODUCT
                       AND GENERATION OF WASTES BY THE
                        PETROLEUM REREFINING INDUSTRY

                        (metric tons/year - dry weight)
                                                                        81
EPA Oil Product!
Regions (103 gal/yr)
I
II
III
IV
V
VI
VII
VIII
IX
X
0
15,200
3,300
8,115
24,535
10,400
2,350
1,150
3,270
575
on
Acid
0
2,995
0
7,483
14,568
8,104
1,130
600
2,622
1,228
SLUDGE
Caustic, others
0
10,870
4,557
0
0
0
0
0
0
0
Clay
0
1,697
466
3,464
6,694
5,477
850
600
820
121
Total Waste
0
15,562
5,023
10,947
21,262
13,581
1,980
1,200
3,442
1,349
Total
68,895
38,730
15,427
20,189
74,346
-------
                                                82
polymers, polar compounds and asphalt volume
remain substantially the same in 1977 as in
1975 reflecting potential improvement in
process methods with decreased losses of
petroleum oil contained in sludge and clay.

Table 24 shows total hazardous__constituent:s_of
all rerefining wastes, but reflects oils and
lead only for spent clay since no complete
analytical data is available.  The largest
quantities of acids and other potentially
hazardous wastes occur in Region V, in which
the larger rerefineries operate, which accounted
for 35% of rerefined oil produced.  In the U.S.
in 1977, it is projected that expansion of
existing rerefineries will occur in EPA Regions
showing the current higher production volumes.

No acid sludge is generated in Region III since
the two rerefiners use caustic pretreatment
processes.  Most of the planned increased
production in this Region is expected to use a
non-acid pretreatment and use of hydrotreating
in place of clay treatment.

Tables 25, 26, 27 show projected 1977 quantities
of metals, oil, polar compounds, and acid found
in sludges and spent clay.  Data for such con-
stituents in spent clay are unavailable except
for lead and oil (including polymers, etc.).
-------
                                     TABLE 24
                TOTAL POTENTIALLY HAZARDOUS CONSTITUENTS IN WASTES
              GENERATED BY THE PETROLEUM REREFINING INDUSTRY IN 1977
                          (metric tons/year - dry weight)
                                                                          83
EPA
Regions Acid
I
II
III
IV
V
VI
VII
VIII
IX
X
Total
-
895

2,244
4,370
2,431
339
180
786
368
11,615

.0
0
.9
.4
.2
.0
.0
.6
.4
.5
Oils
-
5,390.
1,733.
2,314.
6,574.
3,896.
463.
336.
1,088.
466.
22,264.


8
7
7
3
6
4
0
7
3
5
As
-
0.65
0.2
0.34
0.65
0.36
0.51
0.27
0.12
0.05
3.1
Constituents
Ba Cd
-
13.0
4.6
7.48
14.57
8.10
1.13
0.6
2.62
1.23
53.3
-
0.10
0.3
0.06
0.11
0.05
0.01
0.005
0.02
0.01
0.68
Cr
-
0.55
0.18
0.3
0.6
0.32
0.05
0.02
0.10
0.05
2.2
Cu
-
1.66
0.55
0.9
1.75
0.16
0.14
0.07
0.31
0.15
5.6
Pb
-
216.4
70.6
126.8
246.4
142.2
18.2
11.5
42.3
18.9
893.3
Zn
-
29.1
9.6
15.7
58.5
17.0
2.4
1.3
5.5
2.6
141.7
Note:  Includes only oils and lead in clay - others not available.
-------
                                   TABLE 25
           TOTAL POTENTIALLY HAZARDOUS CONSTITUENTS IN ACID SLUDGE
           GENERATED BY THE PETROLEUM REREFINING INDUSTRY IN 1977
                       (metric tons/year - dry weight)
                                                                        84
EPA
Regions Acid
I
II
III
IV
V
VI
VII
VIII
IX
X
Totals

898.5

2,244.9
4,370.4
2,431.2
339.0
180.0
786.6
368.4
11,615.0
Oils*

1,078

1,721
5,244
2,917
406
216
943
442
12,970

.2

.9
.5
.4
.8
.0
.9
.1
.8
As

0.13

0.34
0.65
0.36
0.51
0.27
0.12
0.05
2.43
Constituents
Ba Cd
-
2.10
-
7.48
14.7
8.10
1.13
0.6
2.62
1.23
37.83
none
0
none
0
0
0
0
0
0
0
0
-
.02
-
.06
.11
.06
.01
.005
.02
.01
.83
Cr

0.12

0.3
0.58
0.32
0.05
0.02
0.10
0.05
0.40
Cu

0.36

0.9
1.75
0.10
0.14
0.07
0.31
0.15
3.8
Pb

44.9

112.2
218.5
121.6
17.0
9.0
39.3
18.4
580.9
Zn

6.3

15.7
30.6
. 17.0
2.4
1.3
5.5
2.6
81.4
* Oils includes petroleum oils, polymers, polar compounds and asphalt.
-------
                                                                        85
                                    TABLE 26
             LEAD AND OILY CONSTITUENTS IN CAUSTIC AND OTHER SLUDGE
             GENERATED BY THE PETROLEUM REREFINING INDUSTRY IN 1977
                         (metric tons/year - dry weight)
EPA
Regions
II
III
Total
Constituents
Acid Oils As Ba Cd Cr Cu Pb Zn
0 3,913.2 0.5 10.9 0.08 0.43 1.30 163.1 22.8
0 1,640.5 0.2 4.6 0.3 0.18 0.55 68.6 9.6
5,553.7 0.8 15.5 0.38 0.61 1.85 231.7 32.4
Note:  Caustic and other sludge generated only in EPA Regions II and III.
-------
                                                86

                 TABLE 27
LEAD AND OILS IN SPENT CLAY GENERATED BY
THE PETROLEUM REREFINING INDUSTRY IN 1977

     (metric tons/year - dry weight)
EPA
Region
I
II
III
IV
V
VI
VII
VIII
IX
X
Total
Total
Clay
0
1,697
466
3,464
6,994
5,477
850
600
820
121
20,144
Oils
0
339.4
93.2
692.8
1,338.8
1,095.4 '
170.0
120.0
164.0
24.2
4,037.8
Pb
0
7.1
2.0
14.6
28.1
23.0
3.6
2.5
3.4
0.5
84.8
-------
                                                     87
4.8.2  Projection of Petroleum Rerefining Wastes  in  1983
       Table 28 shows projected rerefined oil  pro-
       duction and waste generation  in  EPA Regions
       for 1983.   Five new and larger rerefineries
       plus increased production by  surviving  1975
       rerefineries are expected to  produce  183.5
       million gallons.

       Table 29 lists total potentially hazardous
       constituents in estimates of  wastes generated
       in 1983.  The totals include  only the lead
       and oils in spent clay.  Oils include petroleum
       oils, polymers, polar compounds, and  asphalt.
       Total lead quantities have been  adjusted for
       the increased use of no-lead  and low-lead
       gasolines.  The figures also  reflect  lower
       volume of petroleum oil in the sludge than is
       found currently.  Hydrotreating  may replace
       clay treatment in some cases  and, hence,
       eliminate clay usage.  A factor  of 3.6  was
       utilized to project an increase  in production
       of 132.7 million gallons in 1983 over 1975.
       The generation of acid sludge decreases, however,
       from 33 thousand metric tons  to  31.6  thousand
       metric tons as a result of declining  use of
       acid pretreatment.  Caustic or other  pretreatment
       sludge generation is projected to rise  by  a
       factor of 7.3.  However, total sludge and  clay
       generated shows an increase by a factor of only
-------
                                                           88
                            TABLE 28


               ESTIMATED PRODUCTION OF REREFINED OIL
            AND POTENTIALLY HAZARDOUS WASTES GENERATED
           3Y THE PETROLEUM REREFINING INDUSTRY IN 1983

                (metric  tons/year - dry weight)
EPA
Regions
I
II
III
IV
V
VI
VII
VIII
IX
X
Production
Gal. lOVyr
15,000
33,000
19,000
27,500
49,000
13,000
3,000
2,500
20,500
1,000


Acid
0
3,280
0
7,220
6,940
6,078
2,280
1,900
4,180
760
Waste
Sludge
Caustic, Others
6,840
14,440
9,120
6,840
15,960
0
0
0
6,840
0

Clay

4,500
1,333
6,700
11,550
15,460
5,075
360
1,300
5,300
200
Total


11,340
18,013
15,820
25,610
38,360
11,953
7,640
3,200
16,320
960
Total
183,500    31,638
60,040
52,578   144,256
-------
                                                                           89
                                       TABLE 29
                       TOTAL POTENTIALLY HAZARDOUS CONSTITUENTS
                GENERATED BY THE PETROLEUM REREFINERY INDUSTRY IN  1983
                            (metric tons/year - dry weight)
EPA
Region Acid
I
II
III
IV
V
VI
VII
VIII
LX
X
fotal
0
684
0
217
208
182
684
570
125
228
2,893
Oils*
4
1
6
8
14
3


6

48
,682
,879
,356
,896
,518
,739
893
944
,327
314
,528
As
0.41
0.96
0.55
0.73
1.27
0.27
0.10
0.09
0.60
0.03
5.01
Constituents
Ba Cd Cr
9.1
21.5
12.1
16.3
28.1
6.1
2.3
1.9
13.3
6.8
111.5
0.07
0.16
0.09
0.12
0.21
0.05
0.02
0.01
0.10
0.01
0.84
0.36
0.86
0.48
0.61
1.13
0.24
0.09
0.08
0.52
0.03
4.44
Ca
1
2
1
1
, 3
0
0
0
1
0
13
.09
.58
.46
.96
.38
.75
.27
.23
.59
.09
.4
Pb
45.8
110.0
70.5
117.7
174.2
66.2
11.9
11.3
74.1
4.1
685.0
Zn
19.2
45.1
25.5
34.4
59.3
12.8
4.8
4.0
28.0
1.6
234.7
* Oils:  includes petroleum oil,  polymers,  polar compounds and asphalt.
-------
                                                            90
             2.9 in 1983.   The acid constituent  drops
             from 9,90CT metric_tons_tp_2^90p_ metric..	
             tons.   Lead also  is  projected to  decrease
             from approximately 900 metric tons  in 1975
             to 700 metric tons in 1983.

             Tables 30,  31,  32 show the distribution  of
             potentially hazardous constituents  in acid
             sludge,  caustic and other sludge, and spent
             clay respectively for 1983.

4.9.  Future Process Changes in Rerefining
      Two rerefiners using caustic soda pretreatment  and
      four using the clay-only process, with no  pretreatment,
      are producing rerefined  oils.  Various other chemical
      and solvent extraction pretreatments are noted  in patent
      literature and practiced to some degree in Europe.
      There has been some pilot plant work done  on solvent
      extraction of unwanted constituents from waste  oils.
      Solvent extraction is widely used in virgin oil
      refining.  Laboratory and pilot plant total vacuum
      distillation of waste oil which was not pretreated  is
      also reported.  These processes indicate that acid
      pretreatment is not the  only feasible way  to rerefine
      waste oils.  All of these methods prepare  the waste
      oil for distillation and post treatment by removing
      sludge materials.

      However, these non-acid sludges or  bottoms offer the
-------
                                   TABLE 30
                                                                       91
           TOTAL POTENTIALLY HAZARDOUS CONSTITUENTS IN ACID SLUDGE
           GENERATED BY THE PETROLEUM REREFINING INDUSTRY IN  1983
                        (metric tons/year - dry weight)
EPA
Regions Acid
I
II
III
IV
V
VI
VII
VIII
IX
X
Total

684

216
208
182
684
570
125
278
2,898
0
.0
0
.6
.2
.3
.0
.0
.4
.0
.50
Oils*

820

2,599
2,498
2,188
820
584
1,504
273
11,390

.8

.2
.4
.8
.8
.0
.8
.6
.40
As

0.10

0.32
0.31
0.27
0.10
0.09
0.19
0.03
1.40
Constituents
Ba Cd Cr

2.28

7.22
6.94
6.08
2.28
1.90
4.18
0.76
31.60

0.02

0.05
0.05
0.05
0.02
0.01
0.03
0.01
0,24

0.09

0.29
0.28
0.24
0.09
0.08
0.16
0.03
1.26
Cu

0,27

0.87
0.83
0.73
0.27
0.23
0.5
0.09
3.80
Pb

11.4

36.1
34.7
30.4
11.4
9.5
20.9
3.81
158.2
Zn

4.8

15.2
14.6
12.8
4.8
4.0
8.8
1.6
66.60
* Oils:  includes petroleum oil, polymers, polar compounds and asphalt
-------
                                 TABLE 31
                                                                       92
              TOTAL POTENTIALLY HAZARDOUS CONSTITUENTS IN
                  CAUSTIC & OTHER SLUDGE GENERATED BY
               THE PETROLEUM REREFINING INDUSTRY IN 1983

                      (metric tons/year - dry weight)
EPA
Regions Oils*
I
II
III
IV
V
VI
VII
VIII
IX
X
Total
3,762
7,920
5,016
3,762
8,778
0
0
0
3,762
0
33,000
As
0.41
0.86
0.55
0.41
0.96
0
0
0
0.41
0
3.6
Ba
9.1
19.2
12.1
9.1
21.2
0
0
0
9.1
0
79.8
Constituents
Cd Cr
0.07
0.14
0.09
0.07
0.16
0
0
0
0.07
0
0.6
0.36
0.77
0.48
0.36
0.85
0
0
0
0.36
0
3.2
Cu
1.09
2.31
1.46
1.09
2.55
0
0
0
1.09
0
9.6
Pb
45.8
96.7
61.1
45.8
106.9
0
0
0
45.8
0
402.1
Zn
19.2
40.5
25.5
19.2
44.7
0
0
0
19.2
0
168.1
* Oils:  Includes petroleum oils, polymers, polar compounds and asphalt.
-------
                                               93

                 TABLE 32
  TOTAL POTENTIALLY HAZARDOUS CONSTITUENTS
       IN SPENT CLAY GENERATED BY
THE PETROLEUM REREFINING INDUSTRY IN   1983

       (metric tons/yr - dry weight)
EPA
Regions
I
II
III
IV
V
VI
VII
VIII
IX
X
Oils
900
266
1,340
2,535
3,242
1,550
72
260
1,060
40
Constituents
Pb
6.3
1.9
9.4
35.8
32.6
35.8
0.5
1.8
7.4
0.3
Total             11,265           131.8
-------
                                                           94
     rerefiner more  options  for use of the  sludge as
     fuel,  or for by-product  recovery, than the acid
     sludge.   EPA sponsored  an investigation of lead
     recovery possibility using caustic  sludge as part of
                                              24
     the fuel for a  lead reverberatory furnace.     It was
     concluded that  more appropriate burners and better
     control  could make  this  recovery method viable.
     Canada's Environmental  Protection Service sponsored
     an investigation of the  suitability of waste oil fuel
                                        25
     for cement kilns with good results.    It is reasonable
     to assume that  non-acid sludge with rerefining distil-
     late or  raw waste oil could be used in this manner.

5.0  Waste Treatment and Disposal Technology
                                        *
     5.1  Introduction
          This section discusses the three  levels of
          technology employed by the oil rerefining industry
          in  disposing of 41,225 tons of sludge and 15,700
          tons of spent  clay in 1975.  The  sludge total
          includes very  small and unknown amounts of tank
          bottoms and wastewater treatment  sludge.  Level I
          is  the most prevalent technology; Level  II, the
          best available technology;  and Level III, the
          technology required for adequate  health and
          environmental  protection.

          Petroleum  rerefining  sludge, clay, and untreated
          wastewaters, particularly that produced by steam
          stripping  during  distillation, are considered to
          be  potentially hazardous wastes due  to the acid,
-------
                                                          95
     metals,  and hydrocarbon constituents  contained in
     the wastes.

5.2  Hazardous  Waste Management  Overview
     5.2.1  Sludge and Clay Waste Management
            Twenty two,  or  81%,  of the  rerefineries dispose
            of  both sludge  and spent  clay  in  landfills  or
            on  roads without any form of treatment.  Only
            one rerefiner uses a clay-lined lagoon  for
            disposal of acid sludge.  Four rerefiners,
            14.8% of the industry treat the sludge  or clay
            for landfill disposal. One rerefiner is
            treating both sludge and  clay  for on-site
            disposal with cement dust to neutralize acids
            and to fix metals, phenols, and hydrocarbon
            hazardous wastes.   Another  sends  sludge and
            clay to a commercial operator  who mixes the
            sludge and clay with a mixture of limestone
            dust and other  wastes. The other two rerefiners
            neutralize the  sludge with  lime,  in one case,
            and with the calcium hydroxide by-product of
            acetylene manufacturing in  the other case.
            While the lime  and calcium  hydroxide will
            neutralize acid, there are  no  data on leaching
            of  these.  Tests,  under EPA sponsorship,  are
            being performed by the Army Corps of Engineers
            at  Vicksburg, Mississippi on mixtures of acid
            sludge/cement dust and spent clay/cement dust
            prepared by a nearby rerefiner with recently
-------
                                              96
installed equipment.   Preliminary and incomplete
test results on bench scale mixing showed
2.6 P?M of lead in the leachate from an acid
                           26
sludge/cement dust mixture.    The raw sludge
had approximately 29,000 PPM of lead.   It is
hoped that even more  mixing and possible use of
a secondary fixative  agent will prevent leaching
of more than the 0.05 PPM lead to meet the
EPA Interim Drinking  Water standards.   One
rerefiner ships his sludge to a municipal land-
fill which handles large quantities of fly ash.
This alkaline material neutralizes the sludge
in the ordinary operation of the landfill.

One rerefiner disposes of approximately 50%
of his caustic pretreatment sludge by adding
it to a large quantity of residual fuel.
Burning tests conducted by major oil companies
and tests sponsored by EPA have shown that
waste crankcase oil mixed with virgin fuel in
percentages of 5% does not emit potentially
hazardous quantities  of lead and other particu-
                                                 27
lates beyong the limits of air quality standards.
One major utility concluded that 25% of settled
crankcase oil mixed with residual fuel could
be used in the boilers and meet acceptable air
                    28
pollution standards.     Therefore, sufficient
dilution of this caustic sludge may be acceptable
with adequate emission controls.  Here, as in
any burning of wastes derived from oil rerefining,
the ultimate destination of hazardous substances,
-------
                                              97
such as lead in fly ash, and other residues
of combustion must ultimately be addressed
and the question of dilution as the answer
to pollution.

Two rerefiners, one using a caustic process,
the other a proprietary process (using neither
acid nor caustic) sell their sludge to asphalt
compound manufacturers for use as an extender
and plasticizer.  While no leach tests of
finished asphalt products have been made, it
seems reasonable to assume that the asphalt
fixes such contaminants as lead and, at worst,
allows only negligible amounts of contaminants
to be leached.

All twenty-seven rerefiners dispose of spent
clay in landfills or on roads.  Nineteen
(70.4%) use off-site landfills for untreated
clay.  Ten rerefiners use their own trucks.
The spent clay of the remaining nine is hauled
by contractors.  Only five rerefiners (48.5%)
use municipal landfills.  The spent clay of
three rerefiners and one third of that generated
by a fourth rerefiner is applied to roads.  Four
rerefiners (15%) dispose of spent clay on-site.
One of these mixes the clay with cement dust.
The others have no treatment method.

One rerefiner uses a commercial firm as a disposal
-------
                                              98
method, which uses a lime dust mixture as a
fixative for landfill preparation.   Six
rerefiners use contractors who truck the waste
to landfills.  In three of these cases, 11.1%
of the industry, the ultimate disposal site
for spent clay is unknown to the rerefiner.
The spent clay of two of the remaining three
is handled by a large and reputable firm with
apparent adequate safeguards.  A third tempo-
rarily stores the clay after mixing with waste-
water in an on-site water lagoon.  Periodically
a contractor removes the clay with  a drag line,
spreads it on the lagoon bank and,  after
drying, loads and trucks the clay to a landfill
site.

Eight, or 29.6%, of the rerefiners  haul spent
clay to commercial landfills, while five, or
18.5%, use sites operated by cities or counties.
One of these disposes of approximately equal
amounts of spent clay in a municipal landfill,
on roads, and on-site.  The 625 tons generated
by this rerefiner is listed in this section
under the municipal landfill category, although
the quantities have been distributed in quantity
and cost analysis totals to the road and on-
site sections.

Three other rerefiners dispose of all of the
clay generated for use on roads. They constitute
-------
                                                      99
        11.1% of the industry.   The three  remaining
        rerefiners dispose of spent clay on-site
        without treatment,  although two mix  clay with
        soil on a periodic basis.

        Tables 33 and 34 show quantity distribution
        of wastes by various  disposal/technology
        methods.  Since only  one rerefiner uses a
        lagoon for sludge the total for this operation
        has been included under the column heading,
        "Landfill-on-site,  untreated" in Table 33.
        Tables 35 and 36 show the  quantity of wastes
        disposed by rerefiners in  each EPA Region.

5.2.2   Process Wastewater Management
        Rerefining generates  three wastewater streams•
        raw waste oil tank bottoms,  cooling  water,  and
        steam stripping water.   The first  is negligible
        and often is removed  at the dehydration step
        before pretreatment and becomes part of the
        sludge or is added to the  water recycle and
        disposal system.  The second, which  contains
        no contaminants, is recycled.' The third,
        generated at the distillation step,  is neutralized
        and oil is separated  in all cases.

        The following summary table lists  the disposal
        methods of the excess process waters generated
        by petroleum rerefiners.
-------
                                                                      100
                                  TABLE 33
     QUANTITIES OF WASTE DISPOSED VIA LEVEL I TREATMENT/DISPOSAL TECHNOLOGY
                 IN 1975 BY THE PETROLEUM REREFINING INDUSTRY
Percent of
'Quantity
Waste Metric
Off-Site
Landfill, untreated
Acid Sludge 23,
Caustic Sludge
Spent Clay 11^
Total 35,
Off-Site
Roads, untreated
Acid Sludge
Caustic Sludge 1,
Spent Clay 1^
Total 3,
Off-Site
Fuel, untreated
Acid Sludge
Caustic Sludge 1,
Spent Clay 	
Total 1,
On-Site
Landfill, untreated
Acid Sludge 2,
Caustic Sludge
Spent Clay !_,
Total 3,
(dry wt)
tons/yr

615
0
930
545
910
440
097
447
0
440
	 0
440
670
0
208
878
Each
Waste

95.3
0
76.0
3.0
17.6
7.0

0
17.6
0

8.1
0
7.7

Total
Waste

41.5
0
21.0
62.4
2.0
2.5
2.0
6.1
0
2.5
0
2.5
4.6
0
2.1
6.8
Rerefiners
Number % of Total

13 48.1
0 0
19 70.4
1 3.7
1 (1) 3.7
2 (1) 11.1

0 0
1 3.7
0 0

2 7.4
0 0
4 (1) 14.8

(1)   Two rerefiners dispose of sludge  or clay in more than one category.
-------
                                                                   101
                               TABLE 34
QUA 4TITIES OF WASTE DISPOSED VIA LEVEL II TREATMENT/DISPOSAL^TECHNOLOGY

             IN 1975 BY THE PETROLEUM REREFINING INDUSTRY

Quantity
Waste Metric
Off -Site
Landfill, treated
Acid Sludge 3,
Caustic, other sludge
Spent Clay
Total 4,
On-Site
Landfill, treated
Acid Sludge 2,
Caustic, other sludge
Clay
Total 2,
Waste Converted to Product
(other than fuel)
Acid Sludge
Caustic, other sludge 5,
Clay

(dry wt)
tons/yr


375
0
965
340


475
0
500
975


0
300
0
Total 5,300
Percent of
Each Total
Waste Waste


10.2 5.9

6.1 1.7
7.6


7.5 4.3

3.2 0.8
5.1



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0
9.3

Rerefiners
Number % of Total


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0
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                                                          104
            Petroleum Rerefining Excess  Process Water Disposal

            Disposal              Number  of       Percent  of
            Method               Rerefiners       Rerefiners

            Sanitary  sev/ers          13               48.0
            Drainage  ditches          5               18.5
            Municipal landfills       1               3.7
            Disposal  well             2               7.4
            Contractor               1               3.7
            Incineration              1               3.7
            Zero discharge            4               14.8
                                    27               99.8
            Very few rerefiners  keep  detailed records  of

            wastewater volume.

            Only two rerefiners,  7.4%, utilize  the more

            sophisticated water  treatment methods such as

            coagulation,  air flotation,  and  clarification.

            Gravity separation,  in one form  or  another,
            such as in tanks, pits, or lagoons,  is practiced
            by all rerefiners to remove  oils and solids.

5.3  Alternative Treatment and Disposal  Methods

     5.3.1  Introduction


            The best method of improving the disposal

            technology of rerefining  wastes  is  the employ-

            ment of pretreatment methods other  than  acid

            treatment and post treatment, such  as hydro-

            treating, which would eliminate  the use  of clay.


            Production of high quality rerefined oils
-------
                                              105
requires removal of non-petroleum oil con-
stituents.  These include solids, water
additive compounds, such as detergents and
viscosity index improvers, which are part of
the original oil, compounds formed during
use, such as oxidates and resins, and those
added to the oil, such as tetraethyl lead
from gasoline.

Resource recovery is a feasible goal.  The
operations of two rerefiners demonstrate this
possibility.  The processed sludge is used as
an asphalt product extender and plasticizer.
Other processing, such as solvent dilution
and filtration, could produce metals, such as
lead, and a material with good extreme pressure
lubricating properties for specialty lubricants
from the original additives and compounds
formed during use.  Larger volume could produce
sufficient sludges or bottoms for possible
reclamation and reuse of additives.  Sludge,
treated to remove objectionable materials,
such as lead, could be used as industrial fuel
without excessively expensive air pollution
control equipment, and certainly, an in-plant
fuel which would not require the air pollution
control equipment for an untreated material.
-------
                                                     108
5.3.2  Sludge Burning
       The use of equipment  and methods,  such  as
       incinerators,  reverberatory  furnaces, fluid
       bed furnaces,  pyrolysis  for  burning  used oils,
       and, by extension,  highly diluted  non-acid
       sludge, have been mentioned  in  the liter-
             3 20 24  29
       ature. '  '   '    Preliminary experimentation
       of acid sludge burning by one rerefiner points
       to the possibility  of on-site burning even of
       acid sludge.  The major  problem in burning of
       acid sludge is achieving a homogeneous  mixture
       with a viscosity reducer such as rerefinery
                          30
       produced distillate.     Heater  or  boiler
       materials of construction must  also  be  con-
       sidered because of  the potential corrosion and
       erosion possibilities..

5.3.3  Chemical Fixation
       Chemical fixation is  being used for  oily wastes
       from sources other  than  rerefining.  One of
       these uses soditm silicate with very good
       fixation results.  However,  this method is too
       costly for the petroleum rerefining  acid sludge
       due to the high acid  content.   A method for
       removal of the inorganic acid  (sulfuric acid)
       would allow more efficient and  less  costly
       chemical fixation.
-------
                                                     107
5.3.4  Clay Reclaiming
       Clay presents  a less  difficult  disposal
       problem.   First,  the  hazardous  constituents
       are present  in greatly reduced  quantities.
       Second,  a large part  of the hazardous  con-
       stituents can  be removed by washing with
       solvents  and even a water/detergent mixture.
       A final  burning in a  kiln  to  remove occluded
       materials provides a  reclaimed  and reusable
       material. Reclamation of  spent clay and
       activated carbon is widely practiced in
       petroleum and  chemical processing.

5.3.5  Wastewater Recycle
       Rerefining uses large quantities of water for
       cooling  and  steam stripping.  Cooling  water is
       not contaminated by oils or other contaminants
       and can  be and is recycled.

       Steam stripping water,  after  oil (hexane
       solubles) removal can be treated by well
       established  wastewater treatment methods, such
       as coagulation,  flocculation, air flotation,
       and filtration.   Such water can be reused in
       boilers.   Minimal treatment of  the water from
       steam stripping allows the water to be reused
       for cooling  if not as boiler  feed water.  Two
       rerefiners use adequate wastewater treatment
       methods  and  four have zero discharge.  Therefore,
-------
                                                    108
       it is not  impossible,  difficult or even too
       expensive  to  achieve  zero  discharge with
       complete recycling.   Sludge  and solids from
       adequate water  treatment are of small quantity
       compared with pretreatment sludge and spent
       clay.  Inclusion  in other  wastes would add very
       little to  the total disposal problem.

5.3.6  Large Scale Operations, Alternatives
       It is possible  that larger scale operations
       could use  pyrolysis either on-site or in
                                 20
       municipal  pyrolysis units.   Here, most  of
       the metals would  be trapped  in the char.  The
       gas or liquid hydrocarbon  could be used as
       plant fuel.

       The use of two  rerefiners' non-acid sludge as
       asphalt extender  and  plasticizer suggests
       resource recovery possibilities in several
       product areas.

       Large scale rerefining operations can support
       the capital investment for hydrotreating
       equipment, thus replacing  clay.  Rerefined oils
       from bench and  small  pilot scale hydrotreating
                                                    31
       are reported  to have  excellent specifications.

       Given a favorable and profitable operating
       climate the rerefining industry has the potential
       for a resurgence  and  can  fill an important re-
       source recovery role  with  zero water  discharge.
-------
                                                          109
5.4  Level I,  II,  and III Treatment/Disposal Technologies
     for Hazardous Wastes
     Twenty-one of the twenty-seven  rerefiners use Level I
     technology for disposal  of petroleum rerefining
     wastes.

     Level II  technology is being  practiced by six rere-
     finers.   Four neutralize wastes either on-site or
     use the  services of a contractor while two use land-
     fills considered secure  by the  author.  There is no
     evidence, at  this time,  that  these  rerefiners utilize
     more than the best available  technology and therefore,
     disposal  practices by these rerefiners are placed in
     the Level II  category.

     At this point,  there are no rerefiners using Level III
     technology.   However, if current leach tests of sludge
     mixed with cement dust and clay mixed with the same
     material  prevents leaching of potentially hazardous
     constituents, there may  be an environmentally adequate
     and suitable  disposal method.

     Neutralization of acid sludge removes the possibility
     of the acid waste being  potentially hazardous but
     there is  no evidence that  such  materials as lead
     compounds will not leach and  migrate into the ground
     water.

     Use of cement dust/acid  sludge  and  cement dust/clay
     mixtures  has  been assigned a  Level  II designation.
-------
                                                     110
Tables 37 and 38 describe Levels I,  II,  and III
technology for sludge and spent clay for 1975.   It
is expected that there will be some  improvement in
the industry's disposal technology in 1977 with
increased use of cement dust fixation, or some  other
effective technology'* and greater use of a non-acid
pretreatment process.  The planned use of hydro-
treating by one rerefiner with a projected annual
production of 10 million gallons could eliminate
approximately 3,500 tons of spent clay.

Tables 39 and 40 show projections of treatment/disposal
technologies for 1977.  Here again,  the  projected new
plants, with 75 million gallons production, are ex-
pected to generate sludge in lower proportional
quantity than that generated by current  operations.
Sludge quantities are shown in these tables although
there is a good possibility that the sludge will be
either processed as products or will be  used as plant
fuel.

Full industry compliance with environmental protection
requirements will necessitate Level  III  disposal
technology! such as use of secure landfills or adequate
treatment of the waste to prevent leaching in landfills
including on-site disposal.  The 1983 projections
show the three levels as the same in Tables 41 and 42.
-------


















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6.0  Cost Analysis
     6.1.  Introduction
           Rerefining industry waste disposal costs
           vary widely for substantially the same
           materials.  In general,  the costs reported
           by rerefineries are low  since in-plant waste
           handling or equipment  costs are seldom sep-
           arated in accounting records.  Reported costs
           vary from $3.00 to $31.00 per ton of sludge
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           waste disposal costs are a reflection more of
           transportation costs than of more effective
           environmental disposal technology.  For example,
           the $31.00 per ton co.st  includes a five hundred
           mile round trip, while a $15.00 per ton cost
           to a well-operated and secure landfill includes
           transportation by the  contractor and a 10 mils
           trip to the landfill site.

           Wastewater disposal cost data is inadequate.
           Neutralization of steam  stripping water is part
           of the rerefining operation, as is the first
           gravity separation of distillate oil and water.
           Here again, few, if any, records of quantities
           or costs are available.   The four rerefiners,
           who do not use a sewer or do not utilize a
           stream for disposal for  wastewater disposal
           have excess wastewater quantities of 10,000 to
           520,000/gallons/year.  Costs range from zero to
-------
                                                    118
     $20.48/ton for incineration of this water.

     In those cases where  sludge is processed to
     produce a product,  such as  asphalt  products
     plasticizer and extender, a zero  cost  or even
     negative cost  results.   As  noted  earlier, these
     have been included  in this  study  as disposal
     methods rather than as  by-products.

     The industry disposal cost  variation is  also
     reflected in the add-on cost per  gallon  of
     product.  Sludge disposal contributes  $0.006 to
     $0.027 per gallon.  Clay costs vary from $0.001
     to $0.006 per  gallon.  Total cost per  gallon of
     product ranges from $0.001  to  $0.031 per gallon.

     Thus, disposal coses, as a  part of  product costs,
     vary widely within  the  industry.  Disposal costs
     for this industry also  do not  necessarily follow
     an increasing  cost  progression through the three
     levels of technology, although well managed
     landfills collect higher charges  than  others.

6.2  Techniques and Assumptions  Used
     Table 43 shows total  disposal  costs for  sludge
     and clay and the disposal cost add-on  per gallon
     of product of  rerefined oil by EPA  Regions.
     Weighted averages were  utilized.  For  example,
     in Region II one rerefiner  disposes of caustic
     sludge in fuel and  on roads and this was taken
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                                                    120
     into account in establishing an average cost.
     In other Regions on-site or reported low costs
     were eliminated from the average since it is
     expected that off-site  secure landfills will
     be mandatory for most,  if not all,  rerefineries.

     Table 44 shows extrapolated typical costs for
     Levels I, II,  and III technology.   Levels II
     and II assume fixation  costs for both on-site
     and secure off-site landfill disposal.   It is
     estimated that fixative chemicals double the
     sludge volume for both  acid, caustic,  and other
     sludge.  Clay volume increases by 50%.

6.3  Industry Waste Treatment/Disposal Costs
     The variations in disposal and product  add-on
     costs listed in Table 43 are caused by several
     factors.  Transportation costs in some instances
     are high because of distant landfill locations.
     Commercial and municipal landfill charges range
     from a reported zero to over $13.00 per ton.
     On-site disposal of untreated sludge and clay
     costs are as low as $1.00 per ton.

     The table also shows weighted average disposal
     costs by EPA Regions using composite typical
     rerefineries with on-site and off-site landfill
     disposal.  Off-site higher costs reflect the
     charges by landfill operators as well as trans-
     portation costs.  In many, if not all cases,
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                                               122
the use of approved or secure landfills
requires transportation to areas much more
distant than those municipal and commercial
landfills which have been used by rerefiners.
Many of the municipal and commercial  landfills
are no longer accepting rerefining wastes.
-------
                                                            123


                         REFERENCES
 1)  Sales of Lubricating & Industrial Oils  & Greases
     U.S.  Bureau of Census,  MA-29C (75-1), September 1976.

 2)  Twomey,  D.  W., The Source & Supply of Virgin Lubes
     Proceedings of the International  Conference on Waste
     Oil Recovery & Reuse,  Washington, D.C.,  February 1974.

 3)  Waste Oil Study,  Report to Congress, U.S.  Environmental
     Protection Agency, April 1974,,

 4)  Weinstein,  N.  J., Waste Oil Recycling Si Disposal
     U.S.  Environmental Protection Agency, EPA-670/2-74-052
     August 1974.

 5)  Interim Primary Drinking Water  Standards,  U.S.  Environ-
     mental Protection Agency, Federal Register Volume 40,
     No. 51,  Part II,  March 14, 1975.

 6)  Whisman, M. L., et al,  Waste Oil  Lubricating Research,
     An Investigation  of Several Rerefining  Methods,  Report
     of Investigations 7884, Department of the Interior,
     U.S.  Bureau of Mines,  Bartlesville Energy Research
     Center,  Bartlesville,  Oklahoma  1974.

 7)  Irwin, W. A. and  Liroff, R. A., Used Oil Law in the
     United States  and Europe, U.S.  Environmental Protection
     Agency,  EPA-600/5-74-025, July  1974.

 8)  Putscher, R. E.,  Separation 8: Characteristics of Acid
     Sludge,  Armour Research Foundation, Illinois Institute
     of Technology, ARF 3859-3, April  1962.

 9)  Fine, David and Fan, R. Y., Report to National Science
     Foundation, Washington, D.C., September 16, 1976.

10)  Sahagian, James,  Waste Oil Recovery & Reuse Program  -
     Residue Management, Acid Sludge Study,  GCA Technology
     Division for Maryland Environmental Services, April  1976,
     Unpublished
-------
                                                            124
11)  Private communication,  Fisher,  E.  E.,  Texas American
     Petrochemicals,  Inc.

12)  Herschel,  W. H.  and Anderson, A. H.,   Reclamation of
     Used Petroleum Oils,  National Bureau  of Standards
     Technology,Papers,  Volume 17, No.  223, October 1972.

13)  Waste Oil  Recycling Study, Department  of Defense,
     Defense Supply Agency,  1974.

14)  Swain, J.  W., Jr.,  Reclaiming, Rerefining & Uses of
     Waste Oil, presented  at Annual  Meeting of the American
     Society of Lubricating Engineers,  Chicago, 111.,  May 1973.

15)  Bethea, S. R., et al, To Hydrotreat Waste Lube Oil,
     Hydrocarbon Processing, September  1973.

16)  Illinois Pollution Control Board,  State of Illinois,
     Water Pollution Regulations of  Illinois, March 7, 1972.

17)  Preliminary Waste Oil Study, Report to Congress,  U.S.
     Environmental Protection Agency, April 1973.

18)  Private communication,  Diamond  Head Oil Company,
     Kearny, N.J., January 1974.

19)  Hazardous  Substances, U.S. Environmental Protection
     Agency, Federal Register Vol.  40,  No.  250, Part IV,
     December 30, 1975.

20)  Leonard, R. P.,   Brief Investigations on the Treatment
     & Recovery of Resources from Waste Oil Sludges,
     Calspan Corporation,  VT-3044-M-1,  January 1973.

21)  Whisman, N. L.,  et al,  Waste Lubricating Oil Research:
     Geographical & Seasonal Variations in Used Lubricating
     Oil Base Stock Composition, Part 2, U.S. Energy Research
     & Development Administration,  Bartlesville Energy Research
     Center, BERC/RI-75/11,  December 1975.

22)  Pedall, R. F., Motor Oils Refining Co., Lyons, Illinois,
     Private communication,  April 1976.
-------
                                                            125
23)  Quang, Dang Vu and Andrews, John W.,  Institut du
     Francais Petrole, et al, Experience with the IF?
     Propane Clarification Process in Rerefining Crankcase
     Oils, International Conference on Waste Oil, Recovery
     & Reuse, February 12-14, 1974.

24)  Sallman, C. M. and Wentz, J. W.,  Demonstration of
     Waste Oil Bottoms as Fuel for a Lead Reverberatory
     Furnace, U.S. Environmental Protection Agency, EPA-
     R2-72-074, October 1974.

25)  Skinner, D. J.,  Preliminary Review of Used Lubricating
     Oils in Canada, Canadian Environmental Protection
     Service, Report No. EPS 3-WP-74-4, June 1974.

26)  Mississippi Leach Test, Jackson Oil Co.

27)  Task Force on Utilization of Waste Lubricating Oils,
     American Petroleum Institute, Publication No. 1588,
     October 1975.

28)  Private communication, Seroussi, Frank, Consolidated
     Edison, October 1969.

29)  GCA Corporation, Waste Automotive Lubricating Oil
     Reuse as a Fuel, Environmental Protection Agency,
     EPA-600/5-74-032, September 1974.

30)  Private communication, Warden, A. L.,  Warden Oil Co.,
     Minneapolis, Minnesota, 1975.
-------
                                  APPENDIX A
                           COMMERCIAL REREFINERS  -  1975
                                  126
Active

1.  Alco Refining. Division
    Bonus International
    133 North First West
    Salt Lake City, Utah  84114
    801/543-0450
    J. R. Mastelotto

2.  Arrowhead Oil Refining Company
    3519 Miller Trunk Hwy
    Duluth, Minn.  55811
    218/729-6122
    William Heine-

3.  Bayside Oil Corporation
    977 Branston Road
    San Carlos, Cal.  94070
    415/593-2944
    A. Ray Banks

4.  Berks Associates, Inc.
    Box 617
    Pottstown, Pa.  19464
    215/385-3031
    Lester Schurr

5.  George T. Booth & Son, Inc.
    76 Robinson Street
    North Tonawanda, N.Y.  14120
    George T. Booth

6.  Cooks Oil Company
    P.O. Box 156
    Boyd, Texas  76023
    Joseph Gillespie

7.  Coral Refining Company .
    765 Pawnee Avenue
   . Kansas City, Kansas  66105
    913/281-5454
    Richard O'Blasny

8.  Davis Oil Company
    Box 1303, 1100 Orange Avenue
    Tallahassee, Fla.  32302
    904/576-3116
    George Davis
   9.
  10,
  11,
  12.
  15.
  16.
Dearborn Refining Co.
3901 Wyoming Ave.
Dearborn, Mich.  48120
313/843-1700
C. 0. Horton
Diamond Head Oil Co.
1427 Harrison Tpk
Kearny, N.J.  07032
201/991-5800
R. W. Mahler

Double Eagle Refining Co.
Box 11257
Oklahoma City, Okla.  73111
405/223-0244
Cameron Kerran

Fabian Oil Refining Co.
4200 Alameda Ave.
Oakland, Cal.  94601
415/532-5051
Bryan Fabian
...13.
  14.
Gurley Oil Co.
Box 2326
Memphis, Tenn.
901/527-9940
                       38102
Jackson Oil Co.
Box 5686
Jackson, Miss.  39208
601/939-3131
H. K. Robertson

Leach Oil Co., Inc.
625 East Compton Blvd.
Compton, Cal.  90220
213/323-0226
Roy Leach

Lubricants, Inc.
1910 South 73rd
W. Allis, Wis.  53214
414/691-3500
Richard W. Drexler
-------
-COMMERCIAL RSREFINERS
                                                                                  127-'
 17.   Motor Otis Refining Co.
      7601 West 47th St.
      Lyons,  111.  60534
      312/242-2306

 18.   Nelco Oil Refining Co.
      1211 McKinley Ave.
      National City, Cal.  92050
      714/747-7511
      Roger Humphrey

 19.   NuWay Oil Co.
      7039 N.E. 46th Ave.
      Portland, Ore.  77218
      503/281-9375
      A. L. Geary

 20.   Peak Oil Co.
      Rte 3,  Box 24
      Tampa,  Fla.  33619
      813/621-7505
      John Norris

 21.   Petrocon Corporation
      P.O. Box 547
      Valley  Forge, Pa.  19481
      215/383-5262
      John Cunningham

 22.   Research Oil Refining Co.
      3680 Valley Road
      Cleveland, Ohio  44109
      216/749-2777
      Jac Fallenberg

 23.   S & R Oil Company
      Box 35516
      Houston, Texas  77035
      713/729-8740
     R. A. Swazey

 24.   Seaboard Industries
     Fox 47333
      4810 Peachtree Rd
      Doraville, Ga.  30040
      404/458-2241
      Byron Cohen

 25.  Texas American Oil Co.
      300 Westwall, Suite 1012
     Midland, Texas  79701
      915/683-4811
     E. E. Fisher
26.  Warden Oil Co.
     187 Humboldt Ave. North
     Minneapolis, Minn.  55405
     612/374-1200
     A. L. Warden

27.  Westville Oil & Mfg., Inc.
     Box 587 State Road No. 2
     Westville, Indiana  46391
     219/785-2534
     Andrew Carson

Inactive - Lube Oil Rerefining

 1.  Keenan Oil Co.
     No. 1 Parkway Drive
     Cincinnati, Ohio  45212
     513/631-2900
     S. R. Passell

 2.  C. S. McAuley, Inc.
     P.O. Box 219
     Downey, Cal.  90241
     213/861-2103
     C. S. McAuley

 3.  Midwest Oil Refining Co.
     1900 Walton Road
     St. Louis, Mo.  63114
     314/427-2662
     Glen Gettinger

 4.  Motor Guard Lubricants,  Inc,
     4334 East Washington Blvd.
     Los Angeles, Cal.   90023
     213/268-6877
     Bruce Howe
 5.
 6.
National Oil Recovery Corp.
Box 358
Bayonne, N.J.
201/437-7300
Talley Bros., Inc.
2007 Laura Ave.
Huntington Park, Cal.
A. W. Talley
                            90255
 7.  D. A.  Stuart Oil Co.  Ltd.
    1509 South Senate
    Indianapolis,  Indiana
    317/632-3613
    R. 0.  Kageff
-------
                                                                           128
                                   APPENDIX B
           DATA QUESTIONNAIRE PETROLEUM REREFINING WASTE STUDY
 Company
 Address

 Contact
                             Date
                             Ref.  No.
 A.  Classification
     Collector   	
     Reprocessor 	

     Rereflner
 B.  Products
     Automotive
     Industrial
     Fuels
     Others
     Remarks
Method
Method
(1)
* C.  Waste 611  received
     Crankcase
     Industrial  (2)
     Fuels, Solvents
     Others
                      1st Qtr      2nd Qtr      3rd Qtr    "4th Qtr  "   Total
-------
                                                                               129
D.  Rereflned Lube (3)
    Distillate      	
    Fuels, used     	
    Fuels, sold     	
    Water used
      Is distillate (fuel) treated?     Yes 	       No 	
(1) If acid, is new or recycled acid used?
(2) Includes all oils other than crankcase oils
(3) Include only oils processed.  Do not include virgin oils or additives

Remarks Section C and D
                                               000 Gal/lbs
E.  Sludge produced     lft Qtf  *   2nd Qtr     3rd Qty.     4tf| Qtr    Total
    Raw storage         	.	/	.	.	
    Pretreatment
    Distillate treat
    Clay and'Miter aid
    Disposal  Method       %
         Landfill        	
         Road 011        	
         Incinerate     	
         Fuel, Internal __;	
         Other                    Describe
-------
                                                                             130
    Does your State or local  government require -                   Yes     No
         Commercial landfill  permits?                               	   	
         On-site (your own)  landfill permits?                      	   	
         Hauler permits?                                           	   	
    Have you had problems with use  of  either commercial  or
    on-site landfill?                                              	   	
         Describe      		
    Have you had your sludge analyzed                     Yes  	     No
                                           000 Gal.
F.  Waste water   lst Qtp      2nd Qtp      3rd qtp       4th Qtr     Total
    Raw storage'	.	.	.	.	
    Chem treau  	
    Steam strip 	
G.  Disposal, water
                       Sanitary    Storm     Stream    Ground    Other     Recycle-
                        sewer      sewer
    flaw- -s-towge-          	      		      	     	       	
    Chem pretreat        	      		     	       	
    Steam strip          	      	       	      	     	       	
    Cooling              	      	       	      	     	       	
    Ground               	      	       	      	     	       	
                                                                 "Yls"        No
    Do you use and API, or similar, separator?                  	       	
    -Go--you treat waters for disposal?                            	       	
    if you had/have water processing facilities would it or
    does it allow for recycling of all waste waters (process)    	       	
                                                    (ground)     	       	
-------
                                                                             131
    Have you had your water analyzed?

    Does your State or local  government require permits
    for water disposal?

    Does State or local government monitor your waste water?

    If yes, underline
                        ,>
         Occasionally     Regularly     Constantly     Never
H.  Information,  general
    (Please read  cover letter Section)

    Have you investigated  any other methods or processes for disposal or
    utilization of sludges or spent clay?  Do you know of others  (rerefiners,
    chemists,  suppliers, contractors)  who have worked on this problem?
    Some methods  are  vacuum distillation, solvent extraction, pyrolysis,
    emulsification.   Uses  are fuels, special lubes, roof coatings, water
    proofing and  road surfacing.  We will appreciate any information you
    have in this  area even if it  is not completely satisfactory.  Please
    furnish names, addresses  and  a short description of the process or use.
I.  Please 11st names, addresses of reprocessors known to you 1n your
-------
                          APPENDIX C
                                                            132
         COMPOSITION OF SOME LUBRICATING OIL ADDITIVES'
Additives

Corrosion
  Inhibitor
Rust
  Inhibitor
Antioxidant


Detergent
Dispersant
Metal
  Deactivator
Color
  Stabilizer

Viscosity
  Index
  Improver

Pour Point
  Depressant
Extreme
  Pressure
  Additive
Composition

Zn and Ba dithiophosphates,
dithiocarbamates, metal
sulfonates and sulfurized
terpenes

Sulfonates, alkylamines,
amine phosphates, alkenyl-
succinic acids, fatty acids,
and acid phosphate esters

Sulfides, phosphites,amines,
phenols, dithiophosphates

Sulfonates, phosphonates,
phenates, alkyl substituted
salicylates combined with
barium, magnesium, zinc,
and calcium

Alkenyl sucinimides,
alkyl-acrylic polymers,
ashless compounds

Organic dihydroxphosphines,
phosphites, and sulfur
compounds
Amine compounds
Isobutylene polymers and
acrylate copolymers
Polymethacrylates, poly-
acrylamides, alkylated
naphthalenes, and phenols

Organic compounds with
sulfur, phosphorous, nitro-
gen, halogens, carboxyl
or carboxalate salt
Function

To react with metal
surfaces to form a
corrosion-resistant
film.

To react ^chemically
with steel surfaces
to form an impervious
film

To inhibit oxidation
of oil

To neutralize acids
in crankcase oils
to form compounds
suspended in oil
To disperse con-
taminants in the
lubricant

To form protective
film on running
surfaces to inhibit
reaction

To stabilize oil
color

To retard loss of
viscosity at high
temperatures

To prevent congealing
of oil at low
temperatures

To form low-shear
strength film providing
lubrication at start-
up and at high   . j
bearing loads
-------
APPENDIX D
133
-------
                         APPENDIX E

                         GLOSSARY A
                                            134
Acid Number
Acid Number,
  Total (TAN)
Additives
Additive
   Package
API

APR

Ash
ASTM
Aviation Oils
- A measure of the inorganic  and organic
  acidity of an oil using the quantity of a
  potassium hydroxide solution necessary  to
  neutralize acids.  See neutralization
  number  ASTM D-974

- A measure of the total acidic constituents
  in an oil;  the milligrams  of potassium
  hydroxide necessary to neutralize all acidic
  constituents in one gram of sample
  ASTM D-3339

- Chemical compounds added to oils to improve
  operating characteristics (e.g.,  lubricity
  agents, detergents)

- Two or more additives mixed by the additive
  manufacturer to impart desired characteristics
  of an oil (e.g., rust and oxidation inhibitor)

- American Petroleum Institute

- Association of Petroleum Rerefiners

- The amount of non-combustible material  in
  an oil;  that which remains after combustion
  under controlled conditions.  An indication
  of impurities and the additive content
  ASTM D-874

- American Society for Testing and Materials;
  establishes analytical and  other test methods
  for several industry products (e.g.,  petroleum,
  paints)

- Lubricants used in aircraft engines;  recipro-
  cating internal combustion  engines;  used
  oils similar to those used  in automobile
  engines.  Jet engines use synthetic lubricants.
                         GLOSSARY B
Base Number,
  total
  A measure of alkalinity of an oil;  the quantity
  of perchloric acid necessary to neutralize all
  basic (alkaline) constituents  ASTM D-2896
-------
                                                            135
Base Stock
Bottoms
BS&W
Lubricating oils which are chemically
treated (e.g., sulfurized, or with which
additives are blended for specific products)

Residue from chemical or thermal distillation
of oils.  See sludga.

Bottoms, Sediment, and Water - ASTM D-96
Laboratory standard method for measuring
water and solids content of oils
                         GLOSSARY C
Carbon Residue  - The amount of carbon remaining after con-
                  trolled evaporation of an oil;  indicates
                  carbon forming characteristic  of an oil  in
                  use.   ASTM D-1.89  D-524
Centrifuge
Clay
Copper
  Corrosion
Crankcase Oil


Crude Oil
A machine which separates materials of dif-
ferent gravity  (i.e., oil and water or a
liquid and solids by centrifugal action
which increases the "G" force);  used in the
laboratory to measvre solids,  water, and
separable sludge ir. waste oils

Specially produced powders used for removing
color bodies, extremely fine solids, and
for neutralizing acidic compounds in oils;
includes Fuller's flarth, activated clay,
and bleaching clay

Determination of free sulfur and corrosive
sulfur compounds using a standard copper strip
immersed in the oi'.. at specified temperatures
ASTM d-130

Used motor oils renoved from combustion
engines;  also called crankcase drainings

Usually used for virgin oil refinery feed
stock but occasionally used by rerefiners for
raw waste oils
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                                                            136
Cutting Oils
Lubricating oils of relatively low viscosity
used for machining of metals;  usually
contain additives, such as fatty oils,
sulfur, and chlorine compounds
                         GLOSSARY D
Dehydration


Demulsifier
Detergents
Diatomaceous
  Earth
Dispersants
Distillate
Distil -*"5on
Removal of water from oil by chemical and/or
thermal methods.  See distillation.

A chemical compound (surfactant) which aids
in removing water from oil by change in
surface tension which allows the finely
divided and dispersed water droplets to
coalesce and separate from the oil by gravity

Chemical compounds added to lubricating oils
which keep sludge, formed during use, in
suspension and surfaces clean (e.g., auto-
mobile engine interior)

A powder derived from fossil remains which
is used in filtration to aid in removing
solids too fine for removal by screen, paper,
or cloth, and to improve filtration flow
rate;  also called filter oil

Chemical compounds similar to detergents but
used more specifically to keep solids, moisture,
and compounds formed during use in suspension
in the oil

The low boiling components (light ends)
removed from an oil during distillation;  in
rerefining the distillate is similar to a
No. 2 fuel oil or kerosene

A thermal process in which oils in commercial
rerefining are heated to 550°-650 F  (atmospheric)
to remove low boiling constituents  (See light
ends, distillate) as vapors to improve lubri-
cating oil performance.  Partial distillation in
refining  (650°F maximum) is usually conducted
with an oil/clay mixture and introduction of
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                                                            137
Distillation
  (cont.)
Drainage
  steam for stripping; odorous compounds, such
  as mercaptans,  and to aid in removing low
  boiling constituents.  The residual oil,
  after filtration,  is the rerefined base stock.
  Total distillation,  using temperatures in the
  950° F range and high vacuum pressure, re-
  moves the lubricating oil fraction, as well
  as, low boiling components.

  Waste oil from internal combustion engines;
  also called crankcase drainings of crankcase
  oil (CCO)
                          GLOSSARY E
Emulsifier
Emulsion
E.P. (Extreme
  Pressure)
  Compounds ranging from fatty oil soaps to
  synthetic detergents which aid in stabilizing
  mixtures of oil and water by reduction of
  interfacial tension.  Some emulsions can be
  formed mechanically by high shearing action.

  A mixture of oil and water which does not
  readily separate by gravity.  In "oil in
  water" (0/W) emulsions, the small oil droplets
  are dispersed in the water;  in "water in oil"
  (W/0) emulsions, the water droplets are dis-
  persed in the oil.

  Denotes a quality of a lubricant which prevents
  metal to metal conzact under conditions of
  high loading (e.g., gears);  a function of
  selected additives
                          GLOSSARY F
Fatty Acids

Fatty Oils
- Organic acids derived from fatty oils

- Oils derived from animal fat or plants
  (e.g.,  lard oil,  tallow, castor oil);  used
  to impart a higher degree of lubricity and
  extreme pressure  Ijbrication.  They are more
  prevalent in industrial waste oils than in
  automotive oils.
-------
Feed Stock
Filtration
Fire Point
Flash Point
Fuel,
  distillate
                                                            138
Material used for a process such as dis-
tillation;  in rerefining the pretreated
waste oil.  See pretreated oil.

The method by which solids are removed from
air or liquid wherein the solids are removed
by a screen, cloth., or paper.  Diatomaceous
earth (filter aid) is often used on the
screen,  cloth, or paper to remove ultrafine
particles.

The temperature at which an oil sample
continues to burn after a controlled flame
is passed over the oil surface.   ASTM D-92
is the standard laboratory analytical method.

The temperature at which an oil shows a puff
of flame using the ASTM D-92 standard labor-
atory method.  The flash point of a lubricating
oil is usually 40 -50 F lower than the fire
point.
Petroleum fuels produced during distillation;
includes No. 1 used in home heating and No. 2
used in home and seme industrial and commercial
heating units
Fuel, residual  - Heavy fuels produced from the crude oil portion
                  remaining after distillation;  used in large
                  industrial and commercial boilers and other
                  heating units
                          GLOSSARY G
Gear Oils
Grease
Oils used to lubricate gears.  These contain
additives such as sulfur, chorine, and
phosphorus compounds, as well as, metals and
soaps to provide the high lubricating require-
ments

Petroleum greases are mixtures of lubricating
oils and soaps or thickeners;  used where non-
non-fluid lubricating is required.  Presence -
of greases in waste oil streams can make recla-
mation difficult or economically unfeasible.
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                                                            139
 Gravity, API
Grinding Oils
  The density of a petroleum product measured
  in API (American Petroleum Institute) units;
  related inversely to  specific  gravity in  that
  the higher the API number  the  lower  the
  density;   used to denote quality, approximate
  hydrocarbon composition, and heat of combustion
  Test method,  ASTM D-287

  Oils used in forming  of metal  by grinding.
  Some grinding oils are emulsifiable  and are
  used as a water mixture of soluble oils.
                          GLOSSARY R
Hydraulic Oil
Hydrotreating
  Oils used to transmit  power and to  actuate
  mechanisms;   usually have  suitable  additives
  to reduce hydraulic  pump wear,  rusting,
  corrosion, and oxidation

  The use of hydrogen  to remove undesirable
  constituents such as sulfur and nitrogen from
  petroleum products under high temperatures
  and pressures in the presence of a  catalyst;
  also called hydrofining.   Potentially hydro-
  treating in rerefining could replace the
  final clay treatment.
                          GLOSSARY 1
Industrial Oils - Lubricating oils used in industrial  machines
                  for lubrication, power transmission,  and
                  machining;   also used in railroad and marine
                  engines and equipment
Inhibitors
  Chemical compounds  used in petroleum products
  to reduce oxidation,  corrosion,  rusting,
  among others
                          GLOSSARY K
Kinematic
  Viscosity
- See Viscosity.
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                                                              140
Light Ends
Lubricity
  Hydrocarbons, which  are vaporized during
  distillation, tha: are  removed and con-
  densed.  See Distillate fuel,  kerosene.
  In rerefining:, tbo^ low boiling constituents
  that are removed  :o  produce a residual lubri-
  cating oil

  That character 1st Lc  of  an oil denoting its
  lubricating value-  (-.I.e., prevention of
  contact betvf'wn Diving  surfqc.es)
                          GLOSSARY
Machining
  Fluids

Hercaptans
Metalworking
  Fluids
- s<
Motor  Oils
  Odoriferous sulfur  compounds in petroleum
  oils.  In rerei'lning,  these are formed
                   during dist LI LatJ on ,
  Combinations of  oil
  for forming of me -a
  steel sheet or f <; i"r.
  and forging;  or R?
  grinding.  These n/i
  oils with various  ,-•<
  treatment of: thn
  Solubles, or envj
  with water foi -.-
                                     ) i •,
  mixtures £>,> •  •>>•-.
  or drawing  ,••••'  ;.-?
  cutting oil '•'<   •?;
        * CO'.  .--. ,MU
 and additives used
Is by rolling, as  in
3;  forming as in  pressing
ohj.nlng, as in cutting or
7 be so™ vailed straight
 idltives cr chemical
         -• s 4 sxil furizat ion.
fioble oLis are mixed
''T, i"".-«ive;, cutting,
              '^;Tapr Ite,
 i-  • •-''   -M, ,An-1  soap
 "..>;-• -.    sh'?cl metal
           ! :n,;5 used are
 ;s; ,,.,. <,<
n.-'.  i' "l.'--.,
                                                     lr  oils
  L' jb r ic ai: trip; c> ? I F
  with .
         •j'.;j  bass stocks
          I'-.a in  Internal
         ,-,•;; 11 fi--, or: dies el
Neutral  Oil
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                                                           141
Neutralization  - The measure of acidity or alkalinity of
  Number          an oil measured by the amount  of a  potassium
                  hydroxide solution or hydrochloride acid
                  necessary to neutralize the  acidic  or
                  alkaline (basic)  components  in the  oil.
                  The standard test method is  ASTM D-974.
                         GLOSSARY 0

Overhead        - The pipe lines which in distillation carry
                  the light ends (distillate)  vapors  to and
                  through condensors

Oxidation       - The chemical  process which changes  the oil
                  molecule by addition of oxygen.   This is
                  one of the causes of sludge and  acid
                  formation in motor  and hydraulic oils.

Oxidation       - Chemical compounds  which reduce  the formation
  Inhibitor       of gxidized compounds
                         GLOSSARY P


pH              - The measure of ac:ldity or alkalinity of  an
                  aqueous solution by indicating the  hydrogen
                  ion content.  See Neutralization number,
                  Total acid, and Total  base number.

Parting Agent   - Oil products used to prevent  adhesion of an
                  initially liquid material,  such as  concrete,
                  plastic,  or metal,  to  the walls of  a mold.
                  Waste oils are used for this  purpose on
                  concrete molds.

Polar Compounds - Chemical compounds which show a greater
                  degree of chemical reactivity than  petroleum
                  oils.  Fatty oils are  such materials.  In
                  waste oils these are the compounds  formed by
                  oxidation or other chemical reactions  during
                  use, as well as,  many  of the  additives
                  blended with the base  stock.
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                                                           142
Polymers        - Complex chemical compounds used in lubri-
                  cating oils as additives to improve
                  Viscosity Index (i.e.,  to reduce viscosity
                  reduction with increasing temperature and
                  to depress the pour point) (i.e., allow
                  the oil to flow at lower temperatures)
                  Polymers may form during use.

Post Treatment  - In rerefining, the method used to produce
                  a finished lubricating oil after distil-
                  lation;  in current rerefining practice,
                  the removal of spent clay by filtration.
                  It can include a sscondary neutralization
                  after distillation.  Laboratory research
                  indicates that hydrotreating after distil-
                  lation can replace use of clay.
Pour Point
Pour Point
  Depressant
Pretreatment
                - The temperature ( F)  at  which a petroleum
                  oil ceases to flow or begins  to flow

                - Chemical compounds which depress or lower
                  the temperature at which a petroleum oil
                  ceases to flow.  See  Polymers.

                - In waste oil processing, a process  in
                  which undesirable constituents of a waste
                  oil are removed by chemical,  physical,  and/or
                  thermal methods.   ['There  pretreatment of a
                  waste oil is the final stem,  which  may
                  include filtration or centrifugation, the
                  process is defined as reprocessing.  In
                  rerefining, the pretreated oil is the feed
                  stock for distillation and clay treatment,
                  or hydrotreating rather than  clay treatment.

Pretreated Oil  - Waste oil from which  unwanted constituents
                  have been removed by  chemical,  or other,
                  action, resulting in  a pretreated oil for
                  distillation and post treatment to  produce
                  a rerefined oil and a sludge
Process Oils
                  Petroleum oils used either in processing
                  (See Quench oils)  or those added to products
                  (e.g., ink, rubber, plastics, insecticides)
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                                                           143
                         GLOSSARY Q
Quench Oils
A process oil used in controlled cooling
of steel parts which has been heated to
high temperatures to improve hardness and
other metallurgies 1 properties
                         GLOSSARY R
Reclaiming
Reprocessing
Rerefining
Residual
Waste oil processing methods which improves
waste oils and uscis gravity settling, centri-
fugation, screening and heating at relatively
low temperatures (100 -160 F) to remove
water, solids, and oil insoluble sludge.
Demulsifiers and other surfactants may be
used but chemical;;, such as sulfuric acid,
sodium hydroxide, or sodium silicate, are
not.  The oil produced may or may not be
defined as a clean fuel.  See Reprocessing,
Rerefining.

Waste oil processing which uses higher
temperatures (150 -210 F) with chemicals
such as sodium hydroxide, sodium silicate,
sulfuric acid, and, possibly, surfactants
to remove water, solids, oil, insoluble
and solxable unwan:ed constituents (e.g
                                                       o* >
additives and corn-pounds formed during use)
Reprocessed oils have applications such as
clean fuel use, matalworking, and process
oils, as well as, feed stocks for the dis-
tillation step in rerefining

Processes which produce a good quality
lubricating oil from waste oil by pretreating
(See Reprocessing) distillation, and clay
contact or hydrotreating

In virgin oil refining, and in rerefining,
the material remaining after removing lower
boiling fractions (components).  The residual
in commercial rerefining is the lubricating
portion after distillation at approximately
550 -650 F (atmospheric pressure).
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                                                           144
Rolling Oils
Rust
  Inhibitors
Rustproofing
  Oils
Oils used in forming of ferrous and non-
ferrous metals (e.g., sheet steel)
These vary from straight fatty oils and
petroleum oils with additives to emulsifiable
oils.

Chemical compounds used to inhibit  and
prevent formation of rust.  In petroleum
products, these are used to inhibit rust
formation in engines, hydraulic mechanisms,
et.al.

Combinations of petroleum oils, and/or
drying solvents,  and/or waxes, and rust-
proofing polar additives which are  used to
coat steel parts  for prevention of  rust
formation during a storage period
                         GLOSSARY S
Sayboldt
Sludge, Acid
A method of measuring the viscosity of an
oil;  units are Sayboldt Seconds Universal
at standard temperatures (SSU @ 100°F,
SSU @ 210°F).  See Viscosity.

The settled residue of reaction of sulfuric
acid and unwanted constituents of waste
oil;  a black, viscous, acidic material
containing solids and additives blended
with the new oil and compounds formed during
use
Sludge, Caustic - The settled residue of reaction of sodium
                  hydroxide, and/or sodium silicate, or other
                  alkaline compounds with waste oils;  a grey
                  to black, semi-gelatinous, neutral to alka-
                  line material containing water, solids, and
                  additives blended with the new oil and
                  compounds formed during use
Sludge, Tank
  Bottoms
A combination of water, solids, and oil
insoluble compounds which settles during
storage of oil
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                                                           145
Soluble Oils
- Emulsifiable oils which, when mixed with
  water, are used as machining fluids,
  rolling oils, agricultural spray oils,
  and others
Specific Gravity- See Gravity, specific.

Steam Stripping - Steam introduced to oil during or after
                  distillation to aid in removal of light
                  ends and odoriferous and acidic constituents
                  of the oil
Sulfur, Actial
Sulfur, Added
Sulfur,
  Natural

Surfactants
- Sulfur in either elemental (or free) form
  or as part of a compound which is corrosive
  to copper.  Provides E.P. (extreme pressure)
  properties;  also called "added" sulfur,
  although not all sulfur compounds are active,
  Some sulfur (thio) compounds are oxidation
  inhibitors.

- Sulfur, either elemental or an organic
  compound, which is added to the oil to meet
  operating requirements;  found in machining
  fluids and such lubricants as gear oils
  which have severe operating requirements

- That sulfur which remains in the oil after
  refining or rerefining

- A term used for a wide variety of chemical
_compounds;  surface active agents which	
  reduce__sur_fac_e_ andJ inter-JfaclalT/Censiqn in
  oils, water, and oil/water mixtures
                         GLOSSARY T
Taik Bottoms

Total Acid
  Number

Total Base
  Number
- See Sludge, tank bottoms,

- See Acid Number, total.


- See Base Number, total.
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                                                           146
Transformer
   Oil

Transmission
  Fluids
Transmission
  Oils
Petroleum oil used in electrical trans-
formers for insulation

Petroleum oils, containing suitable
additives, used in power transmissions.
Automatic transmission fluid for auto-
moviles is designated ATF.

Petroleum oils, containing suitable addi-
tives, used in manual power transmissions
                         GLOSSARY V
Viscosity
Viscosity
  Index
Viscosimeter
The measure of the rate of flow of a
liquid;  technically, the internal resis-
tance to flow.  The test method and
numerical definition consists of timing
the flow of a measured amount of liquid at
prescribed temperatures through a specific
orifice.  The traditional petroleum standard
has been Sayboldt Seconds Universal (SSU).
More recently, kinematic viscometers are
used and measurements are expressed in
centistokes (Cs)  ASTM D-88 D-445 .

The expression of the difference in rate
of flow of a liquid at different temperatures
and expressed as a number (e.g., V.I. 95)
Petroleum oils are tested at 100°F and 210°F.
The difference between the two viscosities
is termed V.I.  The lower the difference,
the higher the V.I.

Laboratory equipment used to measure the
rate of flow of a liquid
V.I. Improvers  - Chemical compounds, usually polymers which
                  reduce the viscosity with increased temper-
                  atures
Volatiles
Those fractions of an oil which boil off
(distill) at a given temperature;  in petrol-
eum oils, usually includes water and light ends-
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                                                           147
                         GLOSSARY W
Waste Oil
Wetting
Wetting Agents
Predominantly, petroleum products which
have degraded in use so as to be unsuitable
for the operating conditions.  Waste oils
can be derived from many sources with auto-
motive and industrial oils comprising the
largest volume.  Fatty oils, synthetic oils,
and solvents also contribute to the waste
oil volume.

The ability of a liquid to spread on a
solid surface;  expressed in surface tension
units (Dynes)

Chemical compounds which increase the
wetting power of a liquid.  See Surfactants.
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                                                       148

                         APPENDIX F
        EXPLANATION OF WASTE OIL GENERATION FACTORS

The estimates for the annual generation of    -   _i
have been calculated from those published in "Waste
Oil Recycling and Disposal,  EPA 670/2 - 74-052",
August 1974.  The author, Norman J. Weinstein,  Recon
Systems, Inc., based his estimates on information
published by the United States Bureau of Census for
1971.  The same assumptions  and distribution percentages
have been used by the author of this report.  The Bureau
of Census report "Sales of Lubricating and Industrial
Oils and Greases, MA-29C(75)-1", September 1976,  has
been the source of the current estimates.

The author has changed some  distribution percentages to
reflect the increasing do-it-selfers engine oil market
and the reduction in sales by service stations.  There-
fore, the market percentages for service stations has
been changed from 24.8% to 19.8% of thev automotive lube
oil market.  Discount sales  have been increased by 5.0%.

Sales by garages and auto supply establishments have
been increased by 2.0%.  Factory fill sales has been
reduced by 1.0%, reflecting  the decrease in auto sales.

A reduction of 0.8% for car  dealers' sales has been
made for the same reason. Other minor reductions have
been made which reflect the  author's best judgment.

The lubricating oil sales and waste oil generation have
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