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
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V
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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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.
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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.
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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
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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
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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,
-------
46
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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.
-------
48
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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,
-------
65
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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
64.8 9.3
0
9.3
Rerefiners
Number % of Total
3 11.1
0
1 3.7
1 3.7
0
1 3.7
0
2 7.4
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
and $1.00 to $15.00 for spent clay. Higher
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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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
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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
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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
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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)
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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
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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
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APPENDIX D
133
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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
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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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