EPA-670/2-74-052 AUGUST 1974 Environmental Protection Technology Series WASTE OIL RECYCLING AND DISPOSAL National Environmental Research Center Office of Research and Development U.S. Environmental Protection Agency Cincinnati, Ohio 45268 ------- EPA-670/2-74-052 August 1974 WASTE OIL RECYCLING AND DISPOSAL By Norman J. Weinstein Recon Systems Inc. Princeton, New Jersey 08540 Contract Nos. 68-01-1870 and 68-03-0394 Program Element No. 1BB041 Project Officer- Leo T. McCarthy, Jr. Industrial Waste Treatment Research Laboratory Edison, New Jersey 08817 NATIONAL ENVIRONMENTAL RESEARCH CENTER OFFICE OF RESEARCH AND DEVELOPMENT U.S. ENVIRONMENTAL PROTECTION AGENCY CINCINNATI , OHIO 45268 For .«le by the Superintendent of Document*, U.S. Government Printing Office. Washington, D.C. 20402 ------- REVIEW NOTICE The National Envirorinental Research Center -- Cincinnati has reviewed this report and approved its publication. Approval does not signify that the contents necessarily reflect the views and policies of the U.S. Envirorinental Protection Agency, nor does mention of trade names or corn- mercial products constitute endorsement or recom- mendation for use. Ii ------- FOREWORD Man and his environment must be protected from the adverse effects of pesticides, radiation, noise and other forms of pol- lution, and the unwise management of solid waste. Efforts to protect the environment require a focus that recognizes the interplay between the components of our physical environment-- air, water, and land. The National Environmental Research Centers provide this multidisciplinary focus through programs engaged in • studies on the effects of environmental contaminants on man and the biosphere, and • a search for ways to prevent contamination and to recycle valuable resources. Little quantitative information has been available on the ultimate fate of waste oil generated from the 2.2. billion gallons of lubricating and industrial oils used annually in the United States. In this study information has been developed on sources and quantities of waste oils, current and potential recycle and disposal methods, and the environmental impact of these methods. A. W. Breidenbach, Ph.D. Director National Environmental Research Center, Cincinnati 111 ------- ABSTRACT Little quantitative information has been available as to the ultimate disposal of the 2.2 billion gallons per year of lubricating and industrial oils used in the U. S.; or of additional waste oils resulting from produc- tion, transportation, refining, and use of petroleum and its products. About 100 million gallons per year is known to be recycled by the re-refining industry, producing lubricating oils; and other oil is used as fuel, road oil, and a variety of other applications. Each of these applications, in- cluding re—refining, has substantial negative impacts on the environment. In this study, information has been developed on sources and quantities of waste oils, current and potential recycle and disposal methods, and the environmental impact of these methods. Several surveys were conducted to aid in the development øf the desired information. These included: 1. Visits to 30 re-refiners and waste oil processors, primarily to obtain technical information. 2. A waste oil survey of the Pittsburgh area, including inter- views with 83 service stations, various industrial organi- zations, waste oil collectors and processors, and others. 3. A nationwide telephone survey of 92 collectors and processors of waste oil. 4. A combined telephone and visit survey of organizations in 57 Standard Industrial Classification major groups. Other data were obtained through an extensive literature search, and by actual sampling of wastewaters in two waste oil processing plants. An estimated 2.5 billion gallons per year of all types of waste oils are generated. The majority of these ultimately find their to the environment or are used as fuel. A relatively small quantity is re-refined to lubricating oils. Acid/clay treatment, the most cormionly used re-refining process for waste lubricating oils, is not an attractive approach for expanding the re-refining industry, because of its high cost and because of undesirable waste products produced (acid sludge, spent clay). More attractive pro- cesses are available, but further development work is required. Use of vehicular waste oils for fuel, road oiling, and dust control, currently major uses, is unsound from the points of view of resource and environment conservation. During combustion, very fine lead particles are emitted to the atmosphere. Waste oils generally make poor road oils, resulting in rapid loss of oil to the surrounding land arid waters. iv ------- Much industrial waste oil is being recovered and reused internally and externally, including considerable fuel usage, but an uncomfortable quantity is being indiscriminately disposed of in road oiling, dust con- trol, dumps, and landfills. The disposal of oily flocs and sludges from wastewater treatment is a major industrial problem. Reconiiiendations are made to encourage the expansion of a technically and environmentally sound oil recycling industry, including licensing of collectors and processors, and a research and development program. This report was submitted in fulfillment of Contract Nos. 68-01-1870 and 68-03-0394 by Recon Systems, Inc. and Response Analysis Corporation under the sponsorship of the U.S. Environmental Protection Agency. V ------- CONTENTS Page Abstract iv List of Figures ix List of Tables X Acknowledgements xiv Sections I. Conclusions 1 II. Reconunendations 6 III. Introduction 9 IV. Classification of Waste Oils 10 Automotive Service Centers 10 The Do-It-Yourself Market 15 Conunercial Engine Fleets 15 Railroad Service Centers 16 Aviation Service Centers 18 The Metal Industry 19 Process Oil Consumers 21 Other Industrial Oils 22 Marine Transportation Waste Oils 23 Industrial Process Waste Oils 24 Petroleum Indus try Oil and Fat Industry Coking Ovens Synthetic Oils 27 vi ------- rage V. Recycle and Disposal Techniques For Vehicular Waste Oils 28 Current Processes For Re—Refining Lube Oils 28 Acid/Clay Treatment Distillation/Clay Treatment Potential Processes for Re-Refining Lube Oils 41 Solvent Extraction/Acid/Clay Treatment Distillation/Hydrogen Treatment Other Re-Refining Approaches Evaluation of Waste Lube Oil Disposal Technology 50 Cost Basis Process Comparisons Other Disposal Techniques VI. Recycle and Disposal Techniques For Other Waste Oils 60 Industrial Lube Type Oils 60 Emulsified Oils 61 Other Petroleum-Based Industrial Oils 63 Waste Vegetable, Animal, and Fish Fats and Oils 64 Oil/Water Mixtures from Marine Sources 66 VII. Foreign Waste Oil Disposal and Recycle Techniques 67 Distillation 67 Solvent Extraction 67 Acid/Clay Treatment 67 Hydrogen Treatment 68 Industrial Waste Oils 68 vii ------- Page VIII. Environmental Assessment of Waste Discharges From Processing of Waste Oils 70 Waste Products Generated 70 Characterization of Wastewaters From Oil Recycling Facilities 83 Existing and Future Regulations Solid Wastes and Land Disposal 93 Water Air Disposal Techniques 97 Overall Assessment and Future Considerations 107 IX. Waste Oil Surveys 109 Pittsburgh Area 109 Waste Oil Processors & Collectors 115 Industrial Waste Oils 124 X. References 129 x i. Appendices 138 A. A List of Re-Refiners And Processors 139 B. Lubricating Oil Additives 144 C. Pittsburgh Survey Methodology And Data 150 D. Waste Oil Collector And Processor Survey Data 184 E. Industrial Survey 243 F. Waste Oil Material Balance Methodology 289 G. Health and Safety Aspects of Re-Refining Process Effluents 320 viii ------- FIGURES No. Page 1 Re—Refining By An Acid/Clay Process 35 2 Vacuum Distillation of Crankcase 39 Waste Oil 3 Re-Refining By A Propane Extraction 44 Process 4 Hydrotreating 47 5 Waste Oil Processor Oil—Water 84 Separator Unit 6 Waste Oil Re—Refining Process 86 F-i U. S. Crude Oil Distribution 290 F-2 Waste Oil Generation 291 F-3 Waste Oil Disposal 292 ix ------- TABLES No. Page 1 Assay of Automotive Crankcase Oils by Esso 11 2 Assay of Crankcase Drain Oils From API 12 3 Typical Gasoline Engine Lubricating Oil Ingredient Cost (1969) 14 4 Survey of Waste Oil Re—Refiners 29 5 Physical Properties of Vacuum Distillation Fractions 40 6 Properties of Distilled Used Motor Oils 42 7 Distillation and Hydrogen Treatment of Used Motor Oil 48 8 Survey of Crankcase Waste Oil Processes 52 9 Crankcase Waste Oil Processing Capital Investment 53 10 Potential Profitability of Crankcase Waste Oil Processes 54 11 Crankcase Waste Oil Process Operating 55 Costs 55 12 Types of Waste Treatment Employed by 108 Meat Packing and Processing Plants 65 13 The Treatment and Disposal of Waste Oils and Waste Oil Residues 71 14 Acid Sludge Analysis 77 15 Acid Sludge Analysis 78 16 Physical Characteristics of Acid Sludge 79 17 Analysis of Petroleum Refining Spent Contact Clays 80 x ------- No. Page 18 Waste Oil Processor (Marine Waste Oils) Oil/Water Separator 91 19 Waste Oil Re—Refiner 92 20 Sulfate Solubility and Environmental Kazards of Acid Sludge Inorganics 99 21 National Sample Structure 116 22 Waste Oil Collection and Use 119 23 Treatment Processes Used 120 24 Types of Oils Produced by Processors 122 25 National Estimates 123 26 Generation and Destination of Waste Oil 128 C-i Oil Changes Done, All Vehicles 157 C-2 Oil Bought and Used For Oil Changes 158 C-3 Waste Available and Collected in Gallons Per Year 159 D-1 Types of Waste Oil Collectors 187 D-2 Amounts of Waste Oil Collected From Sources 189 D-3 Trucks and Truck Capacity 191 D-4 Collection Radius 193 D-5 Intra —and Inter-State Collection 195 D-6 Storage Facilities of Collectors 197 D-7 Users of Stored Waste Oil 199 D-8 Types of Waste Oil Processors 202 D-9 Amounts of Waste Oil Processed in 1973 204 xi ------- No. Page D-l0 Total Proce si g Capacity 206 D-il Estimated Processing (1973) Related To Total Processing Capacity 208 D-12 Processing Treatments Used 210 D—13 Types of Processed Oils Produced 212 D-14 Methods of Disposing of Processing Wastes 214 D-].5 Wastewater Treatment Metkods 216 D-16 Methods of Air Pollution Control 218 D-17 National Estimates of the Waste Oil Industry 220 F-i Key to Sources of Data in Figures F—i, F—2, F—3 293 F—2 Salient Statistics of Crude Petroleum, Refined Products and Natural Gas Liquids in U. S.-1971 Preliminary Data 295 F—3 Estimated Lubricating and Industrial Oil Sales in the U. S. — 1970—71. 296 F-4 Estimated Marine Oil Spills — U. S. - 297 1972 F—5 Estimated Marine Oil Losses — U. S. - 1971 298 F-6 Estimate of Oil Losses and Spills on Land, and Losses from Processing - 1971 301 F-7 Estimated Lube Oil Sales and Waste Oils Generated At Automotive Service Centers 1970—1971 302 F-8 Estimate of Factors for Converting Automotive Sales to Waste Oil Quantities 303 xii ------- No. Page F-9 Generation of Industrial Lubricating Waste Oils 304 F-10 Generation of Other Industrial Waste Oils 305 F—li Generation of U. S. Government Lubrication Waste Oils 306 F-12 Consumption of Lubricating Oils - As Lubricating Oil, Fuel, or Other Uses By Original Purchaser/User 307 F-13 Waste Lubricating Oil Re-Refiners 1973 Production - RECON SYSTEMS Survey 308 F-14 Estimate of Feedstocks to Waste Lubricating Oil Re—Refiners 311 F-15 Estimation of Total Feedstock to Reprocessors 312 F-16 Estimation of Individual Feedstocks to Waste Oil Processors 313 F-17 Destination of Spills and Losses 314 F-18 Estimation of Production of Waste Oil Processors 315 F-19 Estimate of Destination of Industrial Lubricating Waste Oils 316 F-20 Estimate of Destination of Other Industrial Waste Oils 317 F-21 Estimate of Destination of Automotive Lubricating Oils 318 F-22 Estimate of Waste Oil Potentially Entering the Environment 319 xi ii ------- ACKNOWLEDGEMENTS The Project Directors appreciate the efforts of the many people who contrthuted directly or indirectly to this work, including the RECON SYSTEMS and RESPONSE MJALYSIS staffs, personnel of the U. S. Environmental Protection Agency, and to those people in the waste oil and other industries who patiently answered barrages of questions. At the risk of overlooking several contributors, we would particularly like to acknowledge the efforts of Mr. Richard F. Toro in developing Sections VIII and X; Mr. Edward Alper in helping to develop Section V; Mr. Robert Wolfertz for his work in the industrial survey and waste- water characterization; and Dr. Charanjit Rai and Mr. Arthur T. Goding, Jr. in a variety of pertinent tasks. For RESPONSE ANALYSIS, Dr. Michael A. Rappeport directed the Pittsburgh survey, assisted by Miss Wendy Jamieson. Mr. Leonard F. Newton was Project Director for the collector and processor survey, with day—to—day direction provided by Dr. Paul Scipione and Mr. Eugene Heaton, statistical consultation by Miss Charlotte Slider and Mr. Reuben Cohen, and supervision of interviewing by MiSS Wendy Jaxnieson. The work could not have been completed without the tireless efforts of Mrs. Gladys Freeland, Mrs. Emily Dill, and Miss Sunny Hancher. The encouragement and particularly the understanding of Mr. Leo McCarthy, the Project Officer, and Dr. Peter B. Lederman, Director of the Industrial Waste Treatment Research Laboratory in Edison, New Jersey, were vital forces during the entire project. xiv ------- SECTION I CONCLUS IONS WASTE OIL QUANTITY 1. Insufficient information is available to accurately estimate the total quantities of waste oil generated, available for recycle, or disposed of improperly. 2. Best approximations, based primarily on sales figures, has produced the following estimates for waste oil generation: Millions of Gal./Yr. Automotive lubricating oil 616 Industrial & aviation lubricating oil 394 Other industrial oils 87 U.S. Government lubricating oil 18 Marine oil transportation losses and spills 209 Other oil losses in production, refining, transportation and use 1,156 Total for Petroleum 2,480 Oil and Fat Industry Losses 13 Coke Oven Oil Losses 6 2,499 3. The ultimate destination of these oils was also deduced. from limited available survey information: 1 ------- Millions of Gal/Yr. Directly to the environment 978 Processing wastes to the environment 72 Road oil, dust control, runoff, asphalt leaching, land disposal, residue to the environment 281 Sub-total-to the Environment 1,331 Directly for use as fuels 358 Use for processing plant fuels 149 Fuels sold by oil processors 621 Sub—total-Fuels 1,028 Road oil and dust control—rapid biodegradation 38 Re—refined oil sales 83 Sub—total-Other 121 Total for Petroleum 2,1480 4. The 1,331 million gallons per year of oil which may be reaching the environment represents 0.6% of total crude oil, refined products and natural gas liquids produced and imported (231 billion gallons in 1971) . About half of these losses to the environment was estimated to have come from production; refining; transportation; and use of oil--as spills; wastewater discharges; land, ocean, and deepwell disposal of wastewater treatment sludges and flocs, tank cleaning residues, and coke; land spreading of contaminated oils; evaporation; and other miscellaneous losses. 5. Less than 10% of the total potential lubricating oils are recovered. 2 ------- WASTE OIL RECYCLE AND DISPOSAL 1. Fewer than Lb re—refiners producing lube oils remain out of an industry that once numbered 150. 2. The single most difficult problem existing in the re-refining industry today is inability to compete for available crankcase drain oils and industrial waste lubricating oils with fuel, road oil, and dust control applications. 3. Acid/clay treatment, the most commonly used re- refining process for lubricating waste oils, is not an attractive approach for expanding the re-refining industry because of its high cost and because of undesirable waste products produced. Lb. The solvent extraction/acid/clay treatment process is more attractive economically, but it also produces waste products, though in smaller quantities. 5. The distillation/clay process appears to be an attractive approach to re—refining, though a more detailed evaluation and additional development work is required to assure product quality, reli- able operation, and proper disposal of the distillation bottoms product and spent clay. 6. The distillation/hydrogen treating process is the only re-refining scheme available which holds promise for economical vehicular waste oil recycle without producing waste products, assuming that distillation bottoms find an outlet in secondary lead smelting. 7. Most re—refiners are so harassed by adverse business conditions that they are unable to finance necessary plant improvements. 8. In addition to the re—refining industry, a second group of oilreclaimers, designated here as waste oil processors, are engaged in converting waste oils to fuels and other products. 9. Treatment systems used by waste oil processors range from simple settling to filtration and to distillation. 3 ------- 10. With a few exceptions, the treatment systems used by waste oil processors have very limited utility in removing impurities such as lead particles, other fine particulates, and polymer precursors. 11. Uncontrolled use of lead—containing vehicular waste oils as a fuel is a poor approach to disposal be- cause of lea6 and other fine particulate emissions, and because of the loss of important natural re- sources in short supply, namely lead and lubri- cating oil stocks. 12. Uncontrolled burning of all waste automotive crank- case oil (approximately 500 million gallons per year) could result in as much as 40 million pounds per year of lead entering the atmosphere as fine particulates. This represents about 4% of U. S. mine production. 13. The use of vehicular waste oils for dust control and road oiling is wasteful and potentially harm- ful to the environment. 14. An appreciable fraction of industrial waste oils are purified and recycled to their original use. 15. A major fraction of industrial waste oils are used as fuel at the point of generation, or converted to fuel use by the collector. 16. A major fraction of industrial waste oils reach the environment by consumption during use (oxidation, vaporization), by land disposal, dust control uses, and loss to wastewater effluents. 17. very few industrial concerns have records of the ultimate disposal of wasts oils purchased. 18. The collection of waste oils from automotive service stations, industrial plants, and other points of generation is haphazard and inefficient. 19. Of the waste oil picked up by collectors, more than one-half is used as or blended with fuels, with little or no control of quality; major quantities are used for road oiling and dust control, with little or no environmental control; major quantities are processed to lube oil and other products; and unknown quantities enter the environment by dis- posal on land, and loss to wastewater. 4 ------- ENVIRONMENTAL IMPACT OF WASTE PRODUCTS Insufficient information is available to fully evaluate important aspects of environmental impact. Therefore, the following conculsions should be considered as tentative. 1. Acid sludge, in the relatively small quantities now produced by individual re-refiners (about 200-5000 gallons per day), can be disposed of safely in landfills, if proper handling and disposal practices are followed. 2. Disposal of spent clay, by re-refiners and others recycling waste oil, in landfills does not appear to present serious environmental problems if proper practices are followed. 3. Wastewater quantities discharged by waste oil re—refiners and reprocessors is generally small but oil contamination problems are common. 4. Odor and other air pollution problems from waste oil re—refiners and processors are generally minor. 5. Water and air emissions can be adequately con- trolled by existing technology. 5 ------- SECTION II RECOMMENDATIONS 1. Federal and State governments should encourage expansion of the re-refining industry to produce lubricating oils from automotive and industrial lubes. This can be accomplished by: a. Controlling the use of lead-containing oils as fuels, whether or not they are diluted with other fuels, by specifying that air pollution control devices be provided to efficiently remove lead and other particulates. b. Requiring that all parties engaged in the sale of oils at any level disclose the source and characteristics of waste oils, especially contents of lead or other hazardous materials which may be in the oil sold. c. Establishing minimum specifications of oils suitable for roads, dust control, and asphalt, emphasizing lead content and other environmental aspects. A research program would be required to establish these criteria. d. Licensing all waste oil collectors, processors, and waste disposal facilities; and setting minimum standards of per- formance, including requirements that collectors dispose of waste oil to a licensed processor, and that processors dispose of wastes to a licensed waste disposal facility. e. Examining the implication of tax policies for virgin lubricating oil sales versus re—refined oil sales to at least eliminate those policies which discourage oil recycle. f. Requiring that all retail establishments selling lubricating oils provide a waste oil disposal facility. 6 ------- g. Requiring that all establishments which purchase more than 500 gallons per year of lubricating oils provide a suitable segregated disposal facility for the waste oil or obtain an exemption on the grounds that waste oils are not produced. h. Encouraging governmental use of re-refined oils, including the performance of engine tests when such tests are required to meet product specifications. The re-refiner should perform standard chemical and physical tests on oils at his own expense. i. Recognizing that the re-refiner is an essential element in pollution control programs by allowing him access to funding with tax—free pollution control revenue bonds, and by encouraging Small Business Administration support where applicable. j. Allowing the use of the description “recycled oil” on lubricating oil con- tainers, along with a definition of that term. k. Specifying minimum size storage tanks for waste oils in service stations (approximately 500 gallons would be suitable). 1. Supporting research and development and grant programs to improve re-refining and waste disposal technology. 2. Federal and State governments should also en- courage the expansion of a processing industry which handles industrial, marine, and other waste oils which are not of the lubricating type by: a. Requiring that adequate records of purchase, recycle, and disposal be kept. b. Requiring adequate waste oil segregation when large quantities are involved. c. Requiring disclosure of oil composition with respect to hazardous materials when oil sales or other oil transfers are made. 7 ------- d. Licensing collectors, processors, and waste oil disposal facilities. e. Encouraging govermiental use of re- processed oils. f. Allowing the processor access to funding with tax—free pollution control revenue bonds, and by encouraging Small Business Administration support where applicable. g. Supporting research and development and grant programs to characterize industrial oils and to develop improved recycle and disposal techniques. 3. A few specific research and development programs which appear to merit Federal support, in ad- dition to those previously mentioned, are: a. The chemical and physical characterization of acid sludge, spent clay and other waste to aid the assessment of environmental impract. b. Studies of the effect of the above wastes in landfills. c. Completion of the development of a vacuum distillation/hydrogen treatment process for re-refining, include the use of dis- tillation bottoms in secondary lead smelting. d. Investigation of the use of crankcase waste oil and other waste oils as chemi- cal raw materials. e. Work to improve oil recovery from marine transportation and oil spill wastes, and to clean up the resulting wastewater. 8 ------- SECTION III INTRODUCTION The non-polluting disposal of waste oils in the United States is a problem of enormous complexity because it in- volves not only the hundreds of thousands of establishments using fuels and lubricants, but also the hundred million vehicles and over 400,000 service stations, garages, and auto dealers which service these vehicles. Little quanti- tative information is available as to the ultimate disposal of the 2.2 billion gallons per year of lubricating and industrial oils used in the U. S.; or of additional waste oils resulting from production, transportation, refining, and use of petroleum and its products; or of waste oils from other sources such as animal, fish, and vegetable oils and fats, and coking ovens. A waste oil re-refining industry has existed in the U. S. for many years, converting waste lubricating oils to usable lubricants. However, In recent years the number of re-refiners has decreased from about 150 to less than 40. This fact has caused concern as to the disposition of waste oils. / Less is known about another group of oil reclaiming concerns, most of which convert a variety of waste oils to fuels. For purposes of this report, these concerns are called waste oil processors, although this description some- times refers to all oil reclaimers. Information has been developed on quantities of waste oils, current and potential recycle and disposal methods, and the environmental impace of these methods. To assess current disposal techniques, over 150 re—refiners, processors, collectors, and industrial organizations were surveyed, many by plant visits. Literature information and the Contractor’s background in petroleum refining and environmental problems provided the primary basis for assessing processes with potential for waste oil re—refining, and for the environmental assessment of waste discharges. Preliminary waste oil material balances were made with the aid of data collected and previous surveys reported in the literature. 9 ------- SECTION IV CLASSIFICATION OF WASTE OILS In order to consider waste oil recycling and disposal, it is important to understand the wide variety of sources and of composition. Waste oils are classified hera pri- marily by point of generation, a system which closely parallels data available on oil sales. Each waste oil classification is briefly discussed, providing data on com- position, volumes, and present recycle and disposal methods. Waste oil volumes discussed here are developed in Section X. AUTOMOTIVE SERVICE CENTERS This classification includes service stations, garages, new car dealers, other retail establishments, and auto- motive fleet service areas where used oils are drained from crankcases of automobiles and some trucks. The drain oils are generally collected in underground tanks having capaci- ties in excess of 500 gallons, but occasionally above ground in drums or other containers. The drain oils consist pri- marily of crankcase waste oils (greater than 90%), but also include waste transmission fluids, gear lubricants, hydraulic oils, and minor amounts of kerosene and other solvents used in service areas. Some oil is disposed of to solid waste collection with the discard of oil filters. Sales of lubricating oils by automotive service centers has been estimated to be 658 million gallons per year as shown in Table F-7. After correcting for factory fills and waste oils originating in discount store sales, about 500 million gallons per year of waste oil are esti- mated as generated in automotive service centers. This is the largest relatively uniform source of waste oil avail- able for recycling. Typical compositions of drain oil are shown in Tables 1 and 2. The most pertinent features of this oil with re- gard to recycle and disposal problems, are flash point, and water, sediment, ash, nitrogen, and oxygen contents. Many of the impurities are emulsified and very difficult to remove. The stability of the emulsions is enhanced by ad- ditives in the original lubricating oil. The drain oils are normally somewhat acidic in nature. Water content is generally about 3-5%, but may range from less than 1% to 10% or more. Some water results from gasoline combustion, but the very high water contents prob- 10 ------- H H Table 1. CRANKCASE ASSAY OF AUTOMOTIVE DRAIN OILS BY ESSO’ Test New York California Texas(A) Texas(B) New Jersey Flash, COC, 0 F. * . . 360 325 340 350 400 Vis @ 100°F, SSU. . 319 441 404 494 549 Vis @ 210°F, SSU. . 59.6 71.2 69.6 70.0 95.8 Viscosity index... 141 149 156 127 196 Grav.,°API 24.4 23.1 24.6 23.3 22.0 Rob. color Black Black Black Black Black Pour point, 0 F.... <-35 .-35 (-45 <—35 <-30 Neut. No 7.31 4.33 4.36 6.10 5.52 Con. carbon 5.20 4.68 3.80 4.93 5.06 XE’ water, % 0.11 0.26 0.44 0.051 0.41 Water by dist., %. 0.4 0.6 0.1 0.8 Nitrogen, wt. %.. . 0.16 0.21 0.13 0.13 0.17 Sulfur, wt. % 0.32 0.31 0.30 0.26 0.28 Oxygen, wt. % 1.36 1.80 1.83 1.44 2.25 Zinc, wt. % 0.098 0.069 0.084 0.085 0.067 Lead, wt. % 1.8,1.5 1.5 1.1,1.5 1.4 2.2 Vac. dist., 0 F @ 10mm absolute 5—10% 430—452 402—448 430—460 465—485 455—468 20—30 470—483 480—497 483—503 503—524 496—509 40—50 495—506 517—537 523—538 544—565 520--535 60—70 520—535 558—586 560—586 588—618 553—566 80—90 550—? 624—? 622—? 6 3—? 580—? Cracked @, 0 F 558 648 652 686 590 ------- I’J Table 2. ASSAY OF CRANKCASE DRAIN OILS FROM API 1 Mobil burning tests Staten Is.,NY Exxon burning tests Sewell’s Point,VA Shell burning tests Wood River,ILL Gulf burning tests Gulf R&D Co. Flash point, OF.. 215 350—400 175 218 Vis. @ 100°F, SSU ..... 248 268 148.3 256 Vis. @ 210°F, SSU. . . . . . . 56.4 60.1 Viscosity index.. 166 ....... Gravity, °API.... 24.6 26.0 27.3 25.0 Ash.............. 1.81 1.80 1.02 2.41 Water , vol . % . . . . 4 . 4 . . . . . . . 2 . 8 . . . . . BS &W , vol . . . . . . 0 . 6 . . . . . . . 3 . 8 . . . . . Sulfur,wt.%.... 0.34 •••••.. 0.29 0.21 Metals, wt. % Lead . . . . . . . . . . . 1 . 1 1 0 . 9 0 0 . 7 2 . . . . . . z inc . . . . . . . . . . . 0 . 08 0 . 07 0 . 035 . . . . . . Barium......... 0.06 0.10 0.01 Calcium. 0.17 0.10 0.15 Phosphorous.... 0.09 0.11 0.055 Iron........... 0.036 0.02 0.009 ------- ably reflect accidental contamination in holding tanks. Gasoline dilution of the crankcase oil, usually in the range of 1-10%, lowers the flash point of the drain oil to abotit 200-400°F, though lower values are sometimes encountered. Sediment and ash in the drain oil reflect oil additive residues, carbonaceous and metallic fines, and also gasoline additive residues, the most notable being lead and other metallic compounds, but including bromides and chlorides introduced as scavengers. Lead contents of 0.5 to over 2% are commonly reported, but this is expected to decrease as leaded gasolines sales decline. Additives are present in the original lubricating oils in concentrations ranging from 0 to about 20%. A typical blend is shown in Table 3. The wide variety of potential additives is indicated in Appendix B. The organic portion of these additives may be susceptible to losses, combustion, and reactions such as occur with the lube oil. However, the inorganics concentrate in the crankcase as oil losses occur and makeup is added. As judged by the typically high vis- cosity index of drain oil (usually greater than 90), and topped drain oil, a significant amount of the polyisobutylene and polymethacrylate additives remains relatively unchanged. The oxygen and nitrogen contents of the oils reflect not only additives but also products formed by the reaction of blowby engine combustion gases with the lubricating oil at engine temperatures. These reaction products tend to be unstable, producing color and odor problems, and fouling of equipment during processing. Most of the automotive service center drain oils are collected by independent collectors and by waste oil pro- cessors with collection systems. For example, a study in the state of Massachusetts reports that 88% of service sta- tion waste oil is collected, ranging from 95% to the metro- politan Boston area to less than 70% in rural communities. 2 About 88% of car dealer and garage waste oil was also col- lected, but only about 60% of fleet operator waste oils was estimated as being collected. Our own studies in the Pitts- burgh area were consistent with the Massachusetts results. Neither area has an operating re-refiner. Our collector survey showed that the collected drain oils are disposed of as follows: Re-refining to make lubricating oils Processing to prepare fuel oils 13 ------- TABLE 3. TYPICAL GASOLINE ENGINE LUBRICATING OIL INGREDIENT COST (1969) COMPONENT COST INGREDIENT ____ COST $/GAL. ‘ /GAL.LUBE 1. Base 011 86 0.20 17.2 (Solvent 150 Neutral) 2. Detergent Inhibitor 1 2.60 2.6 (ZDDP-zinc dialkyl dithiophosphates) 3. Detergent 4 2.00 8.0 (barium and calcium sulfonates) 4. Multi—functional 4 2.00 8.0 Additive (dispersant, pour—depressant, VI improver-polymethyl - methacrylates) 5. VI Improver 5 0.72 3.6 (polyisobutylene) 100 39.4 14 ------- Processing to prepare process oils such as asphalt flux oil, form oil, and other oils Direct use as a fuel by blending with other fuels Road oils Dust and weed control oils Little, if any, collected oil is now being disposed of directly to dumps, wells, or surface waters, though some processing wastes and much of the uncollected oil is dis- posed of in these ways. THE DO-IT-YOURSELF MARKET Considerable lubricating oil is purchased in retail stores by the individual automobile owner both for makeup and changing purposes. The quantity purchased has been estimated to be 168 million gallons per year, with 106 million gallons of waste oil generated (Tables F-7 and F-B). Allowing for 37 million gallons per year of drain oil re- turned to service stations, 69 million gallons per year are disposed of onto the ground, into garbage cans (most of which ends up in the ground), into storm sewers, into toilets and sinks, etc. The composition of drain oil in the do-it-yourself market should be similar to that reported for automotive service centers, except that the small amounts of trans- mission oil, gear oil, etc. may not appear. COMMERCIAL ENGINE FLEETS It is estimated that about 200 million gallons per year of lubricating oils are sold to commercial fleets, primarily trucks and construction equipment. Most such vehicles use diesel or gasoline engines. Diesel engine drain oils are similar to those described previously for gasoline engines, except that lead content is almost negligible. Flash point may be somewhat higher because dilution is by diesel oil rather than the more volatile gasoline. Very little information is now available on the quanti- ties of waste oil generated by servicing of commercial fleets. Much of the waste oil generated is believed to be used for fuel and dust control. Assuming 50% of sales are generated 15 ------- as waste oil available for collection, about 100 million gallons per year is available for external processing. The collected oils can be disposed of in the ways already discussed for automotive service centers. RAILROAD SERVICE CENTERS Diesel engines are the prime means of locomo Lion in the railroad industry. Railroad diesel engine lubes are usually isolated from other oils when drained. Much of this oil is shipped to re—refining centers for processing, arid returned as usable diesel engine lubricating oil. Sixty million gallons of railroad diesel lubricating oils are purchased annually. All or almost all of this oil is blended from virgin stocks. We have estimated from interviews with re—refiners that about 5-10 million gallons per year of re-refined oil is returned to the railroads. This recycle quantity was probably much higher in earlier years, but several re—refiners controlled by the railroads or heavily in railroad diesel lube re-refining have been shut down. These figures do not include journal box oils. Assuming 7 million gallons per year of re-refined rail- road diesel lubes at a 70% yield, indicates that about 10 million gallons per year of drain oil was recycled by the railroads. For 60 + 7 = 67 million gallons per year of oil used and 63% recovery, 42 million gallons per year of rail- road diesel oil is drained, with 10 million gallons to re- refining and 32 million gallons disposed of in other ways. The possibilities are: Internal use as fuel Internal use for dust control Internal use for non-critical lubricating purposes, perhaps journal boxes Sale for the above purposes Dumping As with commercial fleets, little information is avail- able on the composition of railroad diesel drain oils. Compositions are expected to be similar to those reported here for automotive oils, except lead content will be negligible and flash point may average a bit higher. It should be understood that elemental analysis of the ash will 16 ------- vary from oil to oil depending upon the exact nature of the oil and fuel additive packages, and the type of metal sur- faces encountered in the engine. 17 ------- AVIATION SERVICE CENTERS The aviation industry, including both commercial and private aviation, is an important user of petroleum—based fuels and lubricants. Fueling is performed primarily at airports; servicing is performed both at airports and at central maintenance centers. Major Commercial Airports Waste oil generation at major airports is likely to in- clude the following: — jet fuel drained from aircraft. This is a very minor quantity which finds its way to fuel usage. — aircraft sumping, i.e., water removal from sumps. This becomes a minor constituent in the airport wastewater system. - loading facility spills. These occur but are not predictable. Some oil may be picked up, but oil is also flushed to sewers. — draining of petroleum based engine and transmission lubricants, primarily from ground support equipment. These are generally stored and picked up by a collector. — synthetic lubricants (e.g., phosphate ester base). These are filtered and reused as long as they meet specific gravity, viscosity, acid number, and water specifications. When not reusable, the synthetic lubricants are returned to the manufacturer for reclaiming. — aircraft exterior and ground support equipment washing. Mixtures of dirt, oil, detergent, and water discharged to wastewater s y stern. - deicing fluids, e.g., ethylene glycol. Found in cold weather airports. Generally washed off into storm water sewers. 18 ------- — other ramp area contaminants, including aircraft and ground vehicle leaks and spills. Generally washed off into storm water sewers. A significant quantity of waste oils and other compounds do appear in airport wastewater and storm water sewers. These may reach surface waters, depending upon the effectiveness of treatment which is known to be inadequate in many airports, especially with regard to storm waters. Central Aviation Maintenance Centers The major portion of waste oily materials associated with commercial airlines are generated at central service centers, e.g. the Delta Jet Maintenance Base at the Atlanta, Georgia International Airport, 3 the TWA overhaul base in Kansas. These service centers have comprehensive treating facilities which include segregated oily waste treatment. The oily wastes come from engine overhaul, airframe overhaul, testing, and ground support equipment. Included in this waste are oils, paints, paint strippers, solvents, degreasers, washdown waters, plating wastes, etc. Some oil is separated easily; other oil is emulsified and difficult to separate. Private Airports Little is known about oil disposal in the many private airports in the U. S. However, it may be assumed that some airports utilize waste oil storage and collection, while others, because of their very nature, practice dust and weed control or dumping. The quantities of industrial type waste oil generated are covered in our estimates for other categories. An ad- ditional quantity of petroleum base waste oil from the 8 million gallons per year sold as airplane lubricants should be added to these estimates; probably not more than 4 million gallons per year. These have compositions similar to previ- ously described lubricating oils. THE METAL INDUSTRY Many types of lubricating and cutting oils, ranging from 100% oil to low concentrations of oil in water emulsions are used in metalworking for lubrication of moving parts and for fabrication or working of metals. Oily materials are added to various points in operations to help shape or form metals, to cool both tools and the metal worked, and to lubricate 19 ------- machinery. Typical operations are rolling, drawing, ex- trusion, and machining. As an example, in cold rolling, the steel is usually oiled as it leaves the last wash after pickling. This reduces rusting arid acts as a lubricant in the first—stand reduction. Additional fluids, usually emulsions of oils, fats, and/or fatty acids in water, are applied in subse- quent reductions to cool the rolls or lubricate the strip and, sometimes, the roll bearings. Oil rates of several thousand gallons per minute may be used. Recirculation of the rolling oil emulsion through a treatment plant is practiced, but losses occur, ending up in wastewater; and the recirculated lubricant must also be drained and changed periodically as impurities, such as suspended solids, build up and degradation occurs. Recovery of oil from the “soluble” oil emulsion is much more difficult than the recovery of ordinary uncompounded lubricating oils. This is true, first, because the emulsion must be broken with the aid of chemicals, and second, because soluble oils often contain ingredients such as fatty oils (e.g. lard, tallow, rapeseed, castor, sperm), and compounds formed by chlorination and sulfurization, in addition to other additives. The oil may be diluted to 5:100 parts of water, but occasionally to even 1:100 parts of water. The sulfurized/chlorinated oils are particularly useful for heavy—duty or extreme pressure applications such as pipe threading, automatic screw machines, and heavy duty drilling. In large metal fabricating plants, even where extensive recycling is practiced, relatively large quantities of waste oil are generated. The waste oils may be segregated, for example after draining hydraulic or lubricating systems, but more often the oils are all released to a wastewater treat- ment plant. Here, a major portion of the oils are usually recovered in a concentrated but contaminated form by skimming, while the remaining oils enter the environment by disposal of sludges or floes separated from the water before or after treatment, or as suspended oil remaining in the treated waste— water stream. Relatively large quantities of oil also appear with scale, shavings, and other solid wastes. Based on very limited data from Maryland, 5 it has been estimated that perhaps 100 million gallons of waste oil is generated nationally for possible recycle or alternative uses out of 150 million gallons per year sold as metal-working oils. Much of this oil is incinerated, and some is reprocessed for fuel and other uses. 20 ------- PROCESS OIL CONSUMERS The process oil consumers by definition do not generate large quantities of waste oil, since most of the oil be— comes an integral part of the product produced. For example, process oils made from lube stocks for rubber, ink, textiles, and agricultural sprays, and other uses totaled more than 300 million gallons in 1970. Forty to fifty percent of this quantity was consumed in the rubber industry for plastic!— zation, reinforcement, and extension. 6 Each process use has its own specifications, but many require oils similar to lube stocks. Some other process oils, defined by the U. S. Census Bureau as having a viscosity of more than 45 Saybolt seconds at 100°F, include 7 : Absorbent oils Apron dressings Belt dressings Brick oils Cable oils Coal spray oils Cordage oils Defoamants Flotation oils Farm oils and compounds Fruit and vegetable preservatives Launching grease base and slip coats Paint and putty oils Paper processing oils Petroleum sulfonates Polishing oils Rust preventative oils and compounds Tanners products White oils Spillage and other losses are the only normal sources of waste oil from most of the process oils. However, a few process oils, such as flotation oils, do require discard, generating waste oils. No data are presently available, but a reasonable estimate based on our analysis of a survey in Maryland 5 is that 5-15% of process oils result in waste oil generation. Of course, it should be recognized that process oils do enter the environment directly in a variety of ways; for example, as a liquid when using agricultural sprays for weed control, evaporation from inks, and disDosal of waste rubber products by incineration. 21 ------- OTHER INDUSTRIAL OILS (Lubricating and Non-Lubricating) Included in this general category for purposes of this report are all industrial oils, other than those mentioned in the preceding sections, which have as their source lubricating oil stocks sold to industry. These include: Turbine oils Gas engine oils Transformer oils Refrigeration oils Heat transfer oils Hydraulic oils The total in this category sold to industry is close to 600 million gallons per year including 325 million gallons hydraulic and circulating system oils (refrigeration, heat transfer, other). Additional breakdown, where available, is given in Tables F-9 and F—l0. Internal recycling is prac- ticed by some companies for some of these oils; for example, transformer, turbine, and hydraulic oils. Others, such as gas engine oils, become waste oils when drained. In any case, even where internal recycling is practiced, a major portion of the oils purchased eventually leaves its indus- trial use as waste oil. Estimates for waste oil generated are also given in Tables F-9 and F-lO. Most of the waste oils available have compositions similar to the original product but with impurities such as fine suspended dust and metal particles, and oxidation and decomposition products. However, waste oil picked up from industrial plants may be mixtures of oil types, and may be contaminated with synthetic oils, solvents, polychiorinated heat transfer and transformer oils, etc. Some industrial oil wastes are re—refined and sold or returned to the original user, i.e., in a closed loop system. Others are internally disposed of, e.g. as fuel, by incine- ration, or for alternative non-critical uses, such as oiling belt conveyors and dust control. 22 ------- MARINE TRANSPORTATION WASTE OILS Huge quantities of crude petroleum and refined products are transported by tanker, barqe, and pipeline into and out of refineries and terminals in the U. S. Included are about 60 billion gallons per year imported (1971), over 3 billion gallons exported, and even larger quantities moving in coastal, lake, canal, and river commerce. This transporta— tion results in waste oil generation from spills, bilge and ballast waters, and tanker washinc . Each of these are dis- cussed briefly below. Further detail on the quantities in- volved are presented in Tables F—4 and F-5. Oil Spills Marine oil spills obviously can vary greatly from year to year. Even one major tanker mishap can affect such sta— tistics. However, normal spillaqe alonq the U. S. Coast accounts for only a small fraction of the total waste oil generated. For example, spills in 1972 are believed to have been on the order of 20 million gallons. Waste oil actually recovered from these spills would be even smaller, probably less than 5 million gallons. The composition of the waste oil obviously depends primarily upon the nature of the product, ranging from crude oil to gasoline. Lighter fractions, such as gasoline, if spilled, would evaporate and not be recovered as waste oil. Composition of the waste oil recovered also depends upon the nature of the waterway, the type of recovery used, and materials added to aid in recovery or dispersion. For example, recovered liquids can be very high in salt water content, and can even contain materials such as straw used to aid in recovery. Some oils recovered from spills have been disposed of by landfill. Incineration and processing to product useful fuels are other disposal possibilities, but facilities which can handle recovered oils without producing polluting air or water emissions are usually not available where needed. Ballast Wastewater Water used as ballast must be discharged from tanker oil storage tanks at oil distribution terminals or at sea before taking on a fresh load. This wastewater contains from 0.1 to 2% oil. Assuming an average of 1.25% oil, 145 million gallons per year of waste oil is potentially available from an estimated 11.6 billion gallons per year 23 ------- of ballast water, most of which is still dumped at sea. Proper ballast wastewater treatment, where practiced, consists of a separator to recover the bulk of the free oil, followed by other methods such as air flotation and bio- logical treatment. Onshore ballast treatment makes 90-95% of the ballast wastewater oil available as contaminated oil for subseauent processing to fuel or other uses. Bilge Wastewater Wastewater collected in a shiD’s bilge will often be contaminated by concentrations of oil similar to that in ballast wastewater. Assuming an average of 1% oil, 11 million gallons per year of waste oil is potentially avail- able from an estimated 1.1 billion gallons per year of bilge wastewater. 8 This water can be treated similarly to ballast waste- water, or mixed with the ballast wastewater for common treatment. Tanker Washings Tanker and barge washing is important, especially when changing products to be transported. Assuming an average of 10% oil, 9 31 million gallons per year of oil is poten- tially available from an estimated 313 million gallons per year of tanker washings. 8 Washing is sometimes done at sea, at the oil terminal, or at independent facilities. Here too, oil recovery and water disposal is similar to that described for ballast wastewater. INDUSTRIAL PROCESS WASTE OILS The waste oils considered here are those which emanate from industrial processes such as petroleum refining, petro-- chemicals, meat processing, vegetable oil production, wool processing, and coke manufacture. Unlike many of the waste oils discussed earlier, the quantities of process waste oils are not readily estimated from sales, since they represent waste products generated during processing. Petroleum Industry Refining crude oil and producing petrochemicals may result in losses from about 0.1 to 2% of the total pro- cessed. G Modern well operated refineries are expected to keep these losses to under 0.5%. This consists of con— 24 ------- taminated waste oil; tank cleaning residues; evaporation; losses to discharged process, cooling and runoff water; and losses to liquid and solid wastes, including water treatment sludge and floc, and acid and caustic sludges. Refineries do practice recycle of waste oils, using “slop storage tanks and sometimes special rerun towers for oil recovery. The quantities involved are normally well under 1% of refinery throughput, perhaps as little as 0.1%. The largest single source of oil actually lost in refineries is evaporation from tanks, valves, flanges, and the like. This quantity may reach or exceed 0.4%. However, in addition to losses in the refinery itself, considerable additional losses may occur during production on land and offshore, during overland and inland trans— portation (e.g., pipelines, trucks, barges), during transfers and storage at terminals and bulk plants, during conversion to petrochemicals, and during storage and use by the ulti- mate fuel users. Data obtained from various companies engaged in the petroleum industry and from petroleum users make it seem likely that 0.5% of petroleum liquids or more, excluding refinery evaporative losses, are effectively lost to the industr and to users. Based on 1971 statistics shown in Table F-Z, this amounts to 1156 million gallons per year. Spills of volatile hydrocarbons, such as gasoline fractions, land spills, discharge of wastewaters, and oil— containing sludge disposal results in almost complete un- availability of lost oil for recycle. However, tank clean- ing, recovery from wastewater in oil/water separators, and other loss modes do result in a major portion of the esti- mated loss being available for recycle. Although firm data is not available, an estimate of 50% of oil lost directly to the environment via wastewater, disposal of liquids and sludges on the land and in deep wells, and evaporation outside of the refinery appears reasonable. The balance then, 578 million gallons per year, is theo- retically recoverable waste oil. Some of this is recovered and used for fuel and road oil, some is incinerated, and some may be disposed of in other ways. The composition obviously depends on the source and history of the waste oil. Oil and Fat Industry Fats and oils may be classified as vegetable oils, animal fats and oils, and fish oils. These are mixtures of 25 ------- the glycerides of various fatty acids. Some vegetable and animal waxes, which are mixed fatty acid esters of poiv- hydric alcohols other than glycerol, might also be included in this discussion. The distinction between fats and oils is merely melting point, oils being liquids at or near ordinary ambient temperatures. Fatty acids in oils are more unsaturated than in fats. About 24 billion pounds per year of fats and oils were produced in the U. S. in 1969.’’ Vegetable oils are re- covered by expression or solvent extraction followed by extensive refining. Animal fats and oils and fish oils are recovered by rendering and other cooking processes followed by centrifugation and other separation and purification steps. Vegetable oil yields range from about 5-60% depend- ing on the source, for example about 15—18% from cottonseed and soybeans, 34% yield of linseed oil from flaxseed, and 45—50% from shelled peanuts.’ 2 Fish oil yield is on the order of 20%.12 The residual meals or cakes, usually con- taining some oil, are commonly used for animal feed, and in some instances for human consumption, fertilizers, and industrial uses. Many important byproducts are recovered during fat and oil production. The most important uses are in foods, soaps, paint, varnish, and resins. Other important uses for fats and oils and their derivatives are lubrication and hydraulic oils, medicinal oils, plasticizers, wetting agents, and detergents. Waxes are used for polishes, candles, elec- trical insulation, waterproofing, phonograph records, and a variety of other uses. Almost all of the fats and oils produced are consumed, finally appearing in the environment as human waste, soaps in water, and coatings on solid waste. However, as with petroleum, the production, transportation, and use of fats and oils and their raw materials and oily products do pro- duce oily wastes, usually as a low concentration contarni— nation in wastewaters. About 1% of the total fats and oils are recovered as “waste” materials and sold for use in non- critical applications, for example soap manufacture, at a price of 3-15 cents per pound, depending on quality. An- other 0.5% may be lost with wastewaters and wa tewater sludges, incinerated, collected with other solid wastes for disposal, or collected from retail establishments, such as restaurants, by tallow collectors. This 0.5% amounts to about 13 million gallons per year. 26 ------- Coking Ovens Another important source of oils is the coking, or pyrolysis, of coals. The coke is used in blast furnaces for pig iron production and for other metallurgical purposes. Coking, as usually practiced in the U. S., yields about 2-4 gallons of light oil and 8—12 gallons of coal tar per ton of coal. Based on 90 million tons of coking coal, about 270 million gallons of light oil and 900 million gallons of coal tar are produced in this way. The coal tar is usually dis- tilled to produce additional light oil, heavier oils, and pitch. Each of the oil products can be further processed to produce valuable products such as benzene, toluene, xyienes, pyridines, phenols, creosols, naphthalenes, anthracenes, and fuel oils.’ 2 Some of the oils appear in steel plant wastewaters. Others appear as wastes, as with petroleum, in trans-’ portation and usage. If 0.5% waste oil is generated here also, this would produce about 6 million gallons per year of waste oil. SYNTHETIC OILS Although still a small industry, increasing amounts of synthetic oil are manufactured and used for special lubri— cation problems, for example, very low temperatures, very high temperatures, and other severe services, such as jet aircraft. Some of the synthetic oils in use are polymers of olefinic hydrocarbons (e.g. polyisobutylene VI improver), polyalkylene glycols and perfluorinated polyalkylene glycols, synthetic esters (e.g. phosphate and dibasic acid esters), silicone oils, halogenated hydrocarbons, and polyphenyl ethers. 1 3 Waste synthetic oils should be segregated and recycled where possible, because of their high cost, and because they may contaminate otherwise recyclable oils. This has already been discussed with respect to use in aircraft. Some synthetic oil manufacturers do accept synthetic waste oils for reprocessing. 27 ------- SECTION V RECYCLE AND DISPOSAL TECHNIQUES FOR VEHICULAR WASTE OILS The recycling of crankcase drain oils has reached a critical juncture. On one hand, increasing pressure which would lead to the use of every available combustible mate- rial as fuel is everywhere evident. On the other hand, the desire to conserve natural resources and the environment requires that every consideration be given to the possi- bilities of re-refining drain oil to lube oil base stocks. For many years a group of 150 or more small business- men, called re—refiners, provided a means for recycling substantial amounts of crankcase drain oil and other waste lubricating oils back to the public and to industry in the form of bulk or packaged lubricating oils. This group has now shrunk to less than 40, leaving behind the question as to the ultimate destinations of the oil which used to be re—refined. Some of these destinations are discussed else- where in the report. They include road oiling and dust control which leads to runoff and land and water pollution; use as a low sulfur fuel, which leads to contaminant metal particulate emissions to the air (largely lead from crank- case oils) and heat exchanger tube fouling; and dumping. The reasons for the decline of the re—refining industry have been thoroughly discussed elsewhere.’ The problems are complex and manifold, related to taxes, labeling regu- lations, fewer oil changes, increased use of oil additives, some government specifications which prohibit recycled oil, competition from fuel and road oiling dealers, and out- dated technology. The following discussion deals primarily with the problem of technology and current re—refining processes, which produce waste products difficult and expensive to dispose of according to the rigorous standards which are being imposed today. CURRENT PROCESSES FOR RE-REFINING LUBE OILS A summary of 35 waste oil recycling operations is pre- sented in Table 4. The data is based on visits with 30 companies and other information obtained by telephone. A list of re—refining companies is presented as Appendix A. 28 ------- Table 4. SURVEY OF WASTE OIL RE-REFINERS COMPANY PROCESS ACID CLAY’ OTHER PRODUCT CAPACITY, GPD DESICN OPERATING CRANKCASE OIL SOURCES OF R1 DIESEL XX - X - FEED INDUSTRIAL OILS MAJOR MINOR OTHER PRODUCTS LUBE & TRANSMISSION OILS OTHER COMMENT x x x x 1. 2. 3. 4. 5. 6. 7. x x x x x x x I’J 10,000 25,000 24,000 20,000 25,000 40,000 7,000 10,000 12,000 8,000 20,000 6,500 2 5,000 xx xx xx xx (70%) xx xx xx uel oil (10%) ;ear oil, ompressor il ‘enetrating i1s Tournal box )i l x (20%) x x x x Experimenting with acid sludge lime mixture for disposal as powdered sludge Propane extrac- tion (inactive) xx xx xx x xx xx xx l 1 types of aste oils Caustic soda/ silicate P re - treat- ment of feed & distil— lation ------- Table 4. SURVEY OF WASTE OIL RE-REFINERS (Continued) x x COMPANY PROCESS ACID CLAY• OTHER CAPACITY, GPD CRANKCASE OIL — SOURCES OF XX • MAJOR X - MINOR FEED INDUSTRIAL OILS OTHER PRODUCTS LUBE TRANSMISSION OILS OTHER COMMENTS RP DIESEL DESIGN OPERATING 8. 9. 10. 11. 12. ‘3. 14. 0 8,300 2,500 45— 90,000 25,000 8,30 26,00 x x x x Caus tic pre- treat- ment Not apeci fled Mul.tiatag Cont inuo a distn. 5,200 1,800 20— 30,000 (fuel) 2,000 (lub. oil) 2,000 8,300 12,000 12,000 ‘ cx xx x xx xx xx x animal oils x xx xx x Industrial oil (60%) uel (90%) ydraulic oil, Lach inery ubr icants uel (minor) ndustri al us, trans 155 ion oili achinery ubricants ephalt flu oil xx xx x (10%) xx xx xx x 1.5 nun gal. storage capacity 1anning to stop lube oil )rocessing >lans 25% xpansion 2,000,000 gal storage capa- city Planning nodernization ------- Table 4. SURVEY OF WASTE OIL RE-REFINERS (Continued) COMPANY ACID PROCESS CLAY OTHER PRODUCT CAPACITY, GPO CRANKCASE OIL SOURCES OF XX MAJOR x MINOR FEED INDUSTRIAL OILS OTHER PRODUCTS LUBE TRANSMISSION OILS OTHER COMMENTS RB DIESEL DE OPERATING 15. x x 48,000 40,000 x x xx Journal box Planning hydraulic, modernization gear oils 16. x x Continuous -- 2,000 x x x Hydraulic, Trying to sail fuel, Spray Out form oils 17. x x De—emulsif. 22,000 22,000 x x Soluble xx Road, Some custom of indust. & cut- hydraulic induStrial work oil ting oils. oils 18. x x 8,000 8,000 x x Watered xx Fuel, Planning to fuels, asphalt rotary vac. filter trans- blending odor from water former oil problem oils 19. x x Dewater & 25,000 25,000 X Cutting & X Industrial filter in- other in— oils Expanding capacity- dust. oils dust. oil considerable custou hydraulic indus. work — had oil had poiychlorinated biphenyl problem— acid sludge neu- tralized before disposal ------- Table 4. SURVEY OF WASTE OIL RE-REFINERS (Continued) XX — MAJOR X — MINOR PRODUCTS COMPANY PROCESS ACID CLAY OTNER PRODUCT CAPACITY, GPD CRANKCASE — OIL SOURCES OF NEED INDUSTRIAL RP DIESEL 0I1. .S OTHER LUBE I TRANSMISSION OILS OTHER COMMENTS DESIGN OPERATIN 20. x x 6,000 xx Transmission Trying to oil, form I sell out spray oil (little pro- cessing) 21. x x 9,000 0,000 x x xx Journal box No longer oil, diesel has Bite lubes for acid sludge disposal— may go to dehydration only to make fuel. I ’ , 22. Dietilla— 30,000 x Contami— x uel ‘one tion nated flue is 23. x x 2,500 2,500 — — xx orin oil 24. x x Caustic 6,000 4,000 x —— xx 35. x x 4,000 4,000 x —— xx 26. x x 2,000 2,000 x —— xx 27. Distilla- X X X Jet Fuels, 1ev ra—reIi— tion fuels, asphalt flux ning process inter- under devel. face Customers fuels segregate oils. ------- Table 4. SURVEY OF WASTE OIL RE-REFINERS (Continued) PRODUCTS COMPANY PROCESS ACID .ç1 I OTHER CAPACITY GPO DESIGN OP&RATING CRANKCASE OIL. X-MINOR SOURCES OF FEED INDUSTRIAL PR DIESEL OILS OTHER LUBE a TRANSMISSION OILS OTHER COMMENTS 28. 29. 30. 31. 32. 33. 34. 35. * Norma 4,000 6,000 6,000 12,500 5,000 1,900 * * —— 10,000 —— x —— 15,000 x x —— 6,000 * x —— 7,500 * x —— —— — x Distilla— 25,000 tion x x —— 2,400 * x —— 20,000 ly inc udes an oil stri ping st p. * x x * x x x x * x x x x Cutting and cooling oils Waste diesel fuel Solvents Formerly did railroad bus. custom indus. work major business r Journal oil, industri- al oils Hydraulic oil Fuel Journal box oil Chain oi3 chemical carrier Sweeping compound Trans form oil Journal box oil, diesel lube xx xx xx x x ------- As can be seen from Table 4, the acid/clay treatment process has dominated the re—refining industry. Of the 27 companies producing lube stocks, 24 use acid/clay treatment. A few use distillation/clay treating which,has been devel- oped as an alternative. Following is a discussion of these two processes. A detailed discussion of waste products produced during processing is provided in Section VIII. Acid/C1ay Treatment A process scheme for a typical acid/clay re-refining of waste automotive oils is shown in Figure 1. The process for diesel engine waste oils differs only in process con- dition details. Incoming materials are unloaded into a partially sub- merged tank directly from the collection trucks. This receiving tank must be fitted with grids and screens to remove the debris which is normally found in the waste ma- terials. The recommended tank would be large enough to accept the entire truck load and permit any free water to settle. The oil is then decanted and transferred to feed storage tanks. The water layer is pumped to a skimmer and then to wastewater disposal. The proper handling of the raw material is extremely important to a smoothly operating facility. Based on data obtained from re—refiners, it is believed that a typical analysis of oil in the storage tanks would be Water 3.5% by volume Naphtha 7.0% by volume Oil, etc. 89.5% by volume More detailed analyses were presented in Tables 1 and 2. The feed is pumped through a steam heat exchanger to the flash dehydrator which operates at 300°F and atmospheric pressure. The steam/oil overhead is condensed and sepa- rated; the oil to light end storage to be used for fuel, and the water to the wastewater disposal system. The dehydrated oil is sometimes further stripped of light fractions prior to acid treating, but more often it is pumped directly to dry oil tanks, where it is stored and cooled. It can be stored for 2 to 4 days before it picks up appreciable moisture, which tends to increase acid requirements during the following step. After 48 hours 34 ------- VOLATILE DIST1LLATES TO FUEL WATER TO SUMP PRE-TREATMENT HEATER LUBE STOCK TO STORAGE FLASH DEHYDRATOR FEED WATER TO SUMP 93% DEHYDRATED 300F u - I JACKETED Al R ACID SLUDGE CLAY SLURRY ACID TREATMENT CLAY TREATMENT RE-REFINING BY AN ACID/CLAY PROCESS FIGURE 1 ------- storage the oil temperature has dropped to approximately 100°F. Dry oil is pumped to one of several acid treating units. These units are steam jacketed and are agitated with plant air. Four to six volume percent of 93% sulfuric acid is added to the reactor where the temperature is maintained at about 100°F. Although fresh acid is usually used, several re—refiners use spent alkylation acid from petroleum re- fineries. The oxidized products contained in the oil are usually removed from the oil by the acid within 24 hours, but up to 48 hours may be required depending on the raw material. The acid sludge, containing oil contaminants and ash, separates from the oil and is drawn off from the re- actor bottom. Acid sludge analyses are presented in Section VIII. Acid sludge disposal, usually done in landfills or lagoons, is one of the most critical problems in this pro— ce S s. The acid-treated dehydrated oil is then transferred to the steam stripping-clay treating operations. The clay treater consists of a slurry tank, a tower, a condenser, and a direct fired heater through which the oil is circulated. The capacity of the clay treater is usually on the order of 5000 to 10,000 gallons. It is equipped with a sparger for direct introduction of steam. After the batch has been transferred to the clay treating tower, the temperature is brought up to 550-600°F by circulating through the heater, and live steam is intro- duced. The purpose of the stripping operation is to re- move the remaining light fuel fractions and odorous com- pounds which may be present. The steam—stripped materials are condensed, and the oil separated from the water. The water fraction is treated through the wastewater disposal system, and the oil fraction used as plant fuel. The heat is discontinued after 12—15 hours and part of the oil is diverted to the clay slurry tank. The oil temperature is permitted to drop to approximately 400°F. The clay, often a 50% mixture of activated clay and diato- maceous earth (200-250 mesh), is mixed into the circulating oil. The clay dose is approximately 0.4 pounds per gallon of oil. The clay removes color bodies and colloidal carbon by adsorption. The hot oil (250-350°F) containing the clay is filtered through a plate and frame filter press, sometimes followed by a second filter in series. The clarified oil is then 36 ------- stored either prior to or after having the necessary addi- tives blended into the stock. The filter cake, a mixture of clay, impurities, and oil, is uneconomical to separate and recover after filtration in small plants. It must therefore be discarded, usually by landfill. Paper, which is often used as a fulter medium in the plate and flame press, is discarded with the cake. Odors can be a problem with acid/clay re-refining. These may emanate from storage tanks, processing vessels, wastewater treatment facilities, acid sludge, and oil spills. In some re—refining operations, odors can be controlled adequately by sealing open vessels and tanks, good house- keeping, and by venting process vessels to furnaces where vapors are burned with the normal fuel. Other plants have resorted to control methods such as caustic scrubbers to treat gases vented from the treating steps. The wastewater system varies from plant to plant, de- pending on cooling water and vacuum facilities, water run- off problems, land availability, water contamination of feedstocks, governmental regulations, and availability of a local sewage plant. A typical installation includes an API separator with oil skimming, pH control, some water recycle, and discharge to a sewage plant. Sewage plants will nor- mally accept water with oil contents up to about 100 ppm, a quality level relatively easy to meet. Overall lube stock yields of 45-75% have been reported for acid/clay treatment. These obviously depend upon operating conditions and feed composition, with water sludge, ash, and gasoline contents being most critical. For the feed reported here (3.5% H 2 0, 7.0% naphtha), greater than 70% yield is believed to be possible with careful operation, but a typical yield might be closer to 60-65%. The oil produced by the acid/clay process can be con- sidered a solvent neutral blending stock having an SUS (Say- bolt Universal Second) viscosity generally between 55 and 58 at 210°F. This is equivalent to an SAE 20 oil. The lube stock can be blended to a finished lube by the re-refiner or sold directly to a jobber with blending facilities. For SAE 30 oil, the viscosity is increased to 58—70 SUS (usually 60-65) at 210°F by the addition of virgin bright stocks, or by the addition of polyisobutylene. The viscosity index of re-refined oil normally exceeds 37 ------- 90, even without additional additives. However, convention- al additive packages are used for high viscosity index re- quirements and for high performance specifications. Addition- al data and discussion of oil properties and specifications are available. 1 4, 1 5 Distillation/Clay Treatment The distillation/clay process overcomes the serious acid sludge waste disposal problem connected with acid/clay treat- ment. The following description is based partly on work supported by EPA 16 and partly on patent literature. ,’ 7 ’’ 8 The pretreatment and distillation steps are shown in Figure 2. The waste oils are received at the plant in the usual manner previously described. The oil is dehydrated in a flash tower by heating to 3000F in a direct heater, using as fuel light fractions generated during processing. The flash tower operates at atmospheric pressure and 3000F. The oil/ water overhead is condensed and sent on to an oil decanter. The water phase is separated and removed to the wastewater disposal system. The oil layer is used as fuel. The flash tower bottoms are passed through a heat ex- changer to reduce the temperature to approximately l000F. Light oil, having a boiling range of 150-250 0 F is introduced into the dehydrated oil stream. The quantity used is ap- proximately 20% based on oil volume. A small amount of caustic, 0.2—2.0%, dependent on feedstock emulsions, is also introduced. The addition of the light oil and caustic tends to break the oil-water emulsion and precipitate solids. These materials are removed by centrifugation. The sludge from the centrifuge can be disposed of separately, e.g. by landfill, or it can be mixed with the distillate bottoms as described later. The naphtha/caustic/centrifuge pretreatment. step may not be a necessary adjunct to distillation, but it does tend to eliminate some of the materials which can cause fouling and erosion in the vacuum distillation furnace and column, and associated heat exchangers. The centrifuged oil is then pumped to the vacuum dis- tillation tower through a direct fired heater. The furnace heats the oil to about 700°F. The columns operates at a vacuum of 27 inches of mercury. The overhead naphtha, with a boiling range as shown in Table 5, is condensed, cooled, and used as fuel in the plant. 38 ------- COO LER FEED FUEL TO STORAGE FLASH TOWER VACUUM VACUUM PUMP FURNACE CAUSTIC & NAPHTHA FROM STORAGE NAPHTHA TO STORAGE BOTTOM TO STORAGE SLUDGE PRE-TREATMENT I LUBE DISTILLATE TO CLAY TREATING I (OR HYDROTREATING) VACUUM DISTILLATION VACUUM DISTILLATION OF CRANKCASE WASTE OIL FIGURE 2 ------- Table 5. PHYSIC PROPERTIES OF VACUUM DISTILLATION FRACTIONSI 6 * Afl OUflt, Boiling Specific Flash Pt. Frac- % of Viscosity Range Gravity (Open Cup) tion Name Feed Color SSU 0 F ________ __________ 0.7972 1 Naphtha 1.5 145—446 46° API 2 Baro— 0.8602 metric 9 4 1/2 33—34@ 100°F 400—680 33° API 3 Light 36 8 100 @ 100°F 680—792 0.8735 Side— 39.1 @ 210 0 F 30.5° API 350 0 stream 4 Heavy 28 8 222 @ bOor 792—900 0.8789 Side— 47.6 @ 210°F 29.5° API 430 stream 5 Bottoms 22 dark 284 Sayb. 900+ 0.9937 Furol 10.9° API @ 122°F Residue, Water + Loss 3.5 1.0 10° API Total Av. S.G.of 100% Feed Stock 0.9035 25.1° API * No pretreatment ------- The bottoms, which contain almost the entire ash content of the feed, are cooled and used as fuel, for blending into asphaltic products, or stored in a lagoon. One or more middle distillate cuts are taken (Table 5) and sent to clay treatment for finishing as a lube blending stock. The clay treatment is similar to that described for the acid/clay process except that prior stripping is unnecessary and the clay quantity may be reduced to as little as 0.125 lbs. per gallon of oil. The filter cake obtained during filtration is disposed of in the usual manner. The yields for this type operation, based on input oil, are approximately 70%, comparable to the best acid/clay treating operations. Product quality should also be com- parable, although viscosity at 210°F seems to be somewhat lower due to bottoms removal. By taking more than one side—stream from the vacuum distillation column, it may be possible to obtain a part of the yield as higher viscosity lube stocks. The properties of some distilled motor oils are shown in Tables 5 and 6. It is believed that clay treatment leaves most of these properties relatively unchanged, except for improvements in color, neutralization number, and reductions in oxygen and nitrogen content. Odor and wastewater problems are not believed to be any more serious with this process than with acid/clay treat- ment. However, when a barometric condenser is used for the vacuum column, the quantity of contaminated wastewater is very large. Water or air—cooled surface condensers are preferable to barometric condensers, but are more expensive, though the increased cost must be balanced against the de- creased cost of wastewater treatment. POTENTIAL PROCESSES FOR RE-REFINING LUBE OILS At least two processes are available for re—refining of crankcase drain oils that are not now in use in the U. S. These are: a solvent extraction process followed by treat- ment with reduced amounts of acid and clay as compared to the conventional process; and a vacuum distillation process followed by catalytic hydrogen treating instead of clay treating as discussed earlier. 41 ------- Table 6. PROPERTIES OF DISTILLED USED MOTOR OILS 1 Texas(B) Texas(A) California New York Yields: Overhead, vol.% 0-77 3.5_89.9* 0—82.9k 0—89.9 wt. % 73.5 85.2 79.1 85.7 Bottoms, wt. %. 26.5 14.8 21.9 14.3 DISTILLATE: Vis. @ 100°F, SSEJ 151 197.9 188.8 144 Vis. @ 210°F, SSU 43.6 46.5 46.0 43.1 Viscosity index 104 105 105 105 Color, ASTM 3.5 7.5 8.0 Lt. 7.0 Neut. Number 0.38 0.59 0.23 Polar compounds, wt. % Sulfur 0.09 0.12 0.13 0.12 Oxygen 0.19 0.17 0.35 0.16 Nitrogen 0.04 0.03 0.02 0.02 Boiling range, °F 380—1050 530—1010 472—1022 462—1006 *0...3.5 volume fraction of water and light hydrocarbons was collected overhead, separate from oil product. +Heat treated while purging with nitrogen for 24 hours at 270°F to drive off water prior to distillation. ------- Solvent Extraction/Acid/Clay Treatment The solvent extraction/acid/clay process is a relative- ly new development in the re-refining of waste lubricating oils. It has been tried experimentally in the U. S.,but no plants are now in operation. A 9—million-gallon-per-year plant is operating in Italy based on a process developed by Institut Francais du Petrole (IFP).’ 9 The basis for the process is the use of propane to selectively extract the base lube stock from the additives and impurities. The propane, containing dissolved oil, is removed from the extractor, while the high boiling, dark colored asphaltic and oxidized hydrocarbons and suspended solids are removed from the unit bottom as a residue. The bottoms are mixed with a fuel oil and used as plant fuel, or otherwise disposed of; whereas the propane is flashed from the oil and recycled. The process scheme, as shown in Figure 3, consists of the following: a. Thermal dehydration b. Precipitation and solvent extraction C. Propane recovery d. Acid treatment e. Clay treatment and filtration The incoming waste oil is unloaded into a receiving tank as described before. The feed for the process is pumped through the steam heat exchanger to the flash de-- hydrator, operated at about 300°F and atmospheric pressure. The overhead is condensed and drained into an oil separator. The water layer is disposed of through the wastewater dis- posal system; the oil layer is either stored or processed immediately in the solvent extractor. The oil is pumped to the precipitation tower (solvent extractor) via a heat exchanger. The propane is also heated and introduced into the tower approximately 1/3 up from the bottom. The oil is introduced 1/3 down from the top. The solvent extractor operates at several hundred pounds per square inch pressure. The propane—oil solution (the oil having dissolved in solvent) goes overhead due to specific gravity differences, whereas the precipitate flows to the extractor (contactor) bottom. The counter—current flow is important to efficient extraction. Steam coils, installed at the tower top and 43 ------- FUEL OIL PRE- DISTILLATION EXTRACTION PROPANE SEPARATION PROPANE RECOVERY FINISHING RE-REFINING BY A PROPANE EXTRACTION PROCESS FIGURE 3 FEED LIGHT OIL TO FUEL WATER TO SUMP PROPANE MAKE-UP CONTACTOR 93% CLAY SLURRY RESIDUE ACID SLUDGE FURNACE LUBE STOCK TO STORAGE ------- bottom, control the temperature at the desired level in the l00—200 0 F range. For very high quality lube oil, the solvent-to-feed ratio would be approximately 20:1. This will vary and must be de- termined for each feedstock. The lowest solvent—to-feed ratio would be 1:1, yielding poor quality oil in the raffinate. Current operations are believed to be in the vicinity of 15:1. A small amount of the fuel oil is added to assist in the flow of the high viscosity residue from the unit. The residue is released from the extractor by a liquid level controller. The fuel oil-residue mixture is stored for use as fuel for the direct fired heaters, or for other means of disposal. The propane—oil solution is flashed through a pressure reducing valve into a solvent flash drum. It is usual to use a two—stage flash to separate the propane and oil. The propane gas is then liquefied and recycled. The lube oil is sent on to acid/clay treatment as des- cribed in the acid/clay process. The solvent extraction process requires only about 2% of 93% sulfuric acid by volume based on oil, compared with 4-6% for the acid/clay process. After treatment with about 0.15 lbs. of clay per gallon at 300°F and filtration, the lube oil quality is reported to be superior to the acid/clay product, at least in terms of color and color stability, and perhaps vis- cosity. 1 9 Although the quantities of acid and clay required in the IFP process are greatly reduced, a disposal problem still exists. No acid sludge analysis is available, but the metals content, e.g. lead, is undoubtedly lower than for the acid/clay process. Most of the metals and other impurities appear in the fuel oil-residue mixture. Therefore, the use of this material as a fuel is environmentally questionable, unless accompanied - by a considerable investment in air pollution control equipment. Boiler tube fouling which will also occur due to the ash content, also detracts from the use of the fuel oil- residue mixture in normal applications. 45 ------- Distillation/Hydrogen Treatment The distillation/hydrogen treating process is similar to distillation/clay treating, except for the finishing step, shown in Figure 4. Although this scheme is widely used in petroleum refineries, no plants are now operating on waste oils. However, two European installations to be started up in the period 1974-76 are apparently planning to combine hydrogen treating with the IFP propane extraction process previously described. 2 0 As described before, a pretreat section can be used ahead of vacuum distillation to reduce fouling and erosion problems. The distillate (sidestrearn) from the vacuum distillation column is heated using hydrotreating product and an oil fired heater before being mixed with recycle and makeup hydrogen. The hydrogen-oil mixture is contacted with a standard commercial hydrotreating catalyst in a fixed bed. The hydrogen reacts with oxygen and nitrogen—containing impurities and unsaturates. The pressure is reduced in two flash drums in series and the recovered gaseous hydrogen is recycled. The puri- fied oil is used to preheat the incoming feed and then injected into a vacuum or stream stripping column where the small amount of volatile materials which may have formed is removed. The purified product leaving the stripper can be used to preheat vacuum distillation feed before final cool- ing and storage. Recent work, summarized in Table 7, has shown that the hydrogen treated distillate can match typical properties of 150 vis neutral lube blending stock. Hydrotreating con- ditions used in this work were 650 psig., 650°F, 800 standard cubic feet of hydrogen recycled per barrel of feed, and a space velocity of 1.0 v/v/hr (volumes of feed per hour per volume of catalyst). The distillation bottoms which contain almost all of the objectionable impurities can be disposed of as dis- cussed before. However, work is now underway, under an EPA grant, for use of this high lead material (from automotive crankcase waste oil) as a fuel in a secondary lead smelting operation. If this is successful as expected, the dis- tillation/hydrogen treating scheme holds promise as being the first re—refining process available without a solid waste disposal problem. 46 ------- HYDROTREATED LUBE DISTILLATE LU BE DISTILLATE COOLER COOLER TO FUEL CATALYTIC HYDROTR EATING REACTOR -4 WATER TO WASTEWATER TRE&TMENT STEAM STRIPPER STEAM P1*/ DISTIL LATE LUBE STOCK TO STORAGE VACUUM DISTILLATION FEED TO VACUUM DISTILLATION FURNACE HYDROTREATING FIGURE 4 ------- Table 7. DISTILLATION AND HYD OGEN TREATMENT OF USED MOTOR OIL Distilled- Hydrofined Typical oil 650 psig.,l v/v 1 properties Used* Used+ 800 scf/b H of 150 vis motor oil dis- 2, neutral lube oil tillate 550 0 F 600°F 650°F base stock Vis. 100 0 F, sSu... 237 164 162 159 156 157 Vis. 210°F, SSu... 55.4 44.3 44.1 44.1 43.8 43.0 Viscosity index..... l66i 102 101 104 103 104 Color, ASTM . Black Black Lt. 1.5 Lt. 1.0 Lt. 1.5 1.5 Color stability,TR.. 18 16 17 (16 hrs 212°F) Gravity, 60°F , 26.0 30.7 31.3 31.4 31.5 31.8 Flash, COC,°F 200 440 420 430 410 415 Pour point, °F —30 +15 +20 +20 +15 +15 Neutralization No... 5.87 0.51 0.0 0.0 0.0 0.01 Con, carbon, wt. %.. 3.33 0.01 0.001 0.001 0.001 0.01 Copper strip corr... ..... 2 2 1 1 (3 hrs & 212°F) Sulfur, wt. % 0.30 0.12 0.053 0.031 0.012 0.08 Nitrogen, wt. % 0.08 0.018 0.006 0.006 0.002 *Used crankcase oil from a 30,000-gallon tank at the Sewell’s Point terminal (4/2/70). +35O—945 F cut (14—90 vol. %). *The light materials in used motor oil obscure the determination of the VI of the base oil. ------- As for other environmental problems, the wastewater problem is similar to other re—refining processes and can be overcome by conventional design. A scrubber may be re- quired to remove impurities from the hydrogen purge stream and other minor gaseous discharges. Additional work on catalyst life and hydrogen con- sumption would be desirable before commercialization of this process. Other Re-Refining Approaches Many proposals for alternative re-refining processes have centered about the possibility of using solvents and/ or chemical treating agents. None of these approaches is in use for producing lubricating oils, although some claims are made as to the efficacy of caustic, 2 ’ isopropanol 22 , and butanol treatments. 2 3 The use of several chemical flocculants and solvent precipitants such as aluminum chloride, triethanolamine, and trichioroethylene were studied by Armour Research Foundation about 1960, but they showed little promise at the conditions used. 2 Walter C. McCrone Associates in 1971 investigated a number of non—acid flocculents as alter- natives to sulfuric acid for treating drain oils. 25 Alka- nolamines and a diglycolaniine were found to be the most effective. These research programs were supported by the Association of Petroleum Re—refiners. More recently, National Oil Recovery Corporation (NORCO) under sponsorship of the U. S. Environmental Protection Agency, has investigated a number of materials for waste oil treatment, some of which hold some promise as being economi- cally effective re—refining agents. A report on the NORCO work should be available in 1974. Some of the above and other potential re-refining ap- proaches have been described in a recent state-of-the-art report. 1 5 49 ------- EVALUATION OF WASTE LUBE OIL DISPOSAL TECHNOLOGY An economic comparison has been made of the re—refining schemes previously discussed. Re-refining to lube stocks has also been compared with the cost of distillation to pre- pare a clean fuel oil, and combustion in boilers for steam production as alternative methods for using crankcase waste oils. Other waste lubricating oils and disposal methods are considered. Cost Basis The cost basis chosen is meant to provide: I. comparisons of various re-refining technologies. 2. comparison of re—refining with other environ- mentally acceptable methods of using crankcase waste oils. 3. a measure of the attractiveness of new re—refining facilities to produce lubricating oils from crank- case waste oil not now being recycled. The size of new re—refining facilities should be as large as possible for efficient operation, but oil collection costs, which increase with collection area, provides a major re- straint on plant size. A grass roots acid/clay plant accepting 5 million gallons per year of crankcase waste oil (or drain oil), as will be seen, is about a minimum economic size, resulting in close to break—even operation. All comparisons were made for this size operation. At the 5 million gallon per year size, as many as 80 new facilities could be built to handle the esti- mated 400 million gallons per year of drain oil not now being recycled (excluding industrial lube oils). Operation was assumed to be 24 hours per day, 5 days per week, 50 weeks per year. This type of operation allows repair and maintenance on weekends as necessary, while mini- mizing the complexity of manning, and providing flexibility for increasing plant capacity when necessary. It is the type of operation now most common in this industry. Costs might be reduced somewhat by continuous 7—day-per—week operation with shutdowns as required for repair and main- tenance. 50 ------- The costs (mid-1973 basis) presented are general and meant for orientation purposes only. They are based on process design calculations, but not detailed mechanical designs. Other cost bases are included in Tables 11 and 12. Process Comparisons The costs for the various alternatives have been sum- marized in Table 8. Costs for the acid/clay process are about 3 to 5 /gal. of lube product higher than for the alter- native re—refining schemes, which were essentially a stand- off within the accuracy of this comparison. A new German/ Israeli development described in Section VII reduces acid consumption and cost in the acid/clay process. The distillation/hydrotreating alternative has the ad- vantage of producing no waste products, but the process has not yet been demonstrated on a commercial scale for drain oils. Available experimental data is promising. 26 The propane extraction process, followed by acid/clay treatment at lower levels than ordinarily used, is offered in the U. S. by IFP, a French company. 19 A plant based on this process is now operating in Italy. Pilot plant work on a similar process has also been conducted in the U. s 27 The disadvantage of propane extraction is that, although acid and clay waste are reduced, they are not eliminated. The process also produces a high ash fuel oil which will cause tube fouling problems when burned in ordinary com- bustion equi ment, as has been experienced in the Italian plant cited. ° The distillation/clay process economics are based in part on patent descriptions. 17 ’’ 8 It is believed that two re—refiners in the U. S. operate plants at least similar to these descriptions. The process eliminates acid sludge, but spent clay disposal remains as a problem, though much less serious. In addition, a sludge is produced during pre- treatment, if carried out according to the referenced patent, and a high ash bottoms product results from the distillation step, as is true in all the processes which involve the dis- tillation step. The disposal of the bottoms and solids residues was discussed earlier. The production of clean fuels by distillation does not appear attractive, as compared to the preparation of lubes, unless fuel prices increase significantly relative to lubes. 51 ------- TABLE 8. SUMMARY OF CRANKCASE WASTE OIL PROCESSES Grass Roots Econ.- Primary Wastes 5 Million Gal/Yr. Process Primary Product & Byproducts Investment Op. Cost Comments Acid/Clay Lube blending Acid sludge, $1,153,000 2l.9 /Ga1. Widely used stock spent clay Lube in U. S. Extraction/ Acid/Clay Lube blending Acid sludge, $1,363,000 l8.4 /Gal. One operating stock spent clay; high Lube plant in Italy. ash fuel byproduct Distillation! Clay Lube blending Spent clay; $1,173,000 17.3 /Gal. At least two stock high ash fuel Lube plants in U.S. byproduct U, Disti l lation/ H 2 Treating Lube blending High ash fuel $1,342,000 l9.0 ’/Gal. Under stock byproduct Lube development. Distillation Fuel oil (diesel High ash fuel $ 930,000 l4.6’ /Gal. Can make high fraction could byproduct Fuel oil quality fuel, possibly be re— but economics covered) questionable. Contro1le Steam Ash concentrate $ 492,000 80 /l00O Speculative- Combustion Lbs. Steam fine particle recovery difficult. * Includes 3 /gal. feed cost and 10%/yr. depreciation, but excludes return on investment. See Tables 9,10, and 11. for details. ------- TABLE 9. CRANKCASE WASTE OIL PROCESSING CAPITAL INVESTMENT Basis: 5 Million Gal/Yr. Raw Oil; 250 Days/Yr. Operation Process Acid/Clay Extr/Acid/Clay Dist/Clay Dist/H 2 Dist. Comb. Product Lube Lube Lube Lube Fuel Steam Investment, $1000 Process Equip. 662 829 609 773 423 200 Storage Facil. 367 402 440 440 400 200 Office & Lab. 32 32 32 32 32 32 U i 1061 1263 1081 1245 855 432 Land & Site Improvement 92 100 92 97 75 60 1153 1363 1173 1342 930 492 ------- TABLE 10. POTENTIAL PROFITABILITY OF CRANKCASE WASTE OIL PROCESSES Basis: S Million Gal/Yr. Raw Oil; 250 Days/Yr. Op.ration Process Acid/Clay Extr./Acid/Clay Dist./Clay Dist.J 2 Diet. Incin. Product Lube Oil Lube Oil Lube Oil Lube Oil Fuel Oil Steam Investment, $1000 1153 1363 1173 1342 930 492 Oper. Costs (Exci. Feed ) 17.760/Gal. l4.86 /Ga1. 13.380/Gal. 15.020/Gal. lO. 67 0/Ga l. 50.540/1000 Lbs. Per Unit of Product Feed Costs t 34/Gal. Of Raw Oil 4 7 3•57 3.95 3•95 3.95 29.35 Total Costs 21.930/Gal. 18.430/Gal. 17.330/Gal. 18.974/GaL. 14.620/Gal. 79.890/1000 Lbs. Product Credits Lube Stock • 220/Gal. 22.00 22.00 22.00 22.00 — — Fuel Oil 8 150/Gal. — — — — 15.00 — Steam 9 81.50/1000 Lbs. — — — — — 150.00 High P sh Fuel Oil 9 80/Gal. — 0.59 0.55 0.55 0.55 — 22.000/Gal. 22.590/Gal. 22.550/Gal. 22.550/Gal. 15.550/Gal. 150.000/1000 Lb.. Lube Lube Lube Lube Fuel Oil Steam Profit (Before Tax Per Unit Product 0.070/Gal. 4.160/Gal. 5.220/Gal. 3.580/Gal. 0.930/Gal. 70.110/1000 Lbs. 8/Yr. 2,500 174,700 198,400 136,000 35.400 358,000 %/Yr. Return 0.2 12.8 16.9 3.0.1 3.8 72.8 Return, %/Yr. Before Tax Lube Stock 8 224/Gal. 0.2 12.8 16.9 10.1 Lube Stock B 250/Gal. 9.6 22.1 26.6 18.6 Lube Stock • 300/Gal. 25.6 37.5 42.8 32.8 ------- TABLE 11. CRANKCASE WASTE OIL PROCESS OPERATING COSTS Basis: 5 Million Gal/Yr. Raw Oil; 250 Days/Yr. Operation Process Product — Type — Yearly Prod. Acid/Clay Lube Oil. 3.6 x io6 Gal. Extr./Acid/Clay Dist./Clay Lube Oi 3.8 x 10 Dist./H 2 Gal. 4.2 Lube il x 10 Gal. Lube Yield Investment, $1000 ‘ ant u’; 1061 1263 1081 Land & Site 92 rr 100 r 92 irn Lube Oil 3.8 x 106 Gal 1245 97 fl Dist. Fuel Oil 3.8 x Gal. 855 75 930 cr emicais 93% H 2 S0 4 8 3 /Lb. Clay @ 3.30/Lb. H 2 @ 0.40/SCF Propane 8 20/Lb. Other Utilities Elec. Power 8 30/KWH Water 8 50/1000 Gal. No. 6 Fuel Oil 8 120/Gal. Plant Labor wages @ $11,000/Yr. Supplies & 011 8 50% Maintenance Ins. & Local Taxes 9 3% Invest./Yr. Waste Disposal Incin . Steam 511 x 106 (85,200 Lbs./Hr.) 432 60 Basis’ ç/G l . 1.06 3.18 0.4 1.32 0.1 0.30 0.017 0.09 8 men 2.44 — 1.22 5%P/Yr. .1.47 — 0.96 — 0.50 Basis ’ 0.36 0.15 0.03 0.3 0.04 0.037 8 men 5% P/Yr. c/Gal . 1.08 0.50 0.06 0.90 0.20 0.44 2.10 1.05 1.50 0.97 0.20 Basis . i/Gal. Basis’ c/Gal . .125 0.41 — 3.6 0.2 0.02 8 men 5%P/Yr. Depreci at ion 9 10% P/Yr. Indirect Costs Salaries $80,000 Per Yr. Suppl.& OH 8 50% — Oper. Cost (Excl.Feed ) — 0.40 0.2 0.60 0.021 0.11 8 men 2.32 — 1.16 5%P/Yr. 1.42 — 0.93 — 0.03 — 2.84 $80,000 2.11 Per Yr. — 1.05 13.38 C/Gal. Lube 1.44 0.26 0.60 0 . 10 2.32 1.16 1.64 — 1.06 — 3.28 $80,000 2.11 Per Yr. — 1.05 15.02 C/Gal. Lube Basis, c/Gal . — 0.40 0.15 0.45 0.02 0.10 7 men 2.03 — 1.01 5%P/Yr. 1.13 — 0.73 — 2.25 $65,000 1.71 ‘er Yr. — 0.86 10.67 C/Gal. Fuel Oi 2.95 2.22 1.11 17.76 C/Gal. Lube Bas.s’ c/i.uuu lb . 2.35 7.05 0.3 1.50 S men 10.76 — 5.38 6%P/Yr. 4.24 — 2.89 — 8.45 $35,000 6.85 Per Yr. — 3.42 50.54 0/1000 Lb Ste az — 3.01 $80,000 1.90 Pet Yr. 0.95 14.86 C/Gal. Lube * Per unit of product. ------- The possibility of taking a light fraction of this material as diesel fuel is under study.. Where a market for steam exists, it appears that a com- bustion system with well designed air pollution control equipment could be attractive. If scrubbers are used, for example high energy venturis with 100 inches of water pres- sure drop, a water treatment system for solids recovery must be included. The economics presented here are for orientation pur- poses. Each proposed plant must be designed in detail to account for the range in feedstock compositions and quanti- ties expected, the peculiarities of a particular collection system, local problems of waste disposal, etc. The yields assumed are somewhat optimistic, though attainable with some feedstocks and careful operation, but ot representative of most existing re—refineries. An assumption inherent in the economic comparison of the lube producing processes is that product quality is the same for each process. Insufficient data is available to properly examine the validity of this assumption. Other Disposal Techniques Uncontrolled combustion (with little or no air pollution control), road oiling, and dust control are commonly used alternatives for waste oil disposal. These uses may return anywhere from 1 to l2 per gallon more to the waste oil collector than the 2-7 per gallon of raw oil paid by a re- refiner. For example, a collector may take a dust control contract for l0-l5 /gallon, laying down the oil directly from his collection truck. The re—refiner has a very difficult time competing with such uses for waste lubricating oils on a pure price basis, particularly in times of fuel oil shortage. However, both resource and environmental conservation should be important considerations when contemplating alternative methods for waste oil disposal. Drain Oil as a Fuel — The uncontrolled use of automotive drain oil as a fuel could result in the discharge of 30—40 million pounds per year of lead, plus other metal containing particulates, to the atmosphere. This is, of course, true whether or not the waste oil has been blended with cleaner fuel to avoid exceeding source and air quality standards and 56 ------- to minimize heat transfer surface fouling. This quantity of lead represents about 3-4% of U. S. mine production in 196911 (or about 1% of consumption). Since U. S. lead reserves are limited, some is now imported,’ ’ good conservation practice dictates against indiscriminate emission of lead. Lube oil conservation is also an important consideration. Lubes are now in short su lv, consumption having caught up with production capacity. The production of lubes, which requires a series of expensive refining steps from specially selected crude oils, is not readily expanded. Health hazards associated with the accumulation of lead in the body are well known. Although uncontrolled combustion of waste oils contributes much less lead to the atmosphere than is emitted from gasoline combustion in engines, the amount is significant as discussed above. While health and other environmental effects are not fully understood, there is undoubtedly some risk in uncontrolled combustion, a risk increased by the fact that the particle size of the bulk of the emitted particles is likely to be less than one micron. 29 In view of the potential attractiveness of re-refining, this risk does not seem to be worth taking. If new restrictions on lead in gasoline are maintained, automotive drain oil lead will gradually decrease, but significant levels will persist for many years. Furthermore, pressures to decrease gasoline consumption in automobiles could possibly result in a return to high compression ratio and the renewed need for lead anti—knock compounds. An unconfirmed report that drain oils have been used as a fuel for drying of hops (used in beer) is another illus- tration of the need for controls. Many animal and human foodstuffs undergo direct fired drying as a processing step where contamination could result from the unsuspected use of drain oil blended into a clean fuel. Drain Oil for Road Oiling and Dust Control - A study of run- of f of oils from roads treated to suppress dust clearly shows the potential environmental problems which can result. Conservation of lead and lubrication oils, as discussed above, also dictates against this practice. In spite of this and the availability of more suitable oils, over 300 million gallons per year may be used for this purpose (see Section X, Table 26). 57 ------- Asphalt — Some drain oil and distilled drain oil fractions are used as cutting stocks for asphalt manufacture. Little is known about the environmental effect of such use. Most of the metallic compounds, including lead compounds, present in the oil are relatively insoluble in water and presumably coated with viscous asphaltic materials. Therefore, little rain leaching would be expected for asphalt uses such as roofing and roads. Form Oil — Drain oil and drain oil fractions are also sold for coating forms used for concrete and other building materials. Presumably this drain oil eventually reaches the environment through disposal of forms to landfill, or burning of wooden forms. Chemical Raw Materials - Drain oil fractions retovered by the distillation/clay process (bottoms) and other processes are reported to be useful in rubber products. 6 However, raw drain oil cannot be used, so that this application is not a true competitor for re—refining, but rather may be comple— mentary. Paraffinic materials, such as drain oils, are potenti- ally useful as feedstocks for steam cracking to produce ethylene, propylene, butenes, and butadiene, the most im- portant petrochemicals used in plastics manufacture. The market is so large that it could theoretically use all of the waste automotive and industrial lubricating oils avail- able. However, the presence of ash dictates against the use of raw oils in conventional steam cracking tubular furnaces. The distilled product from drain oil would probably make a good steam cracker feed, but as has been shown, the cost for producing this product in a 5 million gallon per year plant exceeds fuel price. A careful study of yields and costs is necessary to determine the attractiveness of this approach. The excellent yields of monomers obtained with waxy distillate feed, offset by lower aromatic yields, is an indicator of what might occur with drain oil distil- late. Alternative processes, such as high temperature flu- idized bed coking, have been used for cracking crude oil and heavy petroleum to ethylene and other monomers. These might be applied to raw drain oil, but, again, a careful study of yields and costs is required. 58 ------- Light fractions of the paraffinic lube waste oil distil- late could be raw materials for n—paraffin recovery de- pending on the n—paraffin content, not now known. A large market exists f or n—paraff ins in the manufacture of straight chain benzene alkylates, an essential component of bio- degradable detergents. Animal feed protein is also made from n-paraf fins, with a boiling range of 175_3000 C (3L 7—572°F), by fermentation with yeast and appropriate nutrients, producing about one pound of yeast (63-65% protein) per pound of n-paraffin. 32 The pure n-paraffin appears to be the preferred feedstock, but hydrocarbon fractions containing n-paraf fins can also be used. This suggests that a light boiling distillate fraction from waste lube oils might be used if the n-paraf- fin content is sufficiently high. Presumably further puri- fication would be required to remove even traces of lead and other impurities. Partial oxidation to product carbon monoxide/hydrogen mixtures is another possible application for raw drain oil. Partial oxidation to produce synthesis gas can be an im- portant starting point for many industrially important chemicals, including hydrogen, ammonia, methanol, formalde- hyde, and oxo alcohols. The scrubbing system could be de- signed to remove ash components mixed with fine carbonaceous residues, a normal product of partial oxidation. The effect of ash components on the refractory of the 2200-3000°F partial oxidation reactors would require study. Petroleum Refinery Raw Material - The paraffinic crankcase waste oils also could be useful as a catalytic crackin 9 or hydrocracking raw material, except that ash components would most likely act as catalyst poisons. The distilled material could be used for catalytic cracking, but the cost would probably make the economics marginal at best. Even the very small lead residue would make its use in hydro- cracking dubious from an economic viewpoint. The petroleum industry could undoubtedly handle the problem of waste oils if they were forced to, but their reluctance to do so is understandable. 59 ------- SECTION VI RECYCLE AND DISPOSAL TECHNIQUES FOR OTHER WASTE OILS Waste oils, other than the vehicular waste oils dis- cussed in the previous section, include: 1. industrial lube type oils , including lube oils, hydraulic oils, transformer oils not heavily contaminated, where recycle and disposal tech- niques and problems are similar to those des— cribed for vehicular waste oils, except that lead content may not be a problem. 2. emulsified oils , e.g. metal working, lubricating, and some hydraulic oils where separation from water presents a special problem; and where the possible presence of special impurities such as halides, sulfur, and fatty oils are serious deterrents to recycle. 3. other petroleum-based industrial oils including heavily contaminated lube oils, process oils, oils skimmed from oil/water separators, mixed unsegregated industrial oils, and tank clean— ings. 4. waste vegetable, animal, and fish fats and oils . 5. oil/water mixtures from marine sources including spills, ballast, bilge, and tanker washing, a major portion of which is water, often salt water. INDUSTRIAL LUBE TYPE OILS As noted above, recycle techniques for industrial lubes are similar to those for drain oils. Several re-refiners provide services to industry whereby segregated waste oil is collected, processed, and returned to the customer in a closed loop. Oils with a high ash content may undergo con- ventional dehydration arid acid/clay treatment, whereas low solids content oils may undergo only dehydration and clay treatment. Recycling is sometimes done within the industrial plant, with centrifugation to remove metal particles followed by 60 ------- clay treatment as a common approach to the problem. In-plant recycle of transformer oils may involve only vacuum dehy- dration and filtration. Waste industrial lubricating oils are also used as a fuel, with none of the restraints on the similar use of automotive drain oil caused by lead content, unless contaminated with automotive drain oil. EMULSIFIED OILS Where service is not severe and reasonable segregation can be maintained, oil-water emulsions can be recycled, or oil can be recovered from the emulsion, purified, and re— emulsified for re—use. However, in most industrial situations treatment of oil—water emulsions results from oil containi- nation of waters and has as its primary objective the purifi- cation of the wastewater. In such situations, the oil is often disposed of as a high water content floc or sludge, although further concentration to produce a fuel is becoming more common. As an example of internal recycle, soluble (emulsified) cooling oils used for cold rolling in steel mills is often isolated and recycled. The steps involved may include gravity separation and skimming to remove free oils, f lit- ration to remove solid contaminants, and addition of bacteri— cides, antioxidants, or other agents to extend the life of the soluble cooling oil. However, even this recycled coolant eventually degrades and requires disposal by emulsion break- ing. On the other hand, many plant wastewaters systems are contaminated by lubricants from a multitude of sources, for example, cutting oils, hydraulic oils, oil mist collectors, and coolants. Treatment of these wastewaters ranges from simple separators to sophisticated multi-step treatment systems which includes chemical addition. 33 The following description is a hypothetical example of the steps which can be followed to both recover oil and produce an acceptable water quality for discharge or recycle. Few plants practice all of these steps; most practice only one or two of them. 1. Holding Tank-Separator - The oil-water mixture, containing anywhere from 200 to 50,000 ppm oil, is held in a tank where gross oil—water separation occurs. Wet oil is periodically pumped from the top of the tank to a reôlaim oil tank. The remaining oil—water emulsion is transferred to a batch chemical treating vessel. This and similar physical separation steps are often classified as primary treatment. 61 ------- 2. Chemical Treater - The emulsion is heated in the chemical treater to 100-150°F and chemicals added to break the emulsion. The chemicals used de- pend upon the nature of the emulsion, but acids, such as sulfuric or hydrochloric, calcium chloride, alum (aluminum sulfate), or ferric chloride are used, sometimes in sequence. For example, in one case, 95% sulfuric acid is introduced to lower the pH to 2-3, followed by brief air mixing and a 6-12 hour digestion period. Emulsion breaking is completed by adding calcium chloride and caustic soda, bringing the pH to 7.5 to 9 5•3 The oil-water separation is often completed by adding coagulating agents such as alum, ferric chloride, or polyelectrolytes, usually polymers. A typical coagulation process may be represented as follows: Al 2 (S0 4 ) 3 + 3CaCO 3 + 3H 2 0 2A1(OH) 3 + 3CaSO 4 + 3C0 2 (Aluminum hydroxide floc) The polyelectrolytes may be used as a primary coagulant or as an aid. Other aids such as sodium silicate, clay, lime, caustic soda, and soda ash are used to raise the pH and to control the agglQmeration and the density of the floc which adsorbs the oil. Chemical treatment followed by floc separation is often designated as secondary treatment. Air flotation is one method used for floc separation; settling is an alternative. 3. Air Flotation — In dissolved-air flotation, minute air bubbles are formed by saturating the water with air under pressure followed by a reduction in pressure. The air bubbles be- come attached to the oily floc,floating it to the surface. Alternatively, the air can be introduced by turbine aerators or spargers. The floc or scum, which may contain greater than 90% water, is skimmed from the surface and sent to oil recovery equipment, or dis— posed of into lagoons, drying beds, land 62 ------- spreading (sometimes for dust control), by deep well injection, or incineration. 4. Oil Recovery — Where oil quantities are suffi- cently large, recovery may be achieved in the plant or by a waste oil processor by either thermal or acid treatment of the floc, with or without prior dewatering, and water evapo- ration from the wet oil recovered. The re- covered oil can normally be used as a fuel. It may also be possible to reclaim some coagulant in this step. The economics tend to be questionable because of energy require- ments, and in the case of acid treatment, because of corrosion and odor problems which must be solved. Waste solids may also result from this step, requiring landfill. 5. Final Water Cleanup - The water from floc separation often contains unsatisfactory levels of solids, dissolved organics, or, other impurities. Further treatments such as biological oxidation, heavy metal ion precipitation, neutralization, or carbon adsorption may be necessary before discharge to streams or municipal treatment plants, or reuse of the water. Skimming of small quantities of oil may occur during these treatment steps. It may be concluded from this discussion that the re- covery of oil from emulsions with simultaneous water purif i— cation requires sophisticated chemical and engineering technology. The design of such systems requires detailed knowledge of flow rates, water and emulsion characteristics, and sludge and floc characteristics. Adequate design re- quires experimental data and often pilot plant demonstration. OTHER PETROLEUM BASED-INDUSTRIAL OILS The sources of these oils may number in the hundreds of thousands, including refineries, most industrial plants, governmental faci.lities, institutions, etc. Some may be disposed of onsite, especially when the quantities are small. As with oils recovered from emulsions, the waste oils may be used as a fuel, incinerated, used for dust control, pro- tection against water and freezing for coal, ores, etc., and other miscellaneous uses. They may also find their way 63 ------- into lagoons and landfill. As noted earlier, this one category of miscellaneous oils, which includes the entire spectrum of petroleum and coke oven oil losses, could amount to more than one billion gallons per year. The greatest single source of other petroleum—based waste oils are the refineries, where water treatment systems have been developed which internally recycle most oils back to “slop” tanks, thence to distillation for recovery. Little oil leaves the refinery complex except as dredgings, sludges, sediments, tank cleanings, spent catalyst and the like. These generally are landfilled or picked up by collectors, though lagoons are still used to some extent for waste liquid materials. Numerous descriptions of waste oil recove 1 d 3 i osal facilities are available in the literature. ‘ ‘ Oil recovery and disposal facilities available in con- junction with petroleum transportation, marketing, and use - are not nearly so extensive, except within large industrial plants where extensive water treating is practiced. In small installations it is uncommon to find more than a oil/ water separator to treat oily waters. Recovered waste oil is most often landfilled, used as fuel, or collected for road oiling or processing to fuels. Oil—water separation at production facilities has be- come more sophisticated, often using heater—treaters (chemical emulsion breakers), air flotation, or sand filters. Recovered oils are fed to pipelines where possible, turned over to collectors, or disposed of, for example to help stabilize sandy soils. WASTE VEGETABLE, 2 NIMAL ND FISH FATS ND OILS Fats and oils are recovered from wastewater and purified for use in soapmaking. Recovery requires process steps similar to some of thos discussed in the Section on emulsified oils, though as complete a treatment as indicated by all those steps would be unusual at the present time. A 1965 survey of types of treatment in meat packing and pro- cessing plants is shown in Table 12. A more recent survey, if available, would show increased use of more effective techniques for oil recovery and disposal, including chemical 64 ------- Table 12. TYPES OF WASTE TREATMENT EMPLOYED BY 108 MEAT PACKING AND PROCESSING PLJ NTS* 35 Method No. of Plants Screening 59 Sedimentation 71 Filtration 2 Flotation (air) 11 Flotation (gravity) 87 Flocculation 2 Evaporation 2 Chemical coagulation 1 Trickling filter 1 Activated sludge 12 Anaerobic digestion 5 Septic tank 13 Irrigation 2 Stabilization pond 7 * From “Water in Industry,” National Association of Manu- facturers, January, 1965. 65 ------- coagulation, air flotation, and biological treatment. A recent EPA project describes a system for recovery of fatty materials from edible oil refinery effluents, including the upgrading of fatty materials by caustic and sulfuric acid treatment followed by a centrifuge to separate oil, water, and waste sludge phases. l OIL/WATER MIXTURES FROM MARINE SOURCES Ballast, bilge, and tanker washing wastewaters contami- nated with oil are disposed of at sea, to refinery terminal facilities, to independent facilities, and, in the case of U. S. Naval vessels, to Naval stations. The recovery of oil in onshore facilities ranges from those integrated with refineries, already discussed, to simple settlers from which oil is recovered as a fuel. Most such facilities recover the bulk of the oil but many may still be discharging oil contami- nated water. Other sources of similarly contaminated oils may arise from offshore drilling, production, transportation, and mooring facilities. ” 66 ------- SECTION VII FOREIGN WASTE OIL DISPOSAL AND RECYCLE TECHNIQUES Waste oil recycle appears to be practiced much more in- tensively in Europe than in the U. S. Tax incentives and subsidies by European governments are a major reason. On the other hand, plants producing lubes operating in Japan during the 1950’s and early 1960’s, based on imported de- hydrated drain oils, are believed to have been shut down in favor of virgin lube production. Little is known about waste oil practices elsewhere in the world. The basic processing steps being used in Europe for re- refining are essentially the same as those available in the U. S. These are distillation, solvent extraction, and acid, clay, and hydrogen treating. Each of these will be discussed in turn. Most of the information here is based on recent dis- cussions in Europe between Dr. Peter B. Lederman, Director of the Industrial Waste Treatment Research Laboratory, and various people knowledgeable about European practice. 2 ° DISTILLATION At least one plant in France uses distillation followed by acid and clay treatment. Furnace coking is a problem in this plant. Operation and maintenance were found to be problems in earlier German trials with distillation. SOLVENT EXTRACTION The propane extraction process was described in detail in an earlier section. It consists of flash dehydration, propane extraction, and mild acid/clay treatment. 19 IFP’s propane extraction process is operated by Viscolube in Milan, Italy. Plant operation is satisfactory except for combustion of the extraction bottoms product which, blended with fuel oil, contains about 25% solids. Furnace tubes are fouled, 2 ° and presumably particulates are emitted to the atmosphere. ACID/CLAY TREATMENT Bernd Meinken, a small German engineering consulting firm, appears to be the most significant factor in European 67 ------- acid/clay treatment technology. They have been responsible for about 30 plants in Germany, Sweden, and elsewhere. The basic Meinken technology is similar to (3 S. practice, but plant descriptions indicate semi-continuous operation with instrument sophistication unknown in the U. S. re—refining industry. Special dehydration tower and acid treater designs are claimed to be superior to competing practices. The use of circulating hot oil heaters to replace fired heaters re- duces skin temperatures and minimizes heater fouling by waste oils. This approach is used in only one U. S. plant as far as is known. Acid sludge is neutralized with clay and/or caustic and disposed of or burned in an incinerator at 1000°C (1832°F). The incinerator flue gas is diluted with cold air so that so 2 emissions, stemming from the waste acid, do not exceed 0.2—0.3% volume percent (2000-3000 ppm). Particulates from the acid sludge and clay are presumably also emitted. In another scheme, for fuel oil production, phenol con- taining wastewater is vaporized in a direct fuel fired heater and purified by incineration. Heat generated in the incinerator can be used for process purposes. In a more recent version of the Meinken process, a development of Shaintom Lubricants and Chemicals, Ltd. (an Israeli firm), whereby the waste oil is pretreated with silicate, reportedly reduces acid requirement from about 5 to 2 volume percent. HYDROGEN TREATMENT No hydrogen treating plants for waste oils are now being operated. However, two new plants reportedly will replace acid/clay with hydrogen treatment because of regulations against acid discharge. These are a 36,000 gallon per stream day plant due to start up in Syracuse, Sicily during 1974, and a 20,000 gallon per stream day plant due to start up in Belgrade, Yugoslavia during 1976. It is believed that propane extraction will be used in these plants to prepare the lube fraction for hydrogen treating. INDUSTRIAL WASTE OILS A Meinken plant in Sweden makes heating oil from indus- trial waste oils. This is basically a dehydration/filtration 68 ------- operation. Fatty oils can be handled by increasing dehy- dration temperature from about 150°C (302°F) to 200°C (392°F) to decompose the fatty oils and drive them over- head. 69 ------- SECTION VIII ENVIRONMENTAL ASSESSMENT OF WASTE DISCHARGES FROM PROCESSING OF WASTE OILS The adverse effects of oil released to the environment disposal have been widely discussed in the literature, and reviewed in an EPA report to Congress. 43 A qualitative summary of the various aspects of waste oil disposal can be found in Table 13. This discussion deals primarily with the description and effects of solid, liquid, and gaseous e- missions from waste oil processing. A discussion of health and safety aspects is provided in Appendix G. WASTE PRODUCTS GENERATED Acid/clay waste oil re—refining plants produce two waste products: acid sludge and spent clay. At least two re— ref iners, who pretreat with caustic or a caustic—silicate mixture, also product a waste caustic sludge. The distillation/clay process produces a high ash bottoms product and spent clay. At least one processor uses a pre- treatment step which results in a high solids content sludge recovered by centrifugation. The sludge may be acidic or basic depending on whether caustic is used. Other processors are known to filter raw drain oil, producing a high solids content sludge. The following discussion will serve to characterize the major waste products encountered in re—refining, including air emissions and wastewater. Environmental r egulations and disposal practices are discussed later in this Section. Acid Sludge Sulfuric acid treating results in reactions with and dissolving of metal salts, aromatic and asphaltic compounds, organic acids, water, and other polar compounds. A phase separation occurs whereby acid sludge settles and is removed from the treating vessel leaving relatively pure oil behind. For a five volume percent acid treatment (about 10 weight percent), sludge production is about 0.15 gallons per gallon of lube product, or about 0.1 gallons per gallon of drain oil. 70 ------- TABLE 13. THE TREATMENT AND DISPOSAL OF WASTE OILS AND WASTE OIL RESIDUES WASTE OILS Automotive Lubricants (primarily crankcase oil, but contains transmission fluid, gear lubricants, hydraulic oil, solvents, brake fluid, possibly antifreeze) SOURCE Automotive Service Facilities (mc i. discarded filters, and discarded vehicles) COMMON C0NTAM IN ANTS (also see Tables for Additives) Compounds of N,O, and Cl, water, gasoline, metal and carbon particles, Pb and other metal compounds (See Tables 1 and 2 for further detail) PRIME CONTAMINANTS LIMITING REUSE OR SIMPLE DISPOSAL Color and odor bodies (N an .J 0 compounds), suspended inorganics PRINCIPAL TREATMENT AND DISPOSM. METHODS NOW USED (Disadvantages) 1. Re-refining (residue disposal) 2. Fuel (tube deposits and particle emission) 3. Road oil. and dust con- trol (runoff) Railroad Diesel Lubricants (primarily diesel lube, but may contain journal oil, gear lubricants) Truck Diesel Lubricants (primarily diesel lube but may contain trans- mission fluid, gear lubricants, hydraulic oil, etc.) Metal Working Lubricants (often emulsified with water) Similar to automotive lubricants, but no Pb May contain fatty oils, S,N,C1,F from original fluid + metal particles, oxidation and degradation compounds, sediment Color and odor bodies (N and 0 compounds), suspended inorganics Color and odor bodies (N and 0 compounds), suspended inorganics Metal particles, sediment 1. Re—refining (residue disposal> 2. Fuel (tube deposits and particle emission) 3. Road oil and dust con- trol (runoff) 1. Re—refining (residue disposal) 2. Fuel (tube deposits and particle emission) 3. Road oil and dust con- trol (runoff) 1. Chip extraction and settling at elevated temp. (oily solid wastes) 2. Settling & Skinuning (oily water waste & oil flocs and sludges) 3. Incineration (particle and other emissions) Railroad Service Facilities Truck Service Facilities Metal Working P1 ants Similar to automotive lubricants but no Pb ------- TABLE 13. THE TREATMENT AND DISPOSAL OF WASTE OILS AND WASTE OIL RESIDUES (Continued) WASTE 01 1. RESIDUES Acid Sludge (93—98% Sulfuric acid/ oil sludge, on the order of 30% water soluble) Caustic Sludge (caustic, sodiwn silicate, water, metals, oily sludge) Spent Clay (oil and impurity con- taminated clay cake) Pretreat Residues (sludge of oil, water, and inorganic residues) Distillation or Extraction Bottoms (heavy oil fraction high in inorqanics) SOURCE Acid treating of wast, oil. to remove metals and other con- taminants Caustic treat- ing of waste oils to break emulsions Clay treating of waste oils to remove impurities, improve odor and color Residues from settling, filtration, centrifugation, and other pre— treatments Diet lila t ion or extraction to concentrate non-volatile contaminants CO lON CONTAMINANTS N250 4 , PB from crankcase oils, metals and metallic compounds • polymers, heavy oil residues - (see Tables 15—17) NaOIi, Na silicates, Pb and other metallic Compounds Oil, organjc con- taining N and 0 (see Table 18) Pb from crankcase oils, other metals and metallic Compounds, heavy oil residues (also discarded filter papers, clothe, filter aids) Pb from crankcase oils, other metals and metallic compounds, heavy oil residues, coke PRIME CONTAMINANTS LIMITING REUSE OR SIMPLE DISPOSAL H 2 S0 4 , Pb, and other metals, oil. Pb and other metals, oil Oil and other organ ice Pb and other metals, oil Pb and other metals PRINCIPAL TREATMENT AND DISPOSAL METHODS NOW USED (Disadvantages) 1. Landfill with or with- out mixing refuse (water pollution) 2. Lagoons (temporary) 1. Landfill (water pollution, slow de- gradation) 2. Lagoons (temporary) 1. Landfill (water pollution, sl de- gradation) 1. Landf ill (water pollution, slow degradation) 1. Lagoons (temporary) 2. Asphalt 3. Puel (air pollution) ------- TABLE 13. THE TREATMENT AND DISPOSAL OF WASTE OILS AND WASTE OIL RESIDUES (Continued) Condenser Liquids (water from oil and stripping steam & light hydrocarbons; condensed steam and cooling water where steam jet vacuum with barometric condenser used) SOURCE COMMON CONThMINANTS Acid and other processing steps, Water Treatment, Vents, Open Tanks, Leaks Distillation Overheads PRIME CONTAMINANTS LIMITING REUSE OR SIMPLE DISPOSAL Odors Emulsions, dis— solved organics PRINCIPAL TREATMENT AND DISPOSAL METHODS NOW USED (Disadvantages) 1. Serubbers (water pollution) 2. Vent to furnaces 1. Separators (poor efficiency, wet oil residue) 2. Separators/Cooling Towers/Recycle (water pollution from blow— down) Scrubber Waters (usually aqueous NH 3 or caustic with impurities) Gas Scrubbing to eliminate SO 2 , SO 3 , and other volatile acids NaOH or NH 4 OH , SO 2 , SO 3 , water soluble organ ics Water soluble organica 1. Recycle (water pollution from blow— down) 2. Acid treatment of blowdown (dissolved solids residue) Runoff and Other Oily Waters Oily Waters from spilled oils, Leaks, Cooling Tower Slowdown, Other Sources Furnace Tubes and Other Piping Metallic compounds, polymer, coke 1. Separators (poor efficiency, dirt/wet oil residues) 2. Impoundment for reuse (possible water pollution) 1. Landfill (water pollution from ash olubles) WASTE OIL RESIDUES Odors May be trace hydro- carbons, solvents, organic acids, esters, 0, N, S containing compounds, SOP, SO 3 , N H 3 , etc. Phenols, other dis- solved organics, oil Ash and Coke Oil, dirt Oil ------- TABLE 13. THE TREATMENT AND DISPOSAL OF WASTE OILS AND WASTE OIL RESIDUES (Continued) SOURCE Industrial Plants, Power Plants (mci. discarded trans— format-s and machinery) Food Textile Plant I Industrial Plants, Ref Leer iss, Marine Service Facilities, Fuel terminals, Oil Spill Cleanup COMMO CONTAMINANTS (also see Tables for Additives) Turbine Oils: water, ox id - products Transformer Oils: water, oxid-products, polychiorinated oils, Gear oils: S. Pb, dirt, wear metal, water, oxid- products Coagulante from oil re- covery, trace contami- nants including metals Sand, dirt, salts, virgin oil metals such as V, Ni, Fe. foreign matter such as sorbente PRIME CONTAMINANTS LIMITING REUSE OR SIMPLE DISPOSAL Metal particles, water, degradation products 1. See methods for auto- motive lubricants 2. Clay treating (spent clay waste) 3. Filtration (filter aid and particle waste) 4. Centrifugation (particle waste) 5. Recovery to prepare soluble oils 6. Incineration (air pollution) 1. Recovery and repro- cessing for soap manufacture 1. Separators (poor efficiency, wet oil waste) 2. Riochemical treat- ment (expensive, sludge waste) 3. Combined Municipal/ Industrial wastewater plants (pretreatment necessary, possible toxic materials, sludge waste) 4. Physical/chemical treatment (expensive, water contamination with chemicals) WASTE OILS Other Industrial Oil. (turbine oil., trans- former oils, lubricants. hydraulic oils, heat transfer fluids, synthetic oils, etc.) Animal S Vegetable Fats a Oils (Solids or Liquids) Oily Water PRINCIPM.. TREATMENT AND DISPOSAL METHODS NOW USED (Disadvantages) Color, odor suisions, soluble organics, foreign matter ------- TABLE 13. THE TREATMENT AND DISPOSAL OF WASTE OILS AND WASTE OIL RESIDUES (Continued) PRINCIPAL TREATMENT COMMON CONTAMINANTS PRIME CONTAMINANTS AND DISPOSAL METHODS (Also see Tables for LIMITING REUSE OR NOW USED WASTE OILS SOURCE Additives) SIMPLE DISPOSAL ( Disadvantages ) Oily Sludges, Tar., Tank Cleaning, Coke particles, S, N, Solids, 5, N, 0, 1. Incineration (possible Scums, Flocs Refineries, 0, halides, coagulanta, halides air pollution) Coke and water 2. Landfill (water and Petrochemical air pollution) Plants, Oil 3. Ocean disposal (water Spills, Waste— pollution) water Treat- 4. Lagoons (temporary) ment Of fspec and Contaminated Refineries, Light hydrocarbons, Emulsions, sedi— 1. Distillation (possible Fuels Tank Cleaning, sludges, solvents, ments, color, water and residue Airports, water, salts, trace odor problems) Pipelines, contaminants 2. Fuels (possible air Fuel Terminals, pollution) Marine service 3. Incineration (possible Facilities air pollution) ------- Some of the characteristics of the sludge are presented in Tables 14—16. Since little data is available, it is not known whether these analyses are typical. The high acid con- tent requires that sludge be handled as carefully as the original acid. As much as 30—50% of the acid sludge is water soluble, complicating land disposal. Lead content, believed to be in the 2 to 10% range, primarily as Sulfate, is another important factor to be considered. The acid sludge is similar to some sludges produced in petroleum refineries. The volume of these refinery sludges has been decreasing as hydrogen treating has replaced acid treating. Petroleum refineries have disposed of acid sludges by incineration, acid recovery, landfill, and neutralization with disposal to wastewater. All acid sludge disposal by U. S. re—refiners is to landfills or lagoons, usually without neutralization. Neu- tralization and incineration, practiced in Europe, leads to high SO 2 emissions. Acid recovery is too expensive on a small scale and transportation costs are too high to justify centralized recovery plants. Disposal to wastewater can only be practiced where high volume wastewater treatment facilities are available for dilution. Caustic Sludge Caustic sludge is generated from emulsion breaking of waste oils. Only two re—refiners in the U. S. are known to be definitely using this approach, though other waste oil processors may be doing so. The sludge contains caustic, sodium silicate, lead and other metals, and oily sludge. No analyses of caustic sludge have been found. Spent Clay Although little data is available, the clay recovered from re—refining filter presses is believed to contain about 10-40% oil. At 0.4 pounds of clay per gallon of oil treat- merit rate,this results in a 0.5 to 2% oil loss. An analysis for spent clay from petroleum refining is provided in Table 17. Minor components in the spent clay may include oxygen and nitrogen containing polar organic compounds, carbonaceous residues, acid residues, and other polar compounds. Spent clay is ordinarily disposed of to a landfill, though some uses have been found. For example, clay con- taining oil has been used as a surfacing material for stables 76 ------- Table 14. ACID SLUDGE ANALYSIS Derived from 1971 Re-Refiner Data for sulfuric acid treated sludge. WT. % Diesel Stock* % Acid 47.5 40.8 Ash Sulfate 4.45 11.26 Sulfur 14.9 14.1 Sulfur calculated from % acid assuming fl 2 S0 4 15.5 13.3 Coithustibles —---30-42 ELEMENTAL ANALYSIS, ppm Cu 40 40 Al 40 140 Pe 500 1,100 Si 800 1,400 Pb 1,000 20,0.00 Aq 14 0 Zn 200 2,100 Ba 400 1,300 Cr 190 50 Ca 12,600 6,400 Na 200 4,000 P 1,000 4,300 B 40 50 Ni 10 30 Sn 35 30 Mg 70 1,000 17,139 41,940 1.71% 4.19% Sulfated ash by calculation from elemental analysis 5.35% 9.39% * ‘roin independent collectors. All or primarily crankcase oil. 77 ------- Table 15. ACID SLUDGE ANALYSIS* SOLUBLE IN WATER WT. % Ash 4.2 Acid (H 2 S0 4 ) 27.0 INSOLUBLE IN WATER Ash 8.4 Acids 1.6 Volatiles (150°C. @ 1 mm Hg) 0.8 Lube Oil (naphthenes, paraf fins, aromatics) 15.5 Polymers 15.6 Other Polar Compounds 1.8 Ashphaltenes and Other Residues 24.4 99 . 3 * Derived from Putscher 2 ’ 78 ------- Table 16. PHYSICAL CHARACTERISTICS OF ACID SLUDGE From 1971 Re—Refiner Data for sulfuric acid sludge Density, lbs/gal. 10.0 Viscosity, SSU 75° F. 4,000,000 105° F. 457,000 125° F. 150,600 pH 0.1 79 ------- Table 17 ANALYSIS OF PETROLEUM REFINING SPENT CONTACT CLAYS ”’ AVE RAGE RAN GE BTU/lb. 6000 1000 — 9250 Particle Size, sieve no. 170 30 — 300 Volatile Solids, wt. % 14 0 55 Ash, wt. % 53 0 — 99 Water, wt. % 8 0 - 36 Oil, wt. % 19 1 — 45 pH 5.6 3.5 7.5 80 ------- and unpaved road stabilization. Petroleum refineries have regenerated clays by incineration for re-use and disposal, but this approach is expensive on a small scale. Other Residues A variety of other solid, semi-solid, or liquid resi- dues may result from waste oil processing, including tank cleaning sludges, furnace coke, combustion ash, wastewater flocs and scums, etc. All of these are normally disposed of with refuse or separately landfilled, though oil recovery by dewatering and blending may be practiced on some tank sludges. Distillation Bottoms When drain oil is purified by vaporizing the desired product, leaving behind high boiling and non-volatile materials, the residue becomes a waste disposal problem. The residue, or distillation bottoms, is considerably higher in ash, sülfür, nitrogen, oxygen, and acidity content than the lube product. Total ash may reach 10-25%, with lead contents ranging from 5-15% depending on the fraction not vaporized, on the ash and lead contents of the drain oil, and on the extent of pretreatment. Distillation bottoms have been used as an asphalt blending stock, or they have been stored in lagoons. An EPA grant program is underway to demonstrate the utility of this material as a fuel in secondary lead smelting. Air Emissions A properly controlled processing plant will emit few contaminants to the atmosphere. Early plants contatrjed many open vessels, but few of these are now left. Vents from process and wastewater treatment units and storage tanks in many re—refining plants are discharged to a furnace where vented combustible materials are burned. In other plants caustic or ammonia scrubbers are used. Little is known about the actual composition of the gases, but some odors are apparent around most re—refining facilities. The odors are no worse and probably somewhat less intense than those encountered around petroleum re- fineries. Most likely these odors are caused by esters and other organic compounds containing oxygen and nitrogen. Very low concentrations of organic sulfur compounds may 81 ------- also be present, as well as some SO 2 and SO 3 from acid sludge handling where acid treating is practiced. Wastewater The wastewater from a re—refining plant comes from several sources: water separated from the raw drain oil; cooling water used in indirect heat exchange; cooling water contaminated by direct contact with oil, e.g. in the baro- metric condenser of a vacuum system; water from condensed steam which contacts oil, e.g. in steam jet vacuum systems, or stripping steam; vent gas scrubbers; and plant runoff water. Both acid/clay and distillation/clay plants are equipped with oil/water separators and neutralization facilities to handle the process water separated from the oil. Vacuum distillations are usually performed with steam jets and barometric condensers, requiring oil/water separation for these effluents as well. Cooling water used indirectly is sometimes provided on a once—through basis with no treat- ing, sometimes recycled with the aid of a cooling tower, and occasionally joined to other water streams entering an oil/ water separator. Some re—refiners also provide for oil! water separators on runoff water. In the best operations, all direct contact condensers are replaced by indirect air or water cooling; and steam use is minimized by providing efficient mechanical vacuum pumps. Maximum water recycle is practiced with efficient oil sepa- ration from the process and runoff waters. Purge water is sent to a municipal sewer plant or trucked to a landfill site. Advanced wastewater treatment systems for “zero” emissions are not now in use. The characteristics of wastewaters obviously depend upon the type of oil processed, the nature of the process and of wastewater treatment facilities, housekeeping, the degree of recycle, and other factors. However, one expects to find traces of metals which appear in the raw oils, dissolved and suspended solids, dissolved phenols and other organics, arid suspended or emulsified oil. These expectations are borne out by samples obtained by the contractor and analyzed. These are discussed in the following section. 82 ------- CHARACTERIZATION OF WASTEWATERS FROM OIL RECYCLING FACILITIES Wastewaters from a marine waste oil processing plant and from a re—refining facility were sampled and analyzed as part of the program to understand potential pollution problems associated with waste oil recycling. Re—refining crankcase waste oils to lubes is of interest because it is one major type of recycling. Other waste oil processing plants are much more variable in type. The marine waste oil processing plant was chosen mainly because it discharged a relatively large quantity of water from an oil/water separator. The Marine Waste Oil Processing Facility This facility consisted of an oil/water separator with two inlets, one water discharge, and an oil recovery system (Figure 5). The recovered oil is pumped to storage. Samples were obtained from the inlet and discharge streams, the bottom of the separator unit itself, and from the recovered oil. The separator receives feed from tanks used to store oil/water mixtures from a tanker Butterworth steam cleaning system. The feed varies continuously in percentage of oil and water, salinity, and type of oil. The recovered oil from the separator is sometimes recycled to the separator to further reduce the water content. The finished oil is stored, blended, and burned in the plant boilers which produce steam for Butterworth and other operations. The amount of oil re- covered from the operation is estimated to be one million gallons per year. The oil/water separator has an approximate holding capa- city of 14,000 gallons and is operated at a temperature of 120°F. The unit is divided into a series of compartments by steel plates which separate the oil at the surface and allow water to pass underneath toward the discharge pipe. At the surface, pipes cut in half are used as troughs to draw off the top layer of oil, emptying it into a basin. From there the recovered oil is pumped to storage or recycled thru the unit. The wastewater is discharged from the unit by gravity flow via a 4 inch pipe which draws from the bottom of the separator. The wastewater is then piped into a city storm sewer which empties directly into the saline harbor. The residence time in the tank was calculated to be 3.6 hours with a discharge rate of 3,900 gallons per hour, operating 83 ------- A FEEDER- B STOCK INLET SAMPLES WATER DRAWN —18” FROM BOTTOM OF TJINR (DISCHARGE TO CITY STORM SEWER) WATER DISCHARGE C SAMPLE OIL TO STORAGE OR RECYCLE WASTE OIL PROCESSOR OIL-WATER SEPARATOR UNIT D RECOVERED OIL SAMPLE flAFFLE SKIMMING DEVICES TANK WALL OIL STEAM HEATING ELEMENTS Figure 5 ------- over an 8 hour day. The discharge rate was measured by timing the accumulation of five gallon quantities. The Lube Oil Re-Refining Facility The re-refining facility uses acid arid/or clay to process both automotive crankcase drain oils and industrial waste oils. The oil is processed in approximately 7,000 gallon batches with an estimated daily production of about 20,000 gallons. The oil/water separator handles both process wastewaters and storm water runoff. Unfortunately, many of the wastewater streams at the refinery were underground, making them inaccessible for sampling. Water samples were collected from the primary separator, which handles the clay treater/stripper overhead; suinp water accumulated in the dehydrator; purge water from the cooling circuit; and the bottom of the separator near the discharge pipe. The actual discharge line was inaccess— ible. The acid—clay refining operation is illustrated in Fig- ure 6. The feedstock is pumped from storage to the dehyd- rator which operates between 210 and 220°F., using an air- sparger to mix the oil. The water vapor overhead is released directly to the atmosphere. A small quantity of water is periodically discharged from the bottom of the dehydrator (sampling point A). The dehydrated oil is sent to dry stor- age. Dry oil is later pumped to the acid treating units. Acid sludge from the units are hauled to another site, neutralized and discarded in a landfill. The acid—treated dehydrated oil is transferred to the clay treating operation where clay is added, forming a slurry which is pumped to the clay contact/stripping column. The temperature of the batch is brought up to 550°F. by circulating through the column and the furnace, with the light fuel fractions going off overhead. Steam is added to the bottom of the column for agitation and to aid stripping. The overhead vapor, con- sisting of light oils and water, is condensed and separated. The light oils are sent to storage, and the wastewaters to a sump (sampling point B). The hot oil containing the clay is passed through a cooling box to reduce the temperature to approximately 230°F. before being filtered in the first press. A second cooling box further reduces the temperature to 150°F. prior to the 85 ------- Discharge r5 — to sump Disposal WASTE OIL RE-REPINING PROCESS Fi iter Discharge to City Sewer Separator Secondary For all Discharge Waters Water Oil r Water Vapor I Acid Treater Waste Oil I Feed Dehydrator 1 J cx Make-Up Water (City water) I $ $ I I I A Suxnp Water 1 (periodic) 1 Separator -Primary to Box Filter Storm Sewers (Run-Off from Yard) Oil to Storage Figure 6 ------- final or backup filter. The re-refined oil is then pumped to storage. Condensed steam, run—off water from the refinery yard, and all wastewater streams from the operation run directly through a sump to the main oil—water separator before being discharged to a city sewer. The estimated discharge rate from the re-refining process is 10,320 gallons per day, ex- cluding runoff water from the yard. At this rate a calcu- lated residence time for the main oil—water separator unit is 28 hours. Including runoff waters from the yard, the rate of discharge is greatly increased and the residence time is significantly decreased. For example, with a three inch rainfall within a 24 hour period and all runoff waters going through the separator unit, the total discharge volume was calculated to be about 700,000 gallons per day, reducing the average residence time to only 30-35 minutes. Sampling Procedures Due to differences in the two waste oil processes, the sampling procedure varied. Duplicate samples at the final discharge point were taken in both cases. Marine Waste Oil Processing — For the marine waste oil pro- cessing operation, inlet and discharge samples (see Figure 5) were taken directly from the process stream in a plastic bucket and then transferred to prepared sample bottles. Bottom samples from the separator unit were drawn using a ten foot by 1/2 inch aluminum pipe. The pipe was plugged at one end, and the other end submerged to the bottom of the tank. The plug was then removed allowing water to enter the pipe. Replugging the pipe, it was withdrawn and emptied into ap- propriate sample bottles. Re-Refining - For the waste oil re-refining operation the wastewater streams were sampled as follows (see Figure 6); At sample point A, wastewater discharge from the bottom of the dehydrator was obtained by opening a valve and filling the sample bottle. Only a small quantity of water could be collected at this point. At sample point B, wastewater condensed with the clay contact/stripper overhead and passed through a sepa- rator empties directly into the sump. Sample bottles were placed directly under the discharge pipe, rinsed several times, and filled. 87 ------- At sample point 6, purge water from the cooling tower was dumped into the same sump. Samples of the purge water were also obtained by rinsing and filling bottles directly under the outlet pipe. At sample point D, the combined or total discharge (released to the city sewer) for the entire re—refining process passes through the bottom of the last compart- ment of the secondary oil-water separator. A weighted one liter glass stoppered sampling bottle was lowered to the bottom of the separator unit near the discharge pipe and opened at that point by the use of a second cord. The bottle was pulled to the surface*, emptied, and the process repeated to obtain enough sample for all analyses in duplicate. This unorthodox method of sampling was necessary because discharge pipes leading to the city sewer system were underground and inaccess- ible. In all sampling operations the appropriate preservatives were added to samples where required and all samples were transported in ice chests. The pH and temperatures were measured and recorded onsite and unless otherwise noted, all samples were collected, labled, preserved, and stored in compliance with EPA recommendations.’ Analyses All analyses were conducted in accordance with EPA’s “Methods for Chemical Analysis of Water and Wastes,” 5 or “Standard methods for the Examination of Water and Waste- water,h1 4 & when referenced by the EPA methods (phenol corn- pounds, pH, B0D 5 , elemental spectrographic analysis). The analyses performed on the samples collected were: Oil and Grease Dissolved Solids BOD 5 Nitrates COD Phenols TOC pH Total Solids Elemental Spectrographic Analysis Suspended Solids * Due to the sampling bottle being open as it was pulled up thru the oil layer contamination of the water sample with oil is possible and thus reflected in the data (see Table 19, Discharge Samples). 88 ------- Results of analyses and explanatory footnotes pertinent to the sampling method or sample handling are found in Tables 19 and 20. Discussion of Results Waste oil re-refining and processing operations appear to discharge a relatively small quantity of wastewaters per unit volume of product when storm runoff waters are not con- sidered. The operations sampled did not have direct means of measuring wastewater flow rates. Therefore, for both op- erations the discharge rates were calculated from measure- ments taken in the field or extrapolated from records of purchased city water. Sampling point accessibility created no problem except in the case of the discharge stream to the city sewer of the re-refining operation, as previously explained. This problem illustrates the necessity for provision of adequate sampling facilities for wastewater discharge. Analytical methods for analysis of oily wastewaters re- quire further investigation and standardization to overcome the influence of non-homogeneity due to oil globules in the water sample. An example is the total organic carbon (TOC) analysis. It seems likely that oil globules can greatly alter the TOC values, depending upon the manner in which the sample is handled prior to injection into the analyzer. The COD and BOD values can also be influenced by oil globules. Specific Federal effluent guidelines have not been established for waste oil recycling facilities. However, it is interesting to compare the results obtained in this study for the marine oil processor with maximum Federal guidelines proposed for discharge into surface waters by petroleum refiners, and for some typical restrictions for discharge to municipal treatment plants: Effluent Dis- Typical charge Measure— Federal Municipal inent for Marine Guide- Restric- Oil Processor lines tions Oil & Grease, ppm (avg.) 95 10 100 BOD 5 , ppm (avg.) 19 9 300 COD, ppm (avg.) 192 31.7 700 TOC, ppm 60 7.7 Phenol, ppm 15.5 0.07 Suspended Solids, ppm 304 5.8 350 89 ------- The processor effluent would appear to be suitable for dis- charge to municipal treatment, but not to surface waters. The re—refiner effluent has not been compared because the high contaminant levels measured may be due to the sampling procedure, as previously explained. 90 ------- TABLE 18. WASTE OIL PROCESSOR (MARINE WASTE OILS) OIL/WATER SEPARATOR PHENOL POTAL flISSOLVED SUSPENDED *MXSSION SPECTRAL BODç COD TOC OIL COMPOUNDS p 11 NITRATES SOLIDS SOLIDS SOLIDS SURVEY Wi - Discharge mg/i 450 C. mg/i mg/i mg/i Na(2.l-21d : Mg, C 12:00 Noon 16.5 90 TU T [ 0J 6.1 .0S 2T5oo TToo Ca(.2—2.l); Fe,Si (.002—.021.); Al, Mn,B(.0002—.002) C 2:15 PM 22.7 295 64 87 17 6.7 0.70 22,000 22,000 304 Na(2.l—21.);Mg,Ca (.21—2.l); Fe,Si (.002—.021); Mo, Cu( . 00 02—. 002) Inlet A .13.8 290 64 317 14 7.4 0.25 22,000 23,000 291 Na(1.0—10.); Mg, 12:00 Noon Ca(.l0—l.0); Fe, Si(.001—.01) ;Mn, B(.0 00 i—.001) ‘ 0 B ———s 1,210 8,500 9,544 ———s 6.3 0.60 15,000 14,000 969 None (1.7—17.0): 2:00 PM Pe,Mg,Na(.17—l.7); Al ,Si ,Pb,Ba-Cr, Mn,Ni,Mo ,V,Cu,Zfl, (.017—.17); Zr, Ca,Ti(.00l7—.0 17) Recovered Oil D Pe,Ma,Na,Ca(.19- 1.9); Al,Si,V, (.019—.19) : Cr,Sb. Pb,Mn,Ni,Cu,Zn,Ti, Ba(.0019—.019) Bottom S amp lea 11 ——— ——— ——— 178,000 02 ——— ——— ——— 159,000 Waste waters wer. contaminated with sea water since they resulted front tank cieanings from marine tankers. Due to a large amount of oil present in sample, no color developed when titrated for SOD analysis. The large amount of oil also interfered with the phenol determination. ------- TABLE 19. WASTE OIL RE-REFINER PHENOL, TOTAL DISSOLVED SUSPENDED EMISSION SPECTRAL SAMPLE BODc COD TOC’ OIL COMPOUNDS pH NITRATES SOLIDS SOLIDS SOLIDS SURVEY’ Dischar e(D)’ mg/i mg/i mg/i mg/i 150 C. mg/i Strong Medium 11:30 All 2.7 (31,808’) 163 (3,023’) 92 (150) 6.0 0.81’ 959 512. 394 Pe,Mg,Ca, Si Na Discharge (0) 12:30 PM 4.0 (16,943’) 382 (3,629’) 84 6.1 0.64’ 2256 931 401 Pe,Mg,Ca, Si Na Primary Separator Discharge(B ) 6.0 792 121 168 69 4.1 0.25 493 483 4 Fe ,Mg,Ca Na Cooling Tower Blow Dowu(C ) 4.0 43 43 9 4 6.5 None 180 172 7 Mg,Ca,Na —— detectable Water From Bottom of g/l Dehydration Unit (A) ——— ——— ——— 16 5.8 Ca (.39—3.9); Fe, Si,Mg,Na(.039—.39); Al,Pb,Mn ,Ni,B,Zn (.0039 —.039 ) ;Mo , Cu ,Co ,Br 000 39—. 00 39) Discharge samples taken from bottom of secondary separator unit near discharge pipe by a special sample bottle to open under- water. However, samples may have been contaminated as sample bottle was pulled thru the surface layer of oil. This unorthodox method of sampling was necessary because all discharge pipes were underground and inaccessible. 150 mg phenolic compounds/l was reported by outside laboratory for sample 0 11:30 All. I Concentrations reported as only “strong” or “medium” by outside lab. Only a small amount of water sample was obtainable from point A ‘ TOC analyses were conducted excluding any large oil globulas found in the samples. ------- EXISTING AND FUTUP E REGULATIONS While specific regulations covering the disposal of waste oils and emissions from the processing of waste oils do not exist at the Federal level, and are uncommon at state and local levels, existing regulations for solid waste dis- posal, water effluent limitation guidelines and new source standards, and air quality and emission standards do provide some protection against indiscriminate disposal. There is also a strong possibility that new laws and regulations in the areas of solid waste disposal, hazardous wastes, and air and water pollution control will provide further pro- tection. Solid Wastes and Land Disposal On the Federal level, guidelines for disposal of solid wastes have been proposed 47 which, if promulgated, will establish EPA—recommended guidelines for adoption by state and local governments and for direct implementation by federal agencies. These guidelines recommend against accepting wastes for incineration in municipal thermal processing installations if they are hazardous to human health or the environment, if the installation was not specifically designed for the waste, if the chemical and biological characteristics are detrimental to personnel or the facility, if legal require- ments for air quality, water quality, health or safety will be violated. For sanitary landfills, these guidelines generally are similar to the thermal processing guidelines, but recognize that it may be necessary to accept special wastes such as hazardous wastes, bulk liquids, semi—solids, wet sludges, flammable or volatile substances, and industrial process wastes, but special assessments are recommended such as site characteristics and nature and amounts of the wastes. EPA has recommended to Congress that leqislation be enacted to control hazardous waste disposal to the land. 48 It has compiled information on the types of materials in wastes which could be regarded as hazards to public health. A few types which may appear in some waste oils are corn— pounds of heavy metals, including lead; organic halogen compounds, including polychiorinated biphenyls; miscel- laneous organic compound, including carcinogens; and flammables. However, even when present in waste oils from automotive service and industry, these materials usually 93 ------- appear at low concentrations, with the possible exception of lead compounds, and flammables. The proposed Hazardous Waste Management Act calls for authority to regulate the treatment and disposal of hazar- dous wastes. k8 On the state and local level 9 few regulations deal with land disposal of waste oil residues. Some (e.g. Ok — lahoma City, Oklahoma) approve disposal procedures of liquids, hazardous materials and the like. Others (e.g. Chesterfield Township, Michigan) provide procedures which landfills must use if these types of wastes are received. California has set aside certain landfills suitable for chemical wastes to be used for that purpose. Still others (e.g. Westport, Connecticut) ban “dangerous explosive or inflammable materials.” At least one state (New Jersey) requires that the waste producer provide sufficient infor- niation to the disposer to insure safe disposal of hazardous and/or chemical wastes; it also prohibits direct or in- direct contact of chemical wastes (liquid or solid) with surface or ground waters. Water On the Federal level, the Federal Water Pollution Con- trol Act Amendments of 1972, Public Law 92-500 replaced all previous Federal water laws. The critical feature of this act requires effluent limitations consistent with “best practicable” control technology by July 1, 1977, and con- sistent with “best available” technology by July 1, 1983. Pursuant to the 1972 law, EPA is issuing effluent limi- tations for twenty—nine industries, including petroleum re- fining and other industries where oil contaminated waste— water is likely to be encountered. In addition, this act gives EPA, the Coast Guard, and other agencies broad au- thority to clean up oil spills, make polluter pay costs of cleanup, and levy fines and penalties. Discharge of hazar- dous substances is also covered. EPA has issued regulations to prevent oil spills into water, requiring potential “spillers” to prepare “Spill Prevention Control and Countermeasure Plans. ” 5 ° These regulations affect,for example, oil refineries, industrial users of oil, fuel oil dealers, drillers, bulk petroleum facility operators, and waste oil processors. 94 ------- The Marine Protection, Research and Sanctuaries Act of 1972, effective on October 27, 1972, declared national policy “to regulate the dumping of all types of materials into ocean waters and to prevent or strictly limit the dump- ing into ocean waters of any material which would adversely affect human health, welfare or amenities, or the marine environment, ecological systems or economic potentialities.” On the state level, New Jersey, for example, has regu- lations specifically prohibiting discharge of oil refining “sludge acid,” and deleterious, destructive or oisonous substances of any kind into any body of water. 5 In addition, New Jersey has prepared guidelines for “best practicable” technology for oil and petroleum based industries’ emissions (guidelines are not standards and are subject to change) 52 which include, among other requirements, limits of 1.0 ppm for oil and grease, 0.05 mg/I for phenols, and 30 mg/i for TOC. The oil and grease guideline is considerably more stringent than the 10 ppm encountered in Federal effluent limitations, and very difficult to meet. As another example, Illinois prohibits visible oil, unnatural sludge or bottom deposits, floating debris, odor, unnatural color or turbidity, and toxic or harmful con- centrations of matter, and prescribes limits for many ele- ments in the State’s waters. 53 In addition, Illinois prescribes maximum concentrations of contaminants which may be discharged: Settleable solids, floating debris, visible oil, grease, scum, or sludge solids (referred to as offensive discharges) None Color, odor and turbidity Below obvious levels BOD 5 SS BOD and Suspended Solids(SS) mg/l mg/l General 30 37 Sources with untreated waste 20 25 load of 10,000 population Specific situations 4—40 5—45 Effluent with dilution ratio 10 12 of less than 5/1 Effluent with dilution ratio 4 5 of less than 1/1 After 12/31/1977, sources 4 5 with untreated waste load of 500,000 population 95 ------- Bacteria, nitrogen, phosphorus, and the following are also regulated in effluents: Constituent Concentration mg/i Arsenic (total) 0.25 Barium (total) 2.0 Cadmium (total) 0.15 Chromium (total hexavalent) 0.3 Chromium (total trivalent) 1.0 Copper (total 1.0 Cyanide 0.025 Fluoride (total) 2.5 Iron (total) 2.0 Iron (dissolved) 0.5 Lead (total) 0.1 Manganese (total) 1.0 Mercury (total) 0.0005 Nickel (total) 1.0 Oil (hexane solubles or 15.0 equivalent) pH range 5_l0* Phenols 0.3 Selenium (total) 1.0 Silver 0.1 Zinc (total) 10. Total suspended solids 15.0 *The pH limitation is not subject to averaging and must be met at all times. Total Dissolved Solids shall not be increased more than 750 mg/i above background concen- tration levels unless caused by recycling or other pollution abatement practices, and in no event shall exceed 3,500 mg/I at any time. Air On the Federal level, the Air Quality Act of 1967 and the Clean Air Act of 1970 set primary and secondary stan- dards of ambient air quality and directed the states to develop and implement plans to achieve the primary stan- dards by 1975, with a possible two-year extension for tech- nologically impossible situations. ‘ 96 ------- Standards have been set for sulfur oxide, particulate matter, carbon monoxide, hydrocarbons, photochernicals, and nitrogen oxide. In addition, special Federal authority exists to control new stationary sources, hazardous air pollutants, motor vehicle emissions, fuel and fuel addi- tives, aircraft emissions, and low emission vehicle pro— curernent. Performance standards have been devised for five major stationary sources, and are proposed for seven others, in- cluding petroleum refineries and storage vessels. 55 For the petroleum refineries, particulates, carbon monoxide, and sulfur dioxide are regulated. For storage tanks, hydro- carbon emissions are regulated (indirectly, by specifying control measures). National emission standards have been set by EPA for asbestos, beryllium, and mercury. Atmospheric lead is known to be a danger to human health, but national emissions stan- dards have not yet been set, perhaps because in the EPA authority hazardous air pollutants were defined as “materials discharged into the atmosphere that have a proven relation- ship to increased human death rates.” On the state level, numerous approaches have been taken to achieve the air quality standards. Some of the relevant regulations include prevention of open burning, particulate, sulfur oxide, and hydrocarbon emission limitations, and nuisance rules covering odors. DISPOSAL TECHNIQUES The disposal of acid sludge from re-refining is the most serious of the various disposal problems faced by waste oil processors. Oily flocs and sludges from wastewater treating, residues from tank settling, and spent clay also present difficulties. Technology for wastewater treatment and the prevention of air emissions is available, but expensive. Acid Sludge Reconstitution of sulfuric acid from acid sludge has been done in connection with petroleum refining, but this has not been and does not appear likely to be a significant method of disposal for re—refiners, primarily because the quantity is very small at each location. Although even the total quantity of acid sludge from drain oil re-refining in the U. S. is not staggering (about 97 ------- 10 million gallons per year), the nature of this waste makes disposal a difficult problem, from which all re-refiners would welcome relief. An unknown but probably lesser quantity of acid sludge is also generated in the treatment of industrial waste oils. Only one re—refiner is still using lagoons for acid sludge, and obviously this is only a temporary solution. At least two other re—refiners have lagoons containing acid sludge and other residues from earlier operations. The danger in this type of storage is illustrated by an incident where a re—refiner had his lagoons overflow during a hurri- cane several years ago, causing a major discharge of con- taminated oily materials to the nearby river. After la— gooning, it is extremely expensive to find a method of dis- posing of the millions of gallons of sludges stored in this way. Chemical petroleum, and steel companies have had similar problems. Landfilling of acid sludge, the most common disposal method, appears to be a reasonable, though not ideal method of disposal, provided sufficient safeguards protect person- nel, ground water, and nearby streams. The sludge is often mixed with refuse at the landfill site. California has designated a “number one landfill” suitable for acid sludge and other oil and chemical disposal. Few other states have followed suite. The soluble free—acid probably leaches through the soil, and in alkaline soil is finally converted to sulfate salts,entering the ground water or nearby streams. Some other sulfates in the sludge probably end up the same way (see Table 19 for sulfate solubilities), but lead, barium, calcium, silver, arsenic, molybdenum, titanium, strontium, and other heavy metal salts may remain in the landfill. The concentrations are low, and should not be a serious problem, although future use as a growing area may present some danger. This is illustrated by experience with the use of sewage sludge containing metals from in- dustrial sources as a fertilizer, where repeated applications markedly increased soils chromium, lead, copper, zinc, mercury, and cadmium contents. 59 However, these metals may or may not be transferred to vegetation. 60 Work done by Shell Oil under an EPA grant 6 indicated that soil micro—organisms decompose petroleum oily waste and that oil and fertilizer chemicals did not penetrate the soil at the location and conditions of the test. However, resi- 98 ------- Table 20. SULFATE SOLTJBILITY 57 AND ENVIRONMENTAL HAZARDS OF ACID SLUDGE INORGANICS 58 MAJOR ELEMENTS IN SOLUBILITY OF SULFATES COMMENTS ON ACID SLUDGE IN WA’I’ER (GRAM/lOOml ( °C) ENVIRONMENTAL HAZARDS 14.3 (O°) Copper sulfate causes CuSO 4 75.4 (100 ) irritation of skin Al 31.3 (0°) A1 2 (S0 4 ) 3 readily hydro— A1 2 (S0 4 ) 98.1 (1000) lyzes to sulfuric acid which acts as tissue A1 2 (SO ) 18H 0 86.9 (0°) irritant 1104.0 (100°) Fe Fe(S0 4 ) 7H 2 0 15.65 (0°) Ferrous sulfate is used 48.6 (50°) as a nutrient and dietary supplement food additive. Pb PbSO 4 (anglesite) 0.00425 (5°) Pb is cummulative poison. 0.0056 (40°) It produces brittleness of Pb SO PbO red blood cells so they (lanarkite) omo1yze with slight trauma and are destroyed more easily. Zn ZnSO 4 7H 2 0 96.5 (200) Zn is not a toxic element 663.6 (100°) for humans, but zinc oxide dust is known to give eczema in men engaged in packing this compound. Ba BaSO 4 0.000222 (18°) BaSO 4 is non—toxic. So].- 0.000336 (50°) uble impurities can lead 0.00413 (100°) to toxic reactions. One report describes a fatal BaS 2 O 4H 0 case of poisoning due to 8 BaO, with severe abdominal (Barium Peroxy 52.2 (00) pains, vomiting, dyspnoea, disulfate) decomposes in rapid pulse, paralysis of hot water arm and leg. Cr CrSO . 7H 2 0 12.35 (0°) 120.0 (20°) Ca — CaSO 4 0.209 (30°) 0.1619 (100°) CaSO 4 2H 2 0 0.241 (?0) 0.222 (100°) 99 ------- Table 20. (Continued) MPiJOR EL 4ENTS IN SOLUBILITY OF SULFATES COMMENTS ON ACID SLUDGE IN WATER (GRAM/lOOmi ( 0 C) ENVIRONMENTAL HAZARDS Na 2 SO 4 (anhydrous) 4.76 (00) Toxic effects are 42.7 (1000) unknown Na 2 SO • 10H 2 0 11.0 (00) (Glauber’s Salt)92.7 (300) Na 504 20 19.5 (0°) 2 44.0 (200) )4g 50 26.0 (0°) Used as a nutrient and/or 73.8 (100°) dietary supplement food 14g 50 4 7R 2 0 71.0 (20 ) additive. 91.0 (40°) MgS0 4 H 2 O 68.4 (100°) Inhalation of fumes of sublimed MgO may cause metal fume fever. Par- ticles of Mg metal or alloy which perforate the skin or gain entry through cuts or scratches may produce severe local lesion. 100 ------- Table 20. (Continued) ELEMENTS IN ACID SLUDGE PRESENT IN 10 TO SO PPM CONCP 1 SOLUBILITY OF SULFATES IN WATER (GRAM/lOOml(CC) COMMENTS ON ENVIRONMENTAL HAZARDS Ag 2 SO 4 (silver sulfate) 0.57 (00) 1.41 (1000) Silver sulfate decomposes on heating emitting highly toxic fumes of oxides of sulfur. Ni NiSO 4 (Nickel sulfate) 29.3 (0 ) 83.7 (100°) Nickel sulfate is used as food additive NiSO 4 7H 2 0 NiSO 4 6H 2 O 75.6 (15.5 ) 475.8 (100°) 62.52 (0°) 340.7 (100°) Nickel and most salts are not considered to cause systemic poisoning. Ingestion of large do es of nickel compounds (1 to 3 mg/kg of wt) has been shown to cause intestinal disorders, convulsions. 33 (25°) very soluble in cold water. Decom- poses in hot water. As 2 S 2 (Arsenic Disulfide) insoluble As 2 S 5 (Arsenic pentasulfide) 0.000136 (0°) Mo Molybdenum Compounds Some tim salts are ir- ritants or can liberate toxic fumes on decompo- sition. Alkyl tin compds. are highly toxic and produce skin rashes Arsenic compounds used as insecticides Arsenic poisoning can be acute or chronic. Molybdenum compounds are somewhat toxic but in spite of their considerable use, poisoning has yet to be reported. Mn MnSO 4 Mn 2 (S0 4 ) MnSO 4 2H 2 0 MnSO 7H 2 0 MnSO 4 6H 2 0 MnSO 4 5H 2 0 MnSO 4 4H 2 0 MnSO 4 3H 2 0 52.0 (5 ) 70.0 (70 ) Decomposes in hot water, verj soluble in cold water. 85.27 (35°) 106.8 (55°) 172.0 118.0 (13°) 147.4 124 (0°) 142 (540) 105.3 (0°) 111.2 (540) 74.22 (5°) 99.31 (57 ) Manganese sulfate is used as a nutrient and food additive. Does not pose any environnental hazard. Sn SnSO 4 Sn C 504) 2. 2H 2 0 101 ------- Table 20. (Continued) ELDIENTS IN ACID SLUDGE PRESENT IN SOLUBILITY OF SULFATES COMMENTS ON 10 TO 50 PPM CO N. IN WATER (GRAM 1 OOrnl ( °C) ENVIRONMENTAL HAZARDS V VS0 4 7H 2 0 Decomposes in air; no so1ubi1it r data reported. Vanadyl sulfate Very soluble in (minasragrite) cold water. V 2 0 4 ( 50 3 ) 3 .16H 2 0 Decomposes in hot water. 102 ------- Table 20. (Continued) OTHER ELEMENTS PRESENT IN ACID SLUDGE IN LESS THAN 10 PPM SOLUBILITY OF SULFATES COMMENTS ON IN WATER (GRAM/lOOml(°c) ENVIRONMENTAL HAZARD Ti Ti 2 (S0 4 ) (Titanous Sulfate) TiOSO 4 (Titanium basic sulfate) Insoluble in water Decomposes in water Titanium compounds are considered to be physio- logically inert. Cd CdSO 4 (Cadmium Sulfate) 3CdSO 4 8H 2 O (usual commercial form) 75.5 (00) 60.8 (100°) 114.2 (0°) 127.6 (60°) Inhalation of fumes or dusts of cadmium affects respiratory tract and kidneys. High concentra- tion may result in edema and death Co Co (SO 4 ) (Cobalt Sulfate) Co(S0 4 ) 7H 2 0 (bibeorite) Co(S0 4 ) 3 18H 2 0) Be BeSO 4 • 4H 2 0 42.5 (25°) 100.0 (100°) Toxicity of cobalt by mouth is low. It produces dernatitis and h(per— sensitivity of skin. Sr SrSO 4 (Strontium Sulfate, celestite) 0.0113 (0°) 0.0114 (32°) Strontium exhibits low order of toxicity 25.6 36.2 83.0 33.0 (0°) (20°) (100°) (20°) Soluble in water, but decomposes 103 ------- dual naphthenic acids and polyaromatic oils, and rain run- off waters containing 30-100 ppm oil, dictate against in- discriminate use of soil cultivation for disposal of even neutralized sludge. Field tests are underway on oil and machine coolant waste disposal into soil by Union Carbide and Stanford Research Institute. b2 Other companies are known to be using soil cultivation techniques, but technical data is not available. German work reportedly shows that acid sludge carefully disposed of does not present serious environmental problems. 2 ° On the other hand, one poorly designed landfill (dump) in the U. S. later experienced “acid oozing” when a foundation was laid on the completed fillJ’ 3 The acidity, combustible content, metal content, and complex organic content make it imperative that acid sludge not be indiscriminately disposed of. It is a prime candi- date for disposal in a regional hazardous waste disposal center as suggested by EPA, although properly designed and operated landfills can accept it with caution. Solidif i- cation rocesses, now practiced on a number of hazardous wastes, ‘ provides a possible improvement over untreated disposal, but it is expensive. These are believed to be based on exotherrnic reactions, such as acid neutralization, driving off water and forming low solubility salts. Combustion or incineration, even after neutralization, as is done in Europe, is undesirable due to the major amounts of sulfur oxides and very fine metal containing particulates which would be emitted. Ocean disposal, now generally prohibited in all but the most extreme cases, would probably not be permitted, al- though existing data is certainly not conclusive. A study of ocean disposal done for EPA considered industrial wastes such as spent sulfuric acid, chlorinated hydrocarbons, drill cuttings and drilling muds, and waste oils. 65 Although some negative data was found, the authors note that ‘ this minute body of information is totally disproportionate with both the amounts of wastes handled and the potential damage that these wastes can do.” As for other methods of acid sludge disposal, deep wells may be suitable in certain instances, but expensive and difficult to prove as environmentally sound. Municipal wastewater treatment plants would most likely not accept this waste without major pretreatment, e.g. dilution with 104 ------- large quantities of water, neutralization, and oil re- moval. Acid sludge from one re—refiner is being neutralized with limestone flyash from a steel mill ki1n. Acid sludge from another re—refiner is believed to be undergoing similar treatment. In Europe, acid sludge is often mixed with spent clay and/or caustic for neutralization. Neutralization does appear to be desirable, but the cost is significant and care must be taken because of heat release. Some acid sludge is being used in asphalt roofing. Spent Clay Spent clay does not appear to present any significant disposal problem. As an absorbent, the clay should retain the contaminants quite well. One would expect the oil to be gradually consumed by bacteria in the soil when clay is disposed of in landfills. Only about 14,000 tons per year of clay are disposed of by re—refiners, though industrial disposal of spent clay used in oil reclaiming may be larger than this figure. Other Solid and Semi—Solid Wastes Most other solid and semi—solid wastes resulting from waste oil processing is disposed of on land. Perhaps the most important of these are the oily flocs and sludges which result from wastewater treatment. Others include tank cleaning residues, caustic sludges, filter and centrifuge solids, etc. The uncertainties of environmental effects due to land-- fill has already been discussed. The other major approach to disposal of oil—containing solids and semi—solids is incineration. For pumpable wastes, this is accomplished with special thermal incinerators, empty refractory chambers equipped with waste liquid and auxiliary burners; by com- bustion in existing steam boiler furnaces; or in the case of offshore well tests, huge open air atomized burners.b 6 For primarily solid material, incineration is accomplished in rotary kilns and conventional solid waste incinerators, often mixed with other solid wastes. Fluidized bed in- cinerators are now being used for refinery wastes, including API separator sludge, air flotation skimming, spent caustic and other liquid wastes, 67 and could also be applied to other oily waste disposal problems. 105 ------- Incineration has several major disadvantages. The first is that fuel value is lost for high heating value wastes, unless expensive heat recovery facilities are included. For low solids concentrations, auxiliary fuel must be added to support combustion. Finally, incineration of wastes high in ash invariably requires expensive air pollution control equipment to meet present day standards. The soil cultivation approach to waste disposal has already been discussed. Biological degradation of waste oil slud es has also been demonstrated in a laboratory reactor. 8 Distillation and Extraction Bottoms Distillation or extraction bottoms contain from about 5—30% ash, more than one—half of which may be lead com- pounds when running automotive drain oil. At least two plants in the U. S. now use such fractions for asphalt blending; one plant in Europe uses a similar material as a fuel, but heat exchanger tube fouling and presumably high particulate air emissions result. 2 ° Lagoons have also been used for disposal, but these suffer from the difficulties previously discussed. Distillation or extraction bottoms provide an excellent possibility as a fuel source in secondary lead smelting reverberatory furnaces which are equipped with fine dust collection equipment. Test burning in such a furnace is planned in the near future under an EPA grant to NL Indus- tries. The geography of such a scheme appears to be good, with many furnaces located across the country (to reprocess lead from batteries and other scrap). Both fuel and lead values are expected to be recovered. Wastewaters Distillation condenser water and other waste oil pro- cessing wastewaters may contain phenols. Wastewater char- acterization data obtained by the contractor, including phenol analyses, were provided earlier in this section. Additional data is being obtained by NORCO as part of an EPA project. Use of surface condensers should be con- sidered to minimize the water volume. Phenols can be re- moved by oxidation, including bio-oxidation 4 adsorption, or extraction. Water that is discharged directly to rivers and other streams results in environmental problems similar to that from any petroleum refining operation, as discussed in EPA’s preliminary report to Congress. 43 106 ------- In the re-refining facilities visited, only a few aHow- ed oiiy rain water to run off to streams. Runoff was treated with process water by separators. It was reported that most re—refiners were able to meet local regulations for dis- charge to municipal sewers, but it is doubtful whether any could meet new Federal guidelines for discharge to surface waters. Water discharged to municipal sewage plants normally must contain less than 100 ppm oil. A laboratory study has shown that for conventional plant operations, the influent to an activated sludge system should contain less than 75 ppm hexane extractables, and preferably less than 50 ppm, because of adverse effects on sludge settling properties. The oily materials introduced, including crankcase waste oil, were absorbed a]..most immediately onto the biological floc. In general, shock loads up to 5% of the sludge weight under aeration was acceptable, while a 10% load caused significant upset in the system. Air Emissions Loss of volatiles and vapors is usually reduced by closing tanks, applying a slight vacuum to equipment, vent- ing to furnaces, and in severe situations, installation of scrubbers, absorbers, or other suitable air pollution con— trol systems. Burning of lead or other metal containing wastes creates potential air pollution problems (in the form of fine par- ticulates 29 ), and should not be done indiscriminately. Even though air quality standards for lead have not been promul- gated, the uncertainty and controversy surrounding the issue indicates that unnecessary emissions should be at least dis- couraged or controlled; particularly since lead recovery and burning in lead furnaces seem feasible. Numerous re- ferences on this subject are available.’° 78 OVERALL ASSESSMENT AND FUTURE CONSIDERATIONS Acid sludge disposal is the most serious of the re- refining waste disposal problems. Although acid sludge presents serious handling problems, these can be overcome with care. However, due to the contents of lead and other metals, combustibles, and oil, disposal in lagoons, pits, or by any indiscriminate means, poses serious hazards. Mixing with refuse and/or neutralization and spreading in well designed and operated landfills experienced in re- 107 ------- ceiving hazardous wastes seems reasonable, at least as a short term solution. Loss of lead to the land in the quantities now en- countered appears to pose no major environmental threat, but obviously is not desirable from the point of view of re- source conservation, since U. S. lead supplies are limited. Even though lead content of automotive drain oils will de- crease as gasoline lead limitations take effect, it would be very desirable, as soon as possible, to eliminate the acid treating step which generates acid sludge. Disposal of spent clay to a well designed landfill does not appear to be a serious problem, although additional data on spent clay composition, including the possible presence of carcinogens, and on the rate of oil degradation is very desirable. Other known waste products from re—refining and waste oil processing are also not considered to be serious threats to the environment. Undesirable air and water emissions from re—refining operations have been reduced considerably in recent years. Additional controls as necessary can be instituted if ad- equate financing and good management and engineering support are available. Oily flocs and sludges from wastewater treatment in such industries as petroleum, petrochemicals, iron and steel, metal fabrication, pulp and paper, foods, and others, are a serious problem, at least in terms of volume and poorly under- stood environmental effects. There is a need for consider- able investigation in this area. On the whole, the environmental effect of waste products and residues from waste oil processing appears to be much less of a problem than would exist from waste oils if no reclaiming were practiced. The reclaiming business should be encouraged to insure that sufficient capacity is available to receive and adequately process waste oils for secondary use, and aided in overcoming the waste disposal problems which do exist. 108 ------- SECTION IX WASTE OIL SURVEYS Three separate surveys were conducted with varying purposes. In the first, a general survey of the Pittsburgh area was designed to test survey methodology and to obtain preliminary waste oil generation data from a major metro- politan area. As will be shown, the test of methodology showed that such surveys are not accurate. Therefore, the national survey which had been contemplated was abandoned in favor of a survey of waste oil collectors and processors. The third survey was designed primarily to obtain technical information from leading industrial companies on their waste oil practices. PITTSBURGH AREA The survey portion of this study had two distinct, although overlapping objectives. The first was to consider the recycling of waste oil in one major metropolitan area. We were interested in both the current state of waste oil recycling, and in trends with implications for the future. The results, wherever possible, were to be quantitative in nature. Ideally, they would be projectable to the entire metropolitan area studied. The second purpose was to use the sample area as a pilot study for a potential nationwide project. Here the emphasis was on developing understanding and testing techniques. Some of the results, and in particular, some key facts for service stations are projectable. Some results are less quantitative, since they were based on openly—structured interviews, and the respondents themselves did not represent a random sample. This approach was deemed necessary to get a better understand- ing of the nature and relative magnitudes of the various sources of waste oil. 109 ------- Area Studied In accordance with the project requirements, it was necessary to choose one specific metropolitan area for study. The major factors in choosing the specific area are primarily negative. The area chosen had to be: a) not so large as to be unmanageable within the project budget constraints (e.g. New York or Chicago). b) not so small as to not have a representative cross-section of oil users. C) not a one-industry town (e.g. Detroit or Akron). d) not a part of a larger, contiguous megalopolis (e.g. Newark). In addition it was desirable for the area to have both a number of major industrial plants and a number of large corporate headquarters. Among the several areas meeting these requirements, Pittsburgh was chosen more or less randomly. General Discussion An important consideration in conducting a waste oil survey is to distinguish between quantities of oil used , waste oil generated internally, recycled internally, gene- rated externally , and available for recycle externally . The difference etween thiie five terms are affected by con- sumption at the point of use, internal recycle facilities, spills, and questions of quality degradation at every step. An example of significant losses occurs in pipelines which generally have spill tanks at pumping stations. The oil contained in these spill tanks is not (in the Pittsburgh area at least) directly reinserted into the pipeline flow, making this substantial amount of oil available for re- cycling. Detecting the potential significance of pipeline spillage is one of the results of the use of open—ended interviews. Depending on usage and user, the proportion of re- coverable oil varies from none at all up to 85% or 90%. The lowest proportions are for process oil, and oil added to 110 ------- gasoline for lubrication (primarily vehicular - usually two cycle engines). For other industrial uses the main factor in the proportion of recoverable oil appears to be the degree to which the oil must be contaminated before it is unsuitable for further use. For instance, oil used for some lubrication purposes is often almost totally used up since even fairly contaminated oil remains usable, with new oil being added on a continuing basis. Oil used for electrical insulation 1 on the other hand, often loses its quality at relatively low contamination levels and can be recovered and recycled either internally or externally. On the whole, oil used in vehicular and especially automotive crankcases is recoverable in high proportions. Non—recoverable crankcase oil is of two types: oil burnt up by the engine and oil left in the oil filter. This latter can be of considerable significance. If the oil filter is changed every other oil change, about 8-10% of automotive lube oils could be discarded with filters. As noted before, waste oil generated by a particular process (i.e., generated internally ) is not the same as waste oil available for recycling externally . Whether particular sources of waste oil will produce oil available for recycling outside the generating source depends upon several factors, the most important being the following: How much waste oil is produced at a particular point. Paradoxically, the greater the quantity of waste oil produced, the less likely it is that the oil is available for external recycling. This is because large quantities at a single place make it economic for the organization generating the oil to find uses for it themselves (e.g. burning). How much heat or power generation is done by the waste oil generating organization. An organization buying substantial amounts of heating oil will have obvious reasons and potentialities for using its own waste oil as fuel. A corollary is the necessity to distinguish the quality of waste oil generated. Clean oil overflowed into a spill tank is obviously not in the same condition as oil taken from a truck engine after 6,000 miles. While general state- ments are difficult, many industrial uses seem to be at the 111 ------- two extremes. For instance, most insulation and hydraulic uses, and some lubrication uses, lead to a quality of oil equivalent to simple spillage as a source of waste, while some process uses such as rubber compounding change the basic nature of the oil. There is, or course, significant lubrication use,which is similar to vehicle use in the poor quality of the waste oil that is produced. Finally, we found that the waste oil recovery process seems to be going through a period of considerable upheaval. Underlying the changes are the major recent, current,and presumably near—term future changes in the economics of the problem. One example is that the value of oil as a fuel has produced substantial changes in the use of oil directly at the point of collection by industrial users. A major utility, for example, has just recently switched to burning its used electrical insulation oil in its steam generators, and will shortly do the same with crankcase oil collected from its fleet of almost 1,000 vehicles. Similar- ly, as oil becomes more valuable (and continues in short supply), the economics of collection clearly change for the recycler. On the other side, the growing environmental pressure leads to greater concern for recycling wastes of all types. Summary Overall, we found that in the Pittsburgh area most (although not all) recoverable waste oil is being recovered; that the recovery process, especially for industrial wastes, is more and more becoming a process carried out internally for a particular organization; and that the availability of waste oil for recycling must be understood in terms of not only how much, but what types, where and how. The elabo’- ration of these findings for each source of waste oil is presented in Appendix C. The work performed and the results obtained in the survey can be summarized as follows. General — All waste oil is not available for external re- cycling. Aside from those purposes which use up all or most of the oil, substantial amounts of waste oil are, especially in industry, internally recycled or used at the source for fuel, road oil, etc. The proportion of waste oil being in— ternally recycled or reused in industry is rising, and the oil shortage should accelerate this rise. 112 ------- The most significant sources of external recycled waste oil in the Pittsburgh area are automotive crankcase oil and oil spilled in pipeline transportation. Most waste oil in the Pittsburgh area which is potenti- ally recyclable appears to be presently recycled, but for uses other than lube oils, including fuel use. This is partly a result of the fact that there are no re-refiners (producing lube oils) within 230 miles of Pittsburgh. Private Vehicles — A random sample survey of 100 service station owners and/or managers was carried out in the Pittsburgh area. A total of 83 interviews was successfully completed. The service station respondents turned out to be un- able to give consistent information on the amount of waste oil they collect from automotive crankcases. Asked about waste oil in three ways (oil sold for changes, number of changes, and total collected) they provided substantially differing information. On an average basis we estimate that there is about 1,100 gallons of waste oil generated per service station per year in the Pittsburgh area. New car dealers and maintenance centers appear to generate roughly half as much waste oil as do service stations. We estimate that in Pittsburgh about 2.3 million gallons ± 33% is the total waste oil generated from privately owned automobiles per year. Other Sources — There are five main categories of organi- zationally owned vehicles: rental fleets, for-hire trucking, fleets owned for direct organizational use, automotive public transportation, and non—automotive vehicles. Overall we estimate organizationally owned vehicles generate about half as much available—for-external-recycling waste oil as do private vehicles, or about 1.4 million gallons per year. There are five main classes of non—vehicular oil usage. Ranked in order of recoverable waste oil in Pittsburgh, these are: oil spilled and contaminated in transit (pipe- lines), insulation oil, process uses, and lubrication. 113 ------- Based on population ratio from national figures, one would estimate about 10 million gallons of industrial oil sold in the Pittsburgh area per year. Because of the in- dustrial nature of the area this could be as high as 15 million gallons per year. About one million gallons appears to be available for recycling at locations other than those of the original users. Collector Survey — Interviews were carried out with six waste oil collectors in the Pittsburgh area. Of these, three turned out to be collectors who merely deliver the waste oil to the processing plant of the one large operation. From interviews with collectors we estimate 1.973 col- lection by Pittsburgh-based firms at about 11 million gallons. This breaks down as About 4.5 to 5.5 million gallons from the Pitts- burgh area About 3.0 to 3.5 million gallons of pipeline spillage from a wide area around Pittsburgh About 3.0 to 3.5 million gallons from other than pipeline spillage from areas outside Pitts- burgh (e.g. West Virginia, Ohio). Overall Results — The total crankcase waste oil is estimated at about 2.7to 4.8 million gallons with a best estimate of about 3.7 million gallons. About one million gallons per year of industrial waste oil is estimated to be available for recycling. About 9 million gallons of automotive oil are estimated to be sold in the Pittsburgh area per year. About 5 million gallons should be available for recycling based on the estimates made in Section X. This compares with the esti- mate of about 3.7 million from the survey. A National Study It was the original expectation of the Request for Pro- posal which initiated this study that one result would be a proposal for a comprehensive national study of the potential for oil recycling. As a result of the data collection pro- blems discussed above, especially in the service station area, we have come to the conclusion that a national study would be of limited value, if any, unless accompanied by a continual record—keeping system for a large national sample. 114 ------- This approach seems impractical because of cost, which probably would exceed the value of more accurate survey results. Thus, only a limited version of a national study was recommended, concentrating on a study of collectors and processors to obtain accurate current data. For completeness, the sample which would be proposed in a national study, if there were no question of data collection problems, appears as Table 2 i. WASTE OIL COLLECTORS AND PROCESSORS The overall goal of this survey was to provide data on the waste oil industry in the U. S. More specifically, the study has attempted to: (1) assess industry size; (2) determine industry practices; (3) analyze current and future industry trends; and (4)provide national estimates. Some of the results are presented below. Details are provided in Appendix D. Method This study employed telephone interviews with respon- sible executives in waste oil collector and collector/pro- cessor firms as the basic data gathering approach. One hundred such firms were interviewed in April of 1974. Response Analysis,the subcontractor, initially deve- loped a listing of waste oil firms from a variety of sources: telephone directory yellow pages, lists of licensed firms in states where such firms must be registered, and from information supplied by several governmental agencies and industry associations. The Response Analysis national probability sample, with 103 primary sampling units throughout the United States, was the basis for selecting particular waste oil firms. This sampling method provides an accurate basis for making national estimates, within certain statistical limitations. Data on waste oil firms in this study was weighted up to provide national estimates of the industry for several key items. Characteristics of the Waste Oil Industry Nationwide, fewer than 500 firms appear to operate in the waste oil industry. Of these, approximately 60% are 115 ------- Table 21. NATIONAL SAMPLE STRUCTURE Number of Category Sample Basis Interviews Remarks SERVICE STATIONS Regular National probability 750 Highway stations National probability 100 Truck stops National probability 100 OTHER PERSONAL AUTO SERVICING New Car National probability 100 Auto repair National probability 100 Department/discount National probability 100 FLEET AUTOMOBILES Government National probability 100 Public transportation National probability 100 ½ taxis;½ other Utilities (cars,trucks) National probability 50 Distribution firms— ½ truckers; light trucks National probability 100 ½ commercial Auto rental National probability 100 Industrial Fortume 1250 100 Some stratifica- by broad Trucking firms- industry type heavy trucks National probability 100 NON-AUTOMOTIVE USES Airlines Fortume 1250 25 Interviews at maintenance headquarters Pipelines Standard & Poor 25 Airports for general aviation National probability 25 General industrial Standard & Poor 200 Substantial Railroads Fortume 1250 25 stratification by industry type SALES ONLY (Telephone Interviews) National probability 600 Total of 600, including those done in category under department! discount to establish servicing areas 116 ------- collectors and 40% are collector/processors. The waste oil industry is highly fragmented, ephemeral, and not easily characterized in terms of the “average” operator or firm. During the past year many new firms were started, although many will probably go out of business quickly, or move operations to another city or state. Older firms may also change hands, particularly in the current highly competitive situation. Many older firms also appear to change their place of business and market areas at fre- quent intervals. Many firms, both old and new, seem to run their businesses in a highly informal and flexible manner, often operating out of temporary facilities with no formal address or phone number. Under these circumstances, any form of regulation is difficult. Collectors tend to search for waste oil sources on an informal basis without contracts or a specified callback system. Collector/processors, however, do sometimes collect under contractual agreement. There is also evidence to suggest that much of the waste oil initially collected is immediately disposed of. This alternative may still be more economical than transporting the waste oil to a processing plant. Some waste oil executives perceive little or no need for air and water pollution control measures in their in- dustry. Many spokesmen seem defensive when asked whether or not their type of industry produces any form of pollution. The majority of companies dispose of processing wastes in landfills. Trends in the Waste Oil Industry Future industry growth will probably be experienced by the collector/processors at the expense of the collectors. At present, more collector/processors say they are ex- periencing growth than collectors. (When asked to predict future trends in the industry, many more collector/processors were optimistic about future growth than were collectors.) The waste oil industry seems to be at the mercy of many external factors, affecting business in both the short and long run. Recent shortages in petroleum have been a mixed blessing. While more oil is needed for the domestic market (including reprocessed waste oil) less oil is available be- cause people are driving less and no longer require frequent oil changes. Automobile and truck manufacturers have also 117 ------- extended the recommended intervals between oil changes, thus reducing available waste oil even further. All of these factors contribute to operation below the industry’s capa- city. Concern over environmental problems, government regu- lation, licensing, and inspection play both a direct and indirect role in determining practices in the waste oil industry, including “acceptable” methods for handling waste materials. All of these factors have a negative effect on the availability of capital for investing in n.ew state-of- the—art equipment for processing waste oils. Background Impressions Waste oil firms,in general, keep either poor records or no records. Some are even reluctant to attempt estimates. This is more true of collectors-—collector/processors operate larger, more formalized businesses and tend to have more complete records. Collectors and collector/processors are not cooperative respondents. Many refused to grant an interview, and many of those who did refused to answer many of the questions. To date, the waste oil industry has been relatively unknown, unrecognized, and unmeasured. In general, there appears to be little information from any source (including state and federal agencies) on firms in the ,aste oil in- dustry. While this report discusses most phases of the industry, many questions about further aspects of waste oil collection and processing are also raised. Data Summary Some of the more important results of the survey are presented in Tables 2224. A summary of national estimates is provided in Table 25. It is apparent from Table 22 that the industry is dominated by companies who do processing. However, because of the large quantity of oil reported collected, but not accounted for (“Other or Not Reported”), even these companies may be bypassing processing and transferring oil directly from collection to fuel, road oil, dust control, and perhaps landfill or other questionable practices. Table 23 provides some insight into the type of pro- cesses used. It is apparent from these figures that most 118 ------- Table 22 . WASTE OIL COLLECTION AND USE Collector/ Collectors Processors No. Gal/Month No. Gal/Month Collection Total Waste Oil 61 3,531,000 39* 19,114,000 Collected Collected From Other 8 32,000 16 3,850,000 Collectors Net Collected 3,499,000 15,264,000 Collected From Service Stations and New Car Dealers 2,030,000 (58%) 2,745,000 (18%) Uses Road Oil or Dust 15 57,000 8 43,000 Control Fuel 12 75,000 14 300,000 To Processing l4 117,000 39 3,775,000 Other or Not 7 3,282,000 5 14,996,000 Reported 3,531,000 19,114,000 * Includes 8 processors who have no collection facilities of their own, but have a working relationship with collectors. ÷ Includes simple settling. 119 ------- Table 23. TREATMENT PROCESSES USED % of the 39 Processors Who Use Filtration or Centrifugation 87 Settling 56 Flash Drying or Distillation 77 Clay Treatment 46 Acid Treatment 44 Caustic, Silicate or Other 59 Chemical Treatment Other 13 120 ------- plants have multi—step processes, or a choice for each oil processed. Most separate solids and/or water by settling, filtration, or centrifugation and probably dry also by vaporizing water. Acid, clay and chemical treatments seem to be common. The amount of lube oil produced as compared to other products, shown in Table 24, is high, but the total oil accounted for here (51,000,000 gallons per year) is only 22% of that collected by the processors interviewed (19,114,000 gallons per month) , again raising the question of whether much of the collected oil is processed at all. The subcontractor’s projection of the information ob- tained, shown in Table 25, indicates that there are 423 collectors and processors nationwide who collected 1,640 million gallons of waste oil in 1973, and processed 706 million. These figures may be compared to estimates based on 1970—71 sales volumes and estimated recoveries and losses, as shown in Section X: Millions of Gallons Per Year Projections from Survey of Waste Oil Projections Collectors & from Methods Processors of Section X Collection 1,640 1,502 (oil pro- cessed + oil to fuel + road oils, etc.) Processed 706 901 (waste oil processors + re- ref iners) This close check for estimates made entirely independently, by very different methods, lends confidence to their valid— I ty. 121 ------- Table 24. TYPES OF OILS PRODUCED BY PROCESSORS Gallons Produced In 1973 (%) Fuels 19,890,000 (39) Lube Oils 19,890,000 (39) Road Oil 3,570,000 (7) Process Oil 4,080,000 (8) Journal Box Oil 2,040,000 (4) Asphalt Flox & Other 1,530,000 (3) 51,000,000* (100) * Based on 21 of 39 processors who supplied relevant data. 122 ------- Table :25, NATIONAL ESTIMATES 1973 Totals Collection No. Millions of Gallons Collectors 260 Collector! Processors 163 423 1,640 Process jflg* Actual Processed 163 706 Capacity 163 1,055 * Including re—refiners. 123 ------- SURVEY OF INDUSTRIAL FIRMS One organization in each of fifty-seven SIC (Standard Industrial Classification) major groups were interviewed to investigate the purchase and use of oils, and waste oil generation and disposal. These groups included some govern- mental and institutional organizations, as well as industrial companies. Visits were made to about one-half of the organizations; information from the remainder came via telephone and mail. Both visit and telephone interviews were nationwide, pri- marily with leading companies in their fields. Information received was on the basis that the organization contacted would not be identified. The primary purpose of the survey was to obtain tech- nical information on industrial practices. All interviews were conducted by the Contractor’s technical staff who are well versed in waste oil problems. No attempt has been made to handle the data on a statistical basis. The cooperation received ranged from fully cooperative to complete non—cooperation. In the latter cases, a sub- stitution was made for the original organization selected. Most multi-plant companies had no centralized oil purchase records; very few had centralized records of waste oil generation or disposal. Therefore, in many instances infor- mation was gathered from a single location, either typical of the organization, or a plant using a large quantity of oils. Discussions in other sections of this report reflect information gathered during this survey. The data gathered also tended to reinforce material balance calculations shown in Section X. A summary of the information obtained appears as Appendix E. Ultimate disposal of waste oils and other oily materials meant pickup by an independent collector in most cases. Only a few companies were aware of the destination of oil which left the company facilities by this route. 124 ------- A compilation of the number of companies using various disposal methods follows. These are based on 5G answering, with many companies having- multiple disposal methods: Disposal No. of % of Organizations Method Organ! zations Answaring Picked up by collector 38 68 Reclaimed internally or externally for internal use 16 29 Landfill (or dump) 15 27 Used as fuel 14 25 Significant losses to wastewater 9 16 Discarded to trash or refuse 8 14 Road oiling or dust control 4 7 Incineration 2 4 125 ------- SECTION X QUANTIFYING U. S. WASTE OIL GENERATION AND DISPOSAL A waste oil material balance for the U. S. has been attempted. Although major data gaps have been identified, a complete balance has been made, using best estimates to fill these gaps. The data are summarized in Table 26. De- tails are provided in Appendix F. Waste oil balances are basically built up from: — sales data on oil sales in various categories, e.g. automotive lubes, industrial lubes, other industrial oils, etc. - information obtained during the Con- tractor’s surveys, or previous surveys, on the portion of oil sold which becomes waste oils, or best estimates where such data are lacking. As already noted in Section IX, the estimate for total waste oil generated in 1970—71, obtained as follows from Table 26: Millions of Gallons Disposed of to: Per Year Waste oil processors 763 Re—Refiners 138 Road Oils, Asphalt, Etc. 243 Fuel 358 1,502 checks very closely with the estimate of the total quantity collected, 1,640 million gallons per year (1973), obtained from the survey of collectors and processors. The total processed: Millions of Gallons Disposed of to: Per Year Waste Oil Processors 763 Re—Refiners 138 901 126 ------- also provides a reasonable check against the survey result of 706 million gallons per year. 127 ------- TABLE 26. GENERATION AND DESTINATION OF WASTE OIL (WO.) - MILLIONS OF GALLONS PER YEAR W.O. To W.O. To Road Oils, For To Sale Lactor _ W.O. Processors Re-RefinerS Asphalts, etc . Fuel Environment Automotive Lube Oils Service Stations 270 .63 170 Garage., Auto Supply Stor•s 60 .63 38 New Car Dealers 102 .90 92 Retail Sales for Coiiviiercial Engines 90 .63 57 Auto Fleet & Other Lube Oil Users 136 .50 68 Factory Fills (Auto & Farm Equip.) 60 .90 54 Discount Stores 168 .22 37 Commercial Engine Fleets 200 .50 100 loll. 202 105 142 19 148 Industrial & Aviation Lube Oil . Hydraulic & Circulating System Oils 325 .42 137 Metal Working Oil. 150 .70 105 Railroad Engine Oils 60 .53 32 Gas Engine Oils 62 .90 56 Aviation & Other 137 .47 64 7 T 130 16 25 111 112 Other Industrial Oils Process Oils 310 .10 31 Electrical Oils 57 .90 51 Refrigeration Oils 10 .50 5 177 28 3 6 25 25 Lube Oils Purchased by U. 3 . 37 .50 18 4 3 .j _..! Sub—Totals 2234 — 1115 364 127 177 159 288 Other Oil Losses and Spills, iron Production, Refining, Transportation, Marketing, Use - ...!! GRAND TOTALS — 2480 763 138 243 358 978 Disposition from W.O. Proc.ssors (—763) 76 649 38 Disposition from Re-Refiners (-55) - 21 34 ULTIMATE DISPOSAL 83 319 1028 1040 * Re-Refined Products ------- SECTION X REFE RENCES 1. Bethea, S. R., D. S. Bosniak, B.E. Claybaugh, and E. L. Mohuridro. To Hydrotreat Waste Lube Oil. Hydrocarbon Processing :134-136. September 1973. 2. Study of Waste Oil Disposal Practices in Massachusetts. Commonwealth of Massachusetts, Division of Water Pollution. Contractor - Arthur D. Little, Inc. C- 70698. January 1969. 36 pages. 3. Delta Airlines Treatment Plant Handles Chemical and Oily Wastes. Industrial Wastes. 28:27-34, September— October 1973. 4. Industrial Oily Waste Control. American Petroleum Institute and the American Society of Lubrication Engineers, 144 pages. Chapter 8, p. 123-136. 5. Martin, E. J., G. D. Gunty. State of Maryland Waste Oil Recovery and Reuse Program. The Maryland Environmental Service. Contractor — Environmental Quality Systems, Inc. Washington, D. C. EPA 670/2- 74—03. U. S. EPA. January 1974. 247 pages. 6. Royal, T. B. Reprocessed Oils. Rubber Age :45-50, February 1973. 7. Sales of Lubricating and Industrial Oils and Greases. Social and Economic Statistics Administration, Bureau of the Census. Washington, D. C. MA-29C (71)—i. U. S. Department of Commerce. 1971. 10 pages. 8. Forster, R. L.., et al. Port Collection and Separa- tion Facilities for Oily Wastes. Contractor - Frederic R. Harris, Inc. Washington, D. C. 2-36202. U. S. Department of Commerce, Maritime Administration. 1973. 4 volumes. 9. Salvesen, R. H., A. Beerbower, A. R. Garabrant, M. Lieberman. Research of Oily Wastes, Norfolk Area. Naval Supply Systems Command. Contractor - Esso Research and Engineering Company. GRVS 2 EAD. 72. U. S. Navy. January 1973. 53 pages. 129 ------- 10. Beychok, M. R. Aqueous Wastes From Petroleum and Petrochemical Plants. London, John Wiley and Sons, 1967. 370 pages. 11. U. S. Bureau of the Census, Pocket Data Book USA 1971. Washington, D. C., U. S. Government Printing Office, May 1971. 352 pages. 12. Shreve, N. R. Chemical Process Industries, 3rd edition. New York, McGraw-Hill Book Company, 1967. 887 pages. 13. The Encyclopedia of Chemistry, 3rd edition. New York, New York, Van Nostrand Reinhold Company. 1973. Synthetic Lubricants, pages 644-645. 14. Teknekron Report for EPA to be issued. 15. Waste Oil Recovery Practices — State-of-the-Art (1972). Maryland Environmental Service and U. S. EPA, Contractor Environmental Quality Systems. Washington, D. C. December 1972. 250 pages. 16. Conversion of Crankcase Waste Oil Into Useful Products. U. S. EPA, Contractor - National Oil Recovery Corporation. WPCR Series 15080 DBO. March 1971. 87 pages. 17. Chambers, T. M. Crankcase Oil Refining. U. S. Patent No. 3,173,859. March 16, 1965. 9 pages. 18. chambers, J. M. and H. A. Hadley. Crankcase Oil Re- Claiming. U. S. Patent No. 3,625,881. December 7, 1971. 9 pages. 19. Bonnifay, P., et al. A New Process for Reclaiming Spent Lubricating Oils. Institut Francais du Petrole (Presented at the National Fuels and Lubricants Mtg. National Petroleum Refiners Association, New York City, Sept. 14—15, 1972). 10 pages. 20. Unpublished notes from Dr. P. B. Lederman, EPA, Edison, New Jersey. 130 ------- 21. Villanova University, Final Progress Report, FWPCA Grant WPD-174-01-67, unpublished. 22. Automotive Crankcase Drainings Can Yield the Base Lubricating Oil. Chemical Engineering :51, Nay 13, 1974. 23. NORCO report to be published. 24. Putscher, R. E. Study of Re-refining Waste Disposal. Armour Research Foundation of Illinois Institute of Technology. Lyons, Illinois. ARF 3808-5. Associa— tion of Petvoleum Re-Refiners. January 29, 1960. 32 pages. 25. Study of Problems of Refining Lubricating Oil Drain- ings. Association of Petroleum Re-Refiners. Contractor — Walter C. McCrone Associates, Inc. Chicago, Illinois. MA1982. May 11, 1971. 17 pages. 26. Weinstein, N. J. et al. A Non-polluting Oil Re- Refining Process. Recon Systems, Inc., Princeton, New Jersey. (Presented at American Institute of Chemical Engineers Worshop “Industrial Process Design for Pollution Control.”). Chicago. (October 17—19, 1973) . 12 pages. 27. Private communication from Teknekron, Inc., Berkeley, California. 28. Twomey, D. W. Lube Market Getting Tighter. Ilydro- carbon Processing :201-204, November 1973. 29. Chappell, G. A. Waste Oil Processing. Division of Water Pollution Control, Water Resources Commission, Commonwealth of Massachusetts. Con.— tractor — Esso Research and Engineering Company. Linden, New Jersey. 72-5. January 1973. 39 pages. 30. Freestone, F. J. Runoff of Oils from Rural Roads Treated to Suppress Dust. Edison Water Quality Research Laboratory. Edison, New Jersey. EPA-R2- - 054. U. S. EPA. October 1972. 29 pages. 31. 1973 Petrochemical Handbook Issue. Hydrocarbon Processing :128, November 1973. 131 ------- 32. Bennett, I. C., et al. Animal-Feed Protein Made From n—Paraf fins. Chemical Engineering :45-47, December 27, 1971. 33. Oil Pollution Removal Handbook. Park Ridge, New Jersey, Noyes Data Corporation, 1973. p. 339-394. 34. Vaughn, S. H. and R. S. McCurdy. Wastewater Treat- ment at Ford’s Windsor Complex. Industrial Wastes. 34:34—40, May/June 1973. 35. Gilde, L. C. Pollution Control in Food Industries. In: Industrial. Pollution Control handbook, Lund, H. F. New York, McGraw-Hill Book Company, 1971. p. 16—15. 36. Beychok, H. R. Wastewater Treatment, State—of—the- Art. Hydrocarbon Processing :109-112, December 1971. 37. Racine, W. 3. Plant Designed to Protect the Environ- ment. Hydrocarbon Processing :115-119, March 1972. 38. Thomson, S. J. Data Improves Separator Design. Hydrocarbon Processing :81-83, October 1973. 39. Kirby, T. W. Water Conservation at a Major Befinery- Petrochemical Complex. Water-1973, Bennett, G. F. New York, New York, American Institute of Chemical Engineers, 1974, P. 645—653. 40. Willenbrink, R. Wastewater Reuse and In-Plant Treatment. Water - 1973, Bennett, G. F. New York, New York, American Institute of Chemical Engineers, 1974. p. 671—674. 41. Seng, W. C. Recovery of Fatty Material From Edthle Oil Refinery Effluents. U. S. EPA, Contractor - Swift and Company. Washington, D. C. EPA-660/2- 73—015. December 1973. 42. Lewis, W. L. Petroleum Industry Challenge—Pre- vention of Ocean Pollution. Water - 1973, Bennett, G. F. New York, New York, American Institute of Chemical Engineers, 1974. p. 654—666. 132 ------- 43. Waste Oil Study - A Preliminary Report to the Congress. U. S. EPA. Washington, D. C. 93-12. May 1973. 55 pages. 44. Manual on Disposal of Refinery Wastes, Volume VI, Solid Wastes, 1st edition. Washington, D. C., American Petroleum Institute, 1963. 51 pages. 45. Methods for Chemical Analysis of Water and Wastes. National Environmental Research Center, Analytical Quality Control Laboratory. Cincinnati, Ohio. 16020———07/71. U. S. EPA, 1971. 312 pages. 46. Standard Methods for the Examination of Water and Wastewater, 13th edition. Washington, D. C., APHA, AWWA, WPCF, 1971. 874 pages. 47. EPA, Solid Waste Disposal, Proposed Guidelines for Thermal Processing and Land Disposal of Solid Wastes, Volume 38, Number 81, Washington, D. C., Federal Register, April 27, 1973, p. 10544—10553. 48. Report to Congress on Hazardous Waste Disposal. U. S. EPA. Washington, D. C. June 30, 1973. 168 pages. 49. Powell, M. D., et al. Digest of Selected Local Solid Waste Management Ordinances. U. S. EPA, Contractor - National Association of Counties Research Foundation. Washington, D. C. (SW—38c). U. S. EPA. 1972. 376 pages. 50. EPA, Oil Pollution Prevention, Non-Transportation Related On—shore and Off-shore Facilities, Volume 38, Number 237, Washington, D. C., Federal Register, December 11, 1973, p. 34164—34170. 51. New Jersey State Departiitent of Health, Division of Clean Air and Water, Water and Sewage Statutes, Trenton, New Jersey, September 1969, 180 pages. 52. Private communication from the State of New Jersey, Department of Environmental Protection, Division of Water Resources, Trenton, New Jersey. 133 ------- 53. Illinois Pollution Control Board, State of Illinois, Water Pollution Regulations of Illinois, March 7, 1972, 36 pages. 54. Statuatory Authority. U. S. EPA, Washington, D. C. December 1972. 55. EPA, Petroleum Refining Point Source Category, Effluent Limitation Guidelines and New Source Standards, Volume 39, Number 240, Washington, D. C., Federal Register, December 14, 1973, p. 34542—34558. 56. Modern Methods for Acid Sludge Disposal. Oil in Canada :24-27, January 18, 1954. 57. Handbook of Chemistry and Physics, 53rd edition. Chemical Rubber Publishing Company, Cleveland, Ohio. 1973. 58. Sax, N. I. Dangerous Properties of Industrial Materials, Third edition. New York, Reinhold. 1968. 59. Metals from Industrial Waste May Limit Fertilizer Use of Sewage Sludge. Chemical Week :36, April 17, 1974. 60. Ocean Disposal Practices and Effects. (A Report from the Presidentts Water Pollution Control Advisory Board to the U. S. EPA Meeting September 26-29, 1972) 20 pages. 61. Kincannon, C. B. Oily Waste Disposal by Soil Cultivation Process. U. S. EPA. Washington, D. C. EPA—R2-72-11O. December 1972. 115 pages. 62. Soil Microorganisms Offer Pollution Solutions. Chemical Engineering :26, November 26, 1973. 63. Private communication. 64. Ford Calls in the Sludge Experts (Reprint). Business Week. June 16, 1973. 65. Smith, D. D. and R. P. Brown. Ocean Disposal of Barge-Delivered Liquid and Solid Wastes from U. S. Coastal Cities. Solid Waste Management Office, Contractor - Applied Oceanography Division, Dillingham Corporation. SW—19c. U. S. EPA. 1971. 119 pages. 134 ------- 66. Burning Waste Oil. Compressed Air Magazine :14- 16, November 1973. 67. Flood, G. C. and K. L. Kunci. Over 370 tpd of Oily Sludge Converted Into Clean Air and Innocuous Land- fill. Chemical Processing. September 1973. 68. Fragala, R. et al. Microbiological Treatment of Waste Oil Sludge. Commonwealth of Massachusetts Division of Water Pollution Control, Contractor - Tyco Laboratories. Washington, D. C. C-943. June 3, 1970. 40 pages. 69. Barnhart, E. L. The Impact of Oily Materials on Activated Sludge Systems. American Petroleum Institute. Contractor - Hydroscience, Inc. Washington, D. C. 12050 DSH 03/71. March 1971. 110 pages. 70. Lead and Air Pollution: A Bibliography With Abstracts. U. S. EPA, Office of Air Quality Planning and Standards. North Carolina. EPA-450/l-74-001. January 1974. 431 pages. 71. Haley, T. J. A Review of the Toxicology of Lead. Air Quality Monograph, American Petroleum Institute. Washington, D. C. 69-7. 72. Smith, R. G. Air Quality Standards for Lead. Air Quality Monograph, American Petroleum Institute. Washington, D. C. 69-11. 73. Schroeder, H. A. Barium. Air Quality Monograph, American Petroleum Institute. Washington, D. C. 70—12. 74. Schroeder, H. A. Vanadium. Air Quality Monograph, American Petroleum Institute. Washington, D. C. 70—13. 75. Schroeder, H. A. Nickel. Air Quality Monograph, American Petroleum Institute. Washington, D. C. 70—14. 76. Schroeder, H. A. Chromium. Air Quality Mongraph, American Petroleum Institute. Washington, D. C. 70—15. 135 ------- 77. Schroeder, H. A. Cadium, Zinc and Mercury. Air Quality Monograph, American Petroleum Institute. Washington, D. C. 70-16. 78. Schroeder, H. A. Manganese. Air Quality Monograph, American Petroleum Institute. Washington, D. C. 70—17. 79. Miller, N. H. Modern Lubrication Practices - How Lubricants Work. Chemical Engineering:155-162, February 26, 1968. 80. Unpublished study prepared for U.S. Department of Transportation by Jack Fausett Associates. May 1973. 81. Occupational Safety and Health Administration, Depart- ment of Labor: Occupational Safety and Health Standards; National Concensus Standards and Established Federal Standards. Federal Register, Volume 36, No. 105, Part II, May 29, 1971. 82. Sax, N. I. Dangerous Properties of Industrial Materials. Third Edition. Reinhold Book Corp., New York. 1968. 83. Manufacturing Chemists Association, Washington, D. C.: Chemical Safety Data Sheet SD—9, Caustic Soda Chemical Safety Data Sheet SD-20, Sulfuric Acid Chemical Safety Data Sheet SD-8, Ammonia Chemical Safety Data Sheet SD-64, Lead Oxides 84. Christensen, H. E. (Editor). The Toxic Substances List. 1972 Edition. National Institute for Occupational Safety and Health. Rockville, Maryland. June 1972. 563 pages. 85. Ellis, E. G. Lubricants: An Industrial Health Hazard? Industrial Lubrication 19(4) :141—5, 1967. 86. Crude Petroleum and Petroleum Products. Minerals Yearbook. U. S. Bureau of Mines. Washington, D. C. 1971. Page 855. 87. National Petroleum News. McGraw-Hill, Inc. New York. August 1971. p. 54. 136 ------- 88. Oil Spill Technology Takes Big Step Forward. Chemical and Engineering News. April 1973. 137 ------- SECTION XI APPENDICES 138 ------- APPENDIX A WASTE OIL RE-REFINERS AND PROCESSORS ARKAN SAS Henley Oil Compa P.O. Box 141 Norphiet, Arkansas 71759 Telephone: 501—546—2582 Contact: Charles W. Henley Visit Date: None Planned CALIFORNIA X Bayside Oil Corporation 977 Bransten Road San Carlos, Calif. 94070 Telephone: 415—593—2944 Contact: A. Ray Banks Visit Date: 7/18/73 Visit By: N.J. Weinstein (with Teknekron) X Leach Oil Company, Inc . 625 East Compton Blvd. Compton, Calif. 90220 Telephone: 213—323—0116 Contact: George Leach Visit Date: 7/20/73 Visit By: N.J. Weinstein (with Teknekron) C.S. McAuley, Inc . P.O. Box 219 Downey, California 90241 Telephone : 213—869—1179 Contact: C.S. McAuley Visit Date: 7/20/73 Visit By: N.J. Weinstein (with Teknekron) X Motor Guard Lubricants Co . 4334 East Washington Blvd. Los Angeles, Calif. 90023 Telephone: 213—268—6877 Contact: H.B. Millard Visit Date: 7/19/73 Visit By: N.J. Weinstein (with Teknekron) Fabian Oil Refining Co . 4200 Alameda Avenue Oakland, Calif. 94601 Telephone: 415—532—5051 Contact: Bryan Fabian Visit Date: 7/18/73 Visit By: N.J. Weinstein (with Teknekron) X Talley Bros. Inc . 2007 Laura Avenue Huntington Park, Calif.9e255 Telephone: 213—587—1217 Contact: A.W. Talley Visit Date: 7/23/73 Visit By: N.J. Weinstein (with Teknekron) Nelco. Oil Refining Company 1211 McKinley Avenue National City, Calif. 92050 Telephone: 714—474—7511 Contact: Otis F. Humphrey Visit Date: 7/23/73 Visit By: N.J. Weinstein (with Teknekron) 139 ------- COLORADO GEORGIA X Williams Refining Company 5901 North Federal St. Denver, Colorade 80221 Telephone: 303—433—2497 Contact: Lloyd Cunningham Visit Date: None planned FLORIDA X Davis Oil Company Box 1303, 1100 Orange Ave. Tallahassee, Fla. 32302 Telephone: 904—576—3116 Contact: George Davis Visit Date: 8/1/73 Visited By: A.T. Goding Peak Oil Company Route 3, Box 24 Tampa, Floriad 33619 Telephone: 813—626—9116 Contact: John Schroter Visit Date: 7/31/73 Visited By. A.T. Goding Petroleum Products Co . Box 336f South Park Road Pembroke Park Hallendale, Florida 33009 Telephone: 305—989—4000 Contact: Sol Blair Visit Date: 7/31/73 Visited By: A.T. Goding Seaboard Oil Industries of Florida, Inc . Box 6336 Jacksonville, Florida Telephone: 904—389—8845 Contact: Byron Cohen Visit Date: None planned to this plant; see Georgia plant Seaboard Industries Box 47333 5810 New Peachtree Road Doraville, Georgia 30040 Telephone: 404—458—2241 Contact: Byron Cohen Visit Date: 8/2/73 Visited By: A.T. Goding ILLINOIS X Motor Oils Refining Co . 7601 West 47th Street Lyons, Illinois 60534 Telephone: 312—242—2306 Contact: Benton Williams R.E. Poindexter Visit Date: 8/13/73 Visited By: N.J. Weinstein (with Teknekron) INDIANA x Westville Oil & Mfg. Inc . Box 587, State Road #2 Westville, md. 46391 Telephone: 219—785—2534 Contact: Andrew Carson Visit Date: 8/14/73 Visited By: N.J. Weinstein (with Teknekron) KANSAS Coral Refining Company 765 Pawnee Avenue Kansas City, Kansas 66105 Telephone: 913—281—5454 Contact: Robert O’Blasny Visit Date: 8/7/73 Visited By: C. Rai 140 ------- MICHIGAN X Dearborn Refining Company 3901 Wyoming Avenue Dearborn, Michigan 48120 Telephone: 313—VI-3—1700 Contact: Jack W. Epstein B Horton Visit Date: 7/31/73 Visited By: N.J. Weinstein MINNESOTA X Warden Oil Company 187 Humboldt Avenue North Minneapolis, Minn. 55405 Telephone: 612—374—1200 Contact: A. L. Warden Visit Date: 7/30/73 Visited N.J. Weinstein Gopher State Oil Co . 2500 Delaware St. SE Minneapolis, Minn. 55405 Telephone: 612—331—5936 Contact: C.H. Romness Visit Date: None planned MISSISSIPPI X Jackson Oil Products Cc, . Box 5686 Jackson, Miss. 39208 Telephone: 601—939—3131 Contact: H.K. Robertson Visit Date: None Planned MISSOURI X Midwest Oil Refining Co . 1900 Walton Road St. Louis, Mo. 63114 Telephone: 314—427—2662 Contact: Glen Gettinger Visit Date: 7/23/73 Visited By: A.T. Goding NEBRASKA Monarch Oil Company Box 1257 22nd Street & Avenue H East East Omaha, Nebraska 68101 Telephone: 402—341—5254 Contact: Marvin Walenz Visit Date: None planned NEW JERSEY Diamond Head Oil Refining Co . 1427 Harrison Tnpk. Kearney, New Jersey 07032 Telephone: 201—991—5800 Contact: Martin Morrison Visit Date: 8/17/73 Visited By: C. Rai X National Oil Recovery Corp Box 338 Bayonne, New Jersey Telephone: 201—437—7300 Contact: Soifred Maizus Visit Date: 7/12/73 Visit By: N.J. Weinstein C. Rai, A.T. God- NEW YORK ing George T. Booth & Son, Inc . 76 Robinson Street North Tonawanda, N.Y. 14120 Telephone: 716—693—0861 Contact: George T. Booth Visit Date: 7/23/73 Visited By: A.T. Goding 141 ------- Northeast Oil Company 327 Edward Drive Fayetteville, N.Y. Telephone: 315—454—4180 Contact: R.W. Mahier Visit Date: None planned Newtown Refining Corp . 37-80 Review Avenue Long Island City, N.Y. 11101 Telephone: 212-RA9-7660 Contact: R.W. Mahier Visit Date: None planned NORTH CAROLINA Seaboard Industries, Inc . South Oil Division Box 106, Old Burlington Road Greensboro, N.C. 27402 Telephone: 919—375—5811 Contact: Byron Cohen Visit Date: None planned See Georgia OHIO Research Oil Refining Company 3680 Valley Road Cleveland, Ohio 44109 Telephone: 216—749—2777 Contact: Jac Fallenberg Alan Gressel Visit Date: None planned (recent fire) X Keenan Oil Company #1 Parkway Drive Cincinnati, Ohio 45212 Telephone: 513—631—2900 Contact: S.R. Passell Visit Date: None planned OKLAHOMA X Double 9le Refining Co . Box 11257 Oklahoma City, Okla. 73111 Telephone: 405—232—0244 (plant) :405—232—6878 Contact: Frank Kerran Cameron L. Kerran Visit Date: 8/8/73 Visited By: C. Rai OREGON Nu-Way Oil Company 7039 NE 46th Avenue Portland, Oregon 97218 Telephone: 503—281—9375 Contact: A.L. Geary Visit Date: 7/24/73 (at Ager & Davis Refining Co) Visited By: N.J. Weinstein (with Teknekron) Ager & Davis Refining Co . 9901 NE 33rd Street Portland, Oregon 97211 Telephone: 503—288—3584 Contact: Harold W. Ager, Jr. Visit Date: 7/24/73 Visited By: N.J. Weinstein (with Teknekron) PENNSYLVANIA Berks Associates, Inc . Box 617 Pottstown, Pa. 19464 Telephone: 215—385—3031 Contact: Lester Schurr Visit Date: 7/11/73 Visited By: N.J. Weinstein, C. Rai, A.T. Goding 142 ------- Petrocan Corporation P.O. Box 547 Valley Forge, Pa. 19481 Telephone: 215—383—5262 Contact: John Cunningham Visit Date: 8/17/73 Visited By: A.T. Goding (with P.B. Lederman) TENNESSEE X Gurley Oil Company Box 2326 Memphis, Tennessee 38102 Telephone :901—527—9940 Contact: William M Gurley Visit Date: 8/7/73 Visited By: C. Rai TEXAS S&R Oil Company Box 35516 Houston, Texas 77035 Telephone: 713—729—8740 Contact: R.A. Swasey Visit Date: 8/9/73 Visited By C. Rai Capital Supply & Refining Co . Box 597 1401 West Hurst Blvd. Hurst, Texas 76053 Contact: Abel Theriot Visit Date: None planned Texas American Oil 300 Westwall, •Suite 1012 Midland, Texas 79701 Telephone: 915—683—4811 Contact: William F. Judd Visit Date: 8/9/73 Visited By: C. Rai UTAH X Alco Refining Company 133 North First West Salt Lake City, Utah 84113 Contact: J.R. Mastelotto Visit Date: None planned VIRGINIA A.C. Oil Company 1500 North Quincy St. Arlington, Va. 22207 Contact: V.T. Worthington Visit Date: None planned WISCONSIN Warden Refining Company 1910 South 73rd W. Allis, Wisconsin 53214 Telephone: 414—541—1000 Contact: M.A. Warden Visit Date: 8/14/73 Visited By: N.J. Weinstein (with Teknekron) WASHINGTON QED Corporation V.0. Box 1004 Renton, Washington 98055 Telephone: 206—271—1540 Contact: William S. Kemp Visit Date: 7/16/73 Visited By: J. Weinstein (with P.B. Lederman) “X” indicates Members of Association of Petroleum Re— Refiners. 143 ------- APPENDIX B LUBRICATING OIL ADDITIVES 144 ------- LUBRICANT ADDITIVES * Prevent rust formation in areas above the oil level. Volatile ba8ic com- pounds are vaporized with water and keep cone densate basic. ADVERSE EFFECTS LIMITS OF ACTIVITY Can increase oil Most additives vapor pressure, have an optimum promote (in the temperature range case of zinc and are not organics) corrosion uniformly effec- and cause heavy tive at prevent- oil sludging ing all forms of and darkening catalytic oxida— (in some nitrogen tion. compounds). Reduce oil oxidation re- sistance and promote forma- tion of emulsions. Re-inhibition required in systems volatiljz.. ing large volumes of watar. OTHER TYPICAL COMPOUNDS POSSIBLE COMPOUNDS Hindered phenols, bisphenols, metal (especially zinc) dialkyl dithio— phosphates, com- pounds of nitrogen and sulfur. Low-molecular- weight amines having a wide boiling range. Anti— Ensure rapid Poamants collapse of larqe air bubbles; prevent excessive oil oxidation. Attracted to oil/air inter- faces, they lower the surface tension of air bubbles, causing the formation of quick-breaking large bubbles. Silicone types tend to promote air entrainment (the formation of tiny, long— lasting bubbles). Other types may promote emulsion forma- tion. Some lubricant additives or contaminants may render anti— foamants inef- fective. * Derived Silicone polymers, Waxes. methacrylate polymers. from Miller TYPE Oxidation REASON FOR USE HOW THEY WORE Decompose Prevent or control Inhibitor formation of varnish, sludge and corrosive compounds. Limit viscosity increase. peroxides, inhibit free- radical forms— tion, and pa.- sivate metal surfaces. Rust Prevent forma— Polar type Preventive, tion of rust compounds Liquid Phase in areas under the oil, especially during equipment shutdown. react with or are ad— sorbed on metal sur- faces, Vapor Phase I- ’ U, Barium dialkyl dithiophosphates, phosphitas, aisines, Alkyl amines, amine phosphate., acid phosphate esters. Reduce oil oxida- Only effective in Sulfonates, soaps, tion resistance the oil—wetted fatty acids, and promote parts of the phosphates, mono- formation of system. and difunctional emulsions, organic acids and esters. ------- OTHER TYPE REASON FOR USE HOW THEY WORE ADVERSE EFFECTS LIMITS OP ACTIVITY TYPICAL COMPOUNDS POSSIBLE COMPOUNDS Viscosity Reduce th. rate Thsp* polymirs Polymer, shear in Many polymers ax- Polyisobutylen. Succinimid.— Index of viscosity ar. tightly service, thus hibit “VI humps” (such as STP), acrylic acid Improver, change with coiled (and causing the corn- (e.g., concentra- rnethacrylate reaction temperature, relatively pounded oil to tion ranges be— polymers, some products, insoluble) in suffer both yond which further copolymers. ethylene—pro— oil at low “temporary” and additive addition pylene polymer temperatures “permanent” vis- will not increase derivatives. and uncoiled cosity loss. Whsn V i ). (and quite high VI finished soluble) in oils are desired, oil at high the base oils temperatures. must have low VI improver. viscosities, contribute to hence low flash oil viscosity points. at higher tem- pers tu re s preventing “thinning.” Pour Lower the Prevent wax None. Th. pour—point Methacrylat. Polyacrylwnides. Depressant. pour point crystal- depression effect polymer., or “freez— growth or oil of any single alkylated ing point”) absorption at polymer is naphthalen. of paraffinic low tempera- limited and often or phenols. oils. Most turss. specific , So pourpoint de— combinations of pression. ars pour depressant. less than 40’?. are often used. (say ,from 20 to—20F.) and are achi.vød with less than 2% additive. ------- OTHER YPE REASON FOR USE HOW THEY WORX ADVERSE EFFECT$ LIMITS OF ACTIVITY TYPICAL COMPOUNDS ‘ POSSIBLE COMPOUNDS Extreme Modify friction Form physical Promote oil EP agents require Oilnesa—fatty Organic compounds Pressure properties, or chemical oxidation, heat (generated acids and soaps, with barium, (EP), reduce wear, bonds with foaming, by metal—to-metal Antiwear-impure antimony, Oiliness prevent galling rubbing emulsification contact) to be tricresyl bismuth, & Antiwear, and seizing. surfaces that and corrosive effective, Not phosphates, silicon, moly— provide supple— tendencies, all desired oili— metal dialkyl bdenum, sulfur, mental “wearing Thermal ness properties dithiophosphates. phosphorus, surfaces.N stability is are contributed EP-organic nitrogen, The key is weakened, by one set of phosphates, lead halogens, friction and additives. The and chlorine carboxyl or wear control, General Motors compounds. carboxylate rather than Automatic trans— salts, silicones, elimination, mission Fluid (AT?) polyphenyls , is unsuitable for Ford Transmissionsj the Ford ATF does not have suitable friction properties for GM transmissions. ------- OTHER REASON FOR USE HOW THEY WORK ADVERSE EFFECTS LIMITS OF ACTIVITY TYPICAL COMPOUNDS POSSIBLE COMPOUNDS Detergents, Keep sludg.s Chemical and Promote Eventually, Often dispersants Metal containing- Disp.r.ant.. suspended physical emulsification saturation is are referred to barium, calcium, and surfaces forces of water, reached. This as “nonmetallic” magnesium, clean, combine to Compete with is why even or “nitrogen zinc organic., Dispersion keep sludges antifoasnant., 6,000 ml. auto- containing” succinates, implies only solubilized, antiwsar, motive oils organic compounds, transition the act of and thus oiliness, EP must be changed. while sulfonates, metal amino- keeping prevent and antiruet phenates, and phosphoro— sludges in agglomerating, additives for other metal or dithioates, suspension.. interf aces with P2S5 containing phosphonates, air and metal, compounds are alkyl substituted referred to as salicylates; “detergents.” ashless-alkenyl succinlmldes, alkyl-acylic polymers, succinatea, trjazjne and phosphorus acid, polyhydric alcohols + polycarboxylic acids, modified polyola fins, sulfurization/ polyamines, styrene-maleic anhydride Copolymers. ------- OTHER TYPE REASON FOR USE HOW THEY WOPA ADVERSE EFFECTS LIMITS OF ACTIVITY TYPICAL COMPOUNDS POSSIBLE COMPOUNDS Emulsifiers Hold oil & water Polar-type Reduces oil oxide- Different emulsifiers Metal sulfonatas: Fatty acid soaps. together in (both ionic tion resistance, must be used for glycols; ethoxylated emulsion-type or nonionic) Fights activity every oil, every phenols, alcohols cutting fluids, compounds of antiwear, EP, concentration of or acids; naphthenic coolants and line up at oiliness, anti- water and, often, acids. hydraulic fluid .. oil/water rust, and anti- every service interfaces, foam agents. temperature. and thus May cause seal they provide swelling. solubility bridges between the oil and water. w Metal Passivat. A protective Often promotes Each deactivator Zinc dialkyl dithio Organic dihydroxy Deactivators metal eux— barrier is oil color c ia— must be chosen phosphates, metal phosphinea, faces so that formed over gradation. for the metal phenolates, organic phosphitas, they do not the entire it will contact. nitrogen compounds. sulfur compounds. act as a metal surface. When competitive catalyst in surfactants are oil oxidation, around, however, effectiveness is limited. Other Additives: Perfumee .and formaldehyde compounds as antiodorants with EP additives; alcohols, phenol., chlorine compounds as antiseptice for emulsion lubricants; as in. compounds as color stabilizers; polyacrylates and polybutenes as tackiness agents for gear oils. ------- APPENDIX C PITTSBURGH SURVEY METHODOLOGY AND DATA Page METHODOLOGY 151 PRIVATELY OWNED VEHICLES 155 ORGANIZATIONALLY OWNED VEHICLES 163 NON-VEHICULAR USES 169 COLLECTORS SURVEY AND PRELIMINARY MATERIAL BALANCE 172 SAMPLE QUESTIONNAIRE AND DATA 175 150 ------- METHODOLOGY SAMPLE DESIGN In order to define the sample, which would include the entire Pittsburgh Metropolitan area, the six Pittsburgh and suburban telephone directories were used as a source for service station names. These directories were grouped into the following areas: Pittsburgh City, North and West suburbs, Northeast and East suburbs and South and Southwest suburbs. Each area was defined by telephone exchange number and counts were made of the total number for each stratum as shown below: TELEPHONE AREAS PITTSBURGH NORTH AND NORTHEAST SOUTH AND COMPANY CITY WEST AND EAST SOUTHWE$ p Amoco 5 of 44 ARCO 5of55 3of15 3of 15 Boron 6 of 66 3 of 16 3 of 17 EXXON 5 of 44 3 of 22 3 of 14 Gulf 6 of 67 3 of 15 3 of 14 Mobil 3 of 20 3 of 14 Sunoco 5 of 50 3 of 20 Texaco 3 of 23 Other 6 of 142 6 of 90 6 of 75 6 of 63 Where no number appears for a particular company for each stratum, that company was included in the “other” stratum. Also included in the sample were 4 service stations located on highways and 4 truck stops randomly selected from the entire area. Service stations were randomly selected within each stratum, making a total of 100 service stations, ut of a universe of about 900, to be cotitacted. 151 ------- INTERVIEWING EXPERIENCE Interviewer training was held August 18th for all inter- viewers working on the study, to insure a thorough knowledge of the study, the questionnaire, and the sample. Inter- viewers were instructed to approach each assigned service station and ask to speak with the owner or operator. If he was unavailable,appointments were made for a time that was convenient to him. A letter from Response Analysis ex- plaining the nature of the study, that Response Analysis was conducting the Study for the Environmental Protection Agency was handed to the respondent before the interview began. Each respondent was assured through the letter and the in- terviewer that individual answers would be kept in strict confidence and results would be available only as a sta- tistical compilation. According to the interviewers the majority of respondents were knowledgable and very cooperative. The importance of each of the one hundred interviews was stressed to the interviewers since no replacements were to be made. Only if the service station was no longer in business or it had changed companies,was a new station randomly selected to replace it. Every effort was made to complete an interview with each station. The results of the interviewing were as follows: PITTSBURGH CITY #Contacted Complete Refused Amoco 6 4 1 ARCO 5 5 Boron 6 6 EXXON 6 4 Gulf 6 6 Mobil 3 3 Sunoco 6 4 1 Texaco 3 3 Other 8 4* 1 152 ------- NORTH AND WEST #Contacted Complete Refused Amoco ARCO Boron 3 1 2 EXXON 3 2 1 Cu if Mobil Sunoco 3 2* Texaco Other 8 4* 1 NORTHEAST & EAST #Contacted Complete Refused Amoco ARCO 3 1 2 Boron 3 2 1 EXXON Gulf 3 2 1 Mobil 3 3 Sun o co Texaco Other 6 5 1 153 ------- SOUTH & SOUTHWEST #Contacted Complete Refused Amoco ARCO 3 3 Boron EXXON 4 2 Gulf 5 3 Mobil Sun oco Texaco Other 9 6 * Three questionnaires which were completed,one in each stratum, are not included. These were lost in the mail. Out of the 4 highway service stations interviewed,3 were completed. Two truck stop interviews were completed of the seven contacted. The data was collected from 80 service stations,and compiled in order to analyze four areas: - Oil Changes - Removal, collection and storage - Disposal — Estimates of available wastes With this information, the availability of wastes and the disposal of them in the Pittsburgh metropolitan area can be determined. 154 ------- PRIVATELY OWNED VEHICLES OVERVIEW Personal interviews with owners or managers of almost 100 service stations, new car dealers, and garages or auto- mobile maintenance facilities were conducted in the Pitts- burgh area. There were a number of useful results of those interviews. However, the attempt to gather data to give reasonably precise quantitative estimates of the waste oil collected was unsuccessful. The owners or managers of various facilities for doing oil changes simply did not accurately know how many oil changes they did, nor how much waste oil they collected. It is our belief, based on the survey experience,.that no procedure short of monitoring actual service records for a period of perhaps as long as one year could hope to pro- duce data with any real precision. Aside from such com- plications as seasonal variations, the basic problem is that there is no reason for the typical maintenance facility to keep records on the number of oil changes, or even on the total amounts of waste oil collected. The result is that the only collectable data involves the perceptions of the facility owner or manager. From the contradictory results obtained by asking each respondent for the same information in different ways, it is clear that these perceptions do not lead to reliable data. The most important positive result of the survey was to establish that the overwhelming majority of service stations and others who do oil changes on private automobiles do re- cycle the waste crankcase oil. Almost without exception the maintenance facilities were equipped with underground storage tanks which were emptied relatively regularly by waste oil collectors. Generally speaking, the collector provides the convenience of a collection service in return for the oil. It is partly for this reason that the service station owners generally did not even know the total amount collected. OIL PER SERVICE STATION The great bulk of the survey interviews were with service station owners and/or managers. A total of 83 interviews were actually carried out, although three of these were lost in the mail when returned from the inter— 155 ------- viewer. Thus, the tabular results at the end of this Appendix are actually based on 80 interviews. Each respondent was asked in a number of different ways about his oil usage and waste oil collection. The intent of these multiple approaches to obtain the same data was as a check on intentional misrepresentation. The re- sults, however, appear to show unintentional, uninformed error rather than misrepresentation. This follows from the fact that the actual results of the various approaches for each respondent are, if anything, almost random in their variations. The following tables give the results of three ways of asking respondent service station owners or managers for the amount of waste oil they generate per year. In the first table, two columns of figures on waste oil are shown. The first is based on, to us, inexplicable testimony as to quarts of oil removed from a car per oil change. The second gives the waste oil removed from crankcases assuming an average of 4.5 quarts (1.13 gallons) per change. This inability to accurately estimate the waste oil they remove from crankcases turns out to have occurred in, at least, one and quite probably other previous studies. For example, a study in Maryland, 5 the report of which be- came available after this study was carried out., shows the same phenomena. Again the number of oil changes indicates far less waste oil available then does the claimed oil collectable. Using even our estimate of 4.5 quarts per oil change (Table C—i, last column), the three results obtained in the survey vary by a factor of almost two to one. Clearly the precision of any results, obtained from data with such variability, is sharply limited. The best we are able to do is to make some judgmental decision. For the remainder of this report we propose to simply roughly average the three results (allowing for non—response) and use a figure of 1,100 gallons per station per year. This corresponds to about 20 oil changes per station per week. While this figure is obviously just a ball—park estimate which must be checked against other approaches, it does have at least the minimal virtue of seeming reasonable from subjective experience. 156 ------- TABLE C-i OIL CHANGES DONE, ALL VEHICLES* GALLONS/YEAR TESTI- APPROXIMATE MONY TOTAL TOTAL OIL REMOVED SERVICE REMOVED FROM ON BASIS OF 4.5 STATIONS OIL CHANGES QUARTS PER CHANGE No Oil Changes 3 1—5 13 1,750 2,200 6—10 20 6,180 10,100 11—15 20 11,620 16,200 Average Number ganges 16—20 9 6,470 10,100 Per Week 21—25 7 7,400 9,600 26 or more 6 11,980 15,200 Don’t Know 2 TOTAL GIVEN VALUE 78 45,400 63,400 * Based on Questions 5,11,14,18 157 ------- TABLE C-2. OIL BOUGHT AND USED FOR OIL CHANGES* Gallons Per Year SOLD AT ISLAND 46,983 39•9 USED FOR OIL CHANGES 70,419 59.8 OTHER (SOLD TO INDIVIDUALS FOR BOATS, LAWN MOWERS) 452 0.4 TOTAL OIL BOUGHT 117,854 100.0 * Based on Questions 1,4 158 ------- TABLE C-i. WASTE AVAILABLE AND COLLECTED IN GALLONS PER YEAR* WASTE OIL OIL FROM INDIVIDUALS SOLVENTS GREASES TRANSMISSION FLUID BRAKE FLUID ANTIFREEZE TOTAL TOTAL WASTE AVAILABLE 112,780 280 155 14 437 34 4,808 118,508 TOTAL STORED FOR COLLECTION 111,400(99%) 280(100%) 35 (2 3%) 13(93%) 327(69%) 29(85%) 58(1%) 112 , 142 TOTAL UNCOLLECTED 1, 370 (1%) 120 (7 7%) 1(7%) 146(31%) 5(15%) 4,750(99%) 6,392 * Based primarily on Question 34 159 ------- AUTOMOBILE DEALERS AND AUTOMOTIVE SERVICE CENTERS The data on automobile dealers and other forms of auto- motive service centers, such as retailers, are based on 10 interviews in the Pittsburgh area. From these interviews we estimate that the typical service center might do about 40 oil changes a week and the typical new car dealer might do about 80. OVERALL PRIVATE VEHICLE WASTE OIL There are two ways of estimating the total number of service stations in the Pittsburgh metropolitan area. The first is by a direct count of service stations which are listed in the Yellow Pages used in drawing the sample. These Yellow Pages cover about 80% of the population in the Pitts- burgh metropolitan area, although a substantially smaller fraction of the land area. The actual count of service stations was approximately 1,000. If one assumes that the oil changes done are proportional to population, then the equivalent number of service stations doing an average of 20 oil changes per month each would be approximately 1,250. Due to the greater physical area on the communities not covered by those Yellow Pages used in the survey, the number of service stations might be larger, but the number of oil changes per station in the less densely populated areas would presumably be smaller. One alternative method for estimating the number of service stations is use of the 1967 Census of Businesses. According to the Census Bureau there were 2,069 service stations at that time in the four-county Pittsburgh SMSA. However, we believe this figure to be high in relation to our results, because of two reasons: first, the af ore- mentioned question of stations in low density areas; second, the counting by the Census Bureau of garages or service centers such as those at many Sears stores, which we clas- sified in other categories. Allowing for limited non-listing in the Yellow Pages, we take as a best estimate 1,400 equivalent service stations (i.e., service stations with maintenance equivalent to those which formed the population for sampling). For new car dealers and others we made direct counts of the firms listed in any one Yellow Page Directory. This is reasonable, because virtually all firms of this type turned out to be listed in each area Yellow Pages, with the listings 160 ------- for any particular make of car being separated by town. Using this approach we get about 130—140 new car dealers and 60-70 service centers or equivalent maintenance facil- ities. Using these admittedly rough and imprecise figures as a basis, the overall total private vehicle waste crank- case oil available for recovery per year appears to be approximately: 1,400 service stations x 1,100 gallons = 1.5 Service station million gallons + 135 new car dealers x 4,400 gallons = 0.61 Dealer million gal ions + 65 maintenance centers x 2,200 gallons = 0.15 Center million gal ions Total = 2.3 million gallons per year ANOTHER APPROACH AND PRECISION Another way to approach the quantity of waste oil re- coverable from private automobiles is: From national figures on cars per person, estimate the number of private automobiles in Pittsburgh: 900, 000; Estimate the number of oil changes per car per year subjectivel y at 3.7 (allowing for 10% of cars not using service stations and 3 changes); Estimate the quantity of oil recoverable at 4.5 quarts or L13 gallons; giving an estimate of 2.6 million gallons of service station recoverable waste oil. WE EMPHASIZE that we do not have any data on which to base the number of service station changes per car and only data which we have chosen earlier to disbelieve on quarts per oil change. Nonetheless, in light of the pilot nature of the study and the results and 161 ------- claims of previous studies it seems worthwhile to esti- mate the kinds of numbers obtainable in various ways. These numbers give some idea of the precision in the survey based figure of 2.3 million gallons given above. We believe that an allowance for error of as much as + 33% must be attached to these figures. 162 ------- ORGANIZATIONALLY OWNED VEHICLES INTRODUCTION This section deals with vehicles of all types owned by organizations of all types. The data is drawn from about a dozen interviews with a wide variety of types of organi- zations in the Pittsburgh area, and from various published industry sources. No serious attempt is made to give precise quantitative results, although some effort is made to set order of magnitude estimates of the quantities of recoverable waste oil generated. Most of this waste oil is available for recycling although a substantial and growing fraction may not be. The oil which is not or will not be available for recycling is primarily from “company” cars of a wide variety of organizations ranging from utilities and government to manufacturing and distribution firms. The main intent is thus to provide a catalog of uses in- dicating at least an estimate of the order or magni- tude of each use. There are five main categories of vehicles considered: Rental fleets: cars or trucks available for rental by the general public, where the renter provides the driver. For—hire-trucking: trucks available for freight delivery of one form or another, but where the trucking firm provides the driver. This category includes trucks involved in distribution functions such as United Parcel and the U. S. mail. Direct organizational use: cars and trucks used directly by organizations as an integral part of their own business. Automotive forms of public transportation: basically buses and taxis. Non—automotive forms of transportation: various forms, such as planes, ships and trains. RENTAL TO THE PUBLIC From the viewpoint of this study there are, at least, four different types of rental car and truck organizations dealing with the public. 163 ------- Major rental firms with their own service tacilities. Basically, these are the three largest national firms (Hertz, National and Avis) and such other local or regional firms as happen to have a substantial concentration of cars in a single place and do their own servicing. Note that this category includes only situations where the present company does the servicing, not the franchise owner. Rental firms using others for the servicing, where there are generally service stations. Included here are such firms as Budget and Econo- car, as well as local firms. Service stations which have rental facilities. Many of these have franchises from a national firm, but are included when they are responsible for their own maintenance. Auto dealers who also rent cars. These firms generally use their own new car service facilities for servicing their own rental cars. As considered here, rental includes both short and long term arrangements, but only where the dealer, and not the customer, is responsible for maintenance. Trucks, small car trailers, and similar vehicles account for a substantial portion of the total rental vehicles. For instance, various industry reports indicate that nationwide Hertz, Avis and National together own about 300,000 cars and about 50,000 trucks. Altogether, rental vehicles probably make up no more than about one percent of cars, and a slightly higher pro- portion of trucks. However, rental cars generate a signif i— cantly higher proportion of crankcase waste oil available for recycling, since they get so much greater usage per car. Typically, a rental car might be driven about 40,000 miles, or 2 1/2 to 3 times as many miles as a private automobile, with a correspondingly higher oil usage (40,000 miles in one year that is). Further, being new cars they would not usually do oil changes by replacement of burnt oil, as sales 164 ------- of oil at the island indicate is the case in many older cars. The data gathered in Pittsburgh on this class of users was useful mainly in indicating the range and variety of rental car firms. Four interviews were conducted, with three of the respondents also involved in selling and servicing cars other than their own rental cars. We estimate that the approximately 150 rental agencies listed in the Pittsburgh telephone book Yellow Pages might do as many as 1,000 oil changes per week, and generate in the order of 60,000 gallons of waste oil per year. This is slightly over two percent of the oil available from privately owned autos. In dealing with rental firms in a national study, care will have to be taken to distinguish between facilities used for rental cars only, and facilities also used for other purposes. The purpose would be not only to be sure of getting a representative sample, but also to avoid the possible double counting implicit in separate samples of rental firms, new car dealers, etc. FOR-HIRE-TRUCKING According to the Fausett study, 8 ° for-hire-trucking accounts for about seven percent of the waste oil generated by transportation modes. While some trucking firms have their own facilities for maintenance, others and particularly individual owners or small delivery services use public garages or service stations. These latter were covered in the previous section. No interviews were done in the Pittsburgh study with trucking firms which do their own servicing, mostly because it was felt that they would add little or nothing to our qualitative understanding of the problems. Large trucking firms are presumed to behave like other fleet owners, with whom a number of interviews were completed. Those inter- views are discussed below. In any national oil recycling study, two classes of for—hire trucks would have to be considered; inter-city and intra—city. Inter—city trucking would include state and federally licensed trucking firms, licensed for over—road freight. A special category of such firms are movers 165 ------- licensed to move furniture or other office or household goods. Intra—city trucking includes distribution firms such as United Parcel, individual department stores and the great majority of the United States Postal Service vehicles. NOT-FOR-HIRE ORGANIZATIONAL CARS AND TRUCKS Cars and trucks used by organizations for their own purposes, i.e., not for delivery,whether of cargo, packages or mail, are considered in this section, but only when the fleet is serviced by the owning organization. Three main types of organizations appear to maintain fleets of suffi- cient size to be of interest. Utilities: Interviews with two utilities indicated that both have substantial fleets, with each vehicle being used in an extensive fashion. Their vehicles fall into three classes: “company cars,” i.e., cars used for internal company business; cars and light trucks (often quite large) used for general system development and maintenance. While the nature of these vehicles is quite different, all of them are typically serviced in one (or more than one) common maintenance area. The estimated total number of such utility vehicles is about 2,000 vehicles in the Pittsburgh area, or about one vehicle per 1,000 population. Projected nationwide this would be equivalent to about 200,000 to 300,000 vehicles which combined (due to intensive use) might generate between one and two percent of available waste crankcase oil. Manufacturing and merchandising firms: Many large companies have extensive vehicular fleets within plants (e.g. lift trucks), for between-plant move- ment of materials, and for general company purposes. The main difference between these firms and utilities is concentration. A large industrial firm may have 20 to 50 plants (or more) scattered across the country, with concomitant problems in collecting the oil and on gathering data on procedures followed. We spoke with three major Pittsburgh manufacturing firms. 166 ------- Governments: Governments employ a wide range of vehicles. Two features of virtually all govern- ments are fleets of vehicles used by police and fire departments. In addition, many larger govern- ments have fleets for various other uses, such as what amount to company cars, sanitation vehicles and, in some cases, public transport (to be dis- cussed below). Generally, governments with a fleet of any substantial size appear to do their own servicing. Based on a Pittsburgh interview plus experience with a number of local governments in other areas, governments’ own facilities may not always be as sophisticated or as conscientious in recycling waste oil as are utilities or large corporations. Specifically, governments may tend to use waste oil for their road departments for dust settling. They are, however, a fairly easy group to survey and then incorporate into a waste oil recycling network. BUSES AND TAXIS Our interviews in Pittsburgh indicated that taxi fleets of sufficient size who have their own garages do appear to presently recycle oil in the same way as any other garage or service station; that is, by pickup by a waste oil col- lector. The quantities involved would appear to be sub- stantial, given the high number of low speed (i.e., high heat) miles driven by the average taxi. Figures in the neighborhood of about 10 gallons per cab per year seem consistent, both with the limited Pittsburgh data, and known taxi usage. If so, and assuming one fleet—serviced taxi per 1,000 people, fleet taxis in the Pittsburgh area would generate about 20,000 gallons of waste oil per year, or less than one percent of that generated by privately owned vehicles. Buses fall basically into two categories: private and public ownership. Neither category presents any unusual problem with the possible exception of long-haul buses which are similar to larger trucking firms in their diffusion. NON-AUTOMOTIVE VEHICLES The Fausett study 8 ° indicated that airplanes generate less than one percent of all available oil generated in transportation. Three interviews at the Pittsburgh Airport with the airport director, an airline, and the major gasoline 167 ------- firm based at the airport, tended to confirm this low figure. On the other hand, the facilities they do have for reclaiming engine oil are relatively sophisticated. While a national study would certainly have to deal with railroad and ship uses, no attempt was made to do so in the Pittsburgh study. Railroads in particular generate large quantities of oil, according to the Fausett study. However, this is concentrated in a relatively few main- tenance yards, and so appears fairly easy to survey. Ships, on the other hand, present a number of problems from dif- fusion of ownership to spillage at sea. Thus care would have to be taken in a national study to include this seg- ment accurately. TOTAL VEHICULAR CRANKCASE OIL - TWO APPROACHES Based on the relatively meagre results of this study, on the Fausett study, 8 ° and on aggregate data on total vehicles, we estimate that in Pittsburgh organizationally owned vehicles have somewhat over one—half the available oil of privately owned vehicles. Using the rough service station survey results of the previous section this would indicate that organizationally owned vehicles generate between 1.1 and 1.6 million gallons of recoverable crank- case oil per year. Altogether, then, we estimate vehicular crankcase oil at about 2.7 to 4.8 million gallons per year with a best survey estimate of 3.7 million gallons. To give some idea of the relationship of these numbers to the number of vehicles in the Pittsburgh area, we consider the following: Altogether there are approximately 1.4 million automotive vehicles in Pittsburgh. If each vehicle produced about 3 gallons of recoverable waste oil per year (i.e., a little under 3 oil changes per year), the total amount recoverable would be about 4.2 million callons. This would be in the upper range of the survey indicated data, and quite possibly indicates the survey figure is somewhat low. 168 ------- NON-VEHICULAR USES INTRODUCTION This section deals with non—vehicular usage. No at- tempt is made here to be complete. However, five major classes of generation of waste oil are identified. These are lubrication (including cutting and other moving parts usage), electrical insulation, solvents, processes, and spillage (including pipeline spillage during transportation of the oil itself). A striking (if only tentative) result using our somewhat limited data is that lubrication uses may rank as low as fourth among the five classes considered in terms of quantity of waste oil recoverable or available for recycling. Specifically, use of oil for electrical in- sulation, for solvents, and the amount of lost oil (spillage during transportation of the oil) all seem to produce greater quantities of oil suitable for recycling. We emphasize that the accuracy of this conclusion requires substantial further testing, with the surest approach being a project- able national survey. On the other hand, the conclusion is consistent with a reasonable interpretation of previous work. For instance, in the Maryland study, 5 two-thirds of all non-vehicular industrial oil had to be classified “other” and less than one—fourth was grouped in the three separate lubrication categories specified. LUBRICATION It appears that lubrication of machines today is done with very limited amounts of recoverable oil. Our first indication of this phenomenon was in the pretest stage. We could not find machine shops in New Jersey which generated sufficient waste oil to justify an interview. Other studies, notably the Maryland one, have also found lubrication to account for only a small fraction of oil used. Interviews with major Pittsburgh firms (including the utilities), bore out this initial impression, with one ex- ception. Rolling mills do generate substantial amounts of lubrication waste oil. This oil is used over and over but eventually becomes contaminated. The firm we spoke with, which generated substantial rolling mill waste oil, was already using it for fuel. The utilities we talked to had little if any lubri- cation oil available. From our New Jersey experience the 169 ------- same would apply to smaller machine shops in general. On this basis we would anticipate that a national study should expect most lubricating uses to be in heavy industrial settings such as rolling. NON-LUBRICATION INDUSTRIAL USES A major use of oil for industrial purposes is in the insulation of a vast array of electrical equipment, includ- ing cable, switches and generators. The waste oil develops from spillage, contamination, and obsolescence of the parti- cular equipment. Waste oil of this type was the single largest kind found in interviews with utilities and in manufacturers of electrical equipment. Lube type oils are used as a solvent or process oil in a wide variety of industrial processes. Any resulting wastes can be segregated into two classes: those uses where the oil is reclaimable in an economic manner either because it has not been appreciably altered in use or be— cause the material dissolved in it can be easily removed, and those uses where the dissolved material can only be re- moved at considerable cost. In interviews with industrial users we found a significant amount of reclaimable oil. However, our data is far too sparse to allow meaningful statements about total oil available for recycling. SPILLAGE In interviews with collectors, we found that one of the largest, if not the largest single source of waste oil in the tn-state area centered around Pittsburgh, was spillage of the oil in the process of transportation, specifically at pipeline pumping stations. Given the very large quanti- ties of oil that may be involved, spillage of even a small fraction means the availability of large quantities of oil. The characteristics of this oil may vary from day to day, and this oil actually includes such types as home heating oil. OVERALL AVAILABILITY Industrial uses of oil are believed to account for about 55—60% of all oil sold in the U. S. However, they account for a far smaller portion of recoverable oil (pro- bably no more than one—quarter) and a still smaller fraction of oil available for external recycling. We would very roughly estimate that industrial oil accounts for 170 ------- around 20% of the used (as opposed to pipeline spilled) oil presently being collected in Pittsburgh. This estimate is based primarily on subtracting vehicular estimates from the total collection figures to be presented in the next section. Further, waste oil available for external recycling from industrial uses is surely declining as industry more and more uses any large quantities for its own fuel needs. 171 ------- COLLECTOR SURVEY AND PRELIMINARY MATERIAL BALANCE COLLECTORS-ANOTHER APPROACH TO AVAILABILITY In the previous sections we have dealt with qualitative and quantitative data related to the generation of waste oil. It is also possible to approach waste oil recycling from the other end, that is from the viewpoint of what is presently collected. This viewpoint has the obvious limi- tation that it can describe only that oil which is already being handled in at least potentially environmentally sound ways. Given the very wide gaps and imprecisions in our knowledge of the quantities of waste oil generated, it can- not even by subtraction indicate the quantities either being used or internally recycled by the generators themselves or disposed of by dumping. Once these limitations are understood it is useful to develop an understanding of what is presently being re- covered. We conducted six interviews with collectors of waste oil in the Pittsburgh area. Of these, three turned out to be middlemen who merely collect the oil for delivery to the storage and refining plant of the one large operation. We estimate on the basis of these interviews that the total waste or spilled oil collected by recyclers located in the Pittsburgh area to be about 11 million gallons per year. This, however, includes significant quantities of oil actually generated outside the Pittsburgh SMSA, including West Virginia, Maryland and Ohio. On the other hand, almost without exception, every Pittsburgh area generator of waste oil, and in particular the service stations who could name their collector, specified a Pittsburgh based firm. Thus, there was a significant net inflow of waste oil for recycling into Pittsburgh. Overall, based on interviews, we estimate that the Pittsburgh based collectors gather about 4.5 to 5.5 million gallons from the Pitts- burgh area; about 3.0 to 3.5 million gallons of pipeline oil spillage from a wide area around Pittsburgh; and about 3.0 to 3.5 million gallons from other than pipeline sources outside Pittsburgh. 172 ------- PRELIMINARY MATERIAL BALP CES Given the vastly different distribution, usage, waste generation and collection procedures, it is worthwhile to divide an oil material balance into two segments; auto- motive and industrial. In this section we describe some of the factors involved in such balances and give some very tentative figures for Pittsburgh. Automobile oil: Total automobile oil sold in the United States is estimated at about 1.1 billion gallons annually. Figures on a state by state basis show that sales are far from uniform. Specifi- cally, states with the majority of their populations in metropolitan areas have consistently lower per capita usage than do farm states or states with widely scattered populations. Elsewhere in this report we estimate that just about half of all oil sold is available for recycling. Two major factors in this lower than usual estimate are the large amounts of oil burnt in 2 cycle engines and the amounts of industrial auto fleet oil which is used internally. This would imply that in Pittsburgh a total of perhaps 7 million gallons of new oil was sold per year with about 4 million gallons being available for recycling. Extrapolating from the national sales figures and taking into account the lower per capita usage in metropolitan areas, these figures still seem low. A more reasonable figure appears to be about 9 million gallons sold implying about 5 million gallons available for recycling. It is, of course, feasible that a significant portion of the difference between 4 million and 5 million gallons is being recycled by fleet auto owners themselves. Industrial users: Based on survey both from col- lectors and large industrial users, the quantities of industrial waste oil collected by outside firms is relatively small and declining. An overall figure for Pittsburgh of approximately one million gallons is probably about the right size. This compares with projected Pittsburgh area sales of perhaps 15 million gallons. Of the remainder, substantial amounts are actually recoverable, but are not available for external recycling because of internal recycling or use. 173 ------- Combined: Overall, with the usual cautions on gross margins or error, we estimate, based on all the various approaches considered, that the individuals and firms in Pittsburgh 1. Purchase about 24 million gallons of oil per year (9 million gallons auto- motive and 15 million gallons industrial). 2. Use up directly or in secondary uses about 19 million gallons per year. 3. Have available for external recycling, almost all of which is actually being recycled, about 5 million gallons per year. 174 ------- TIPS STP’.RTED OIL RECYCLING P y name is _________ and I am an interviewer for Response Analysis Corporation of Princeton, ew Jersey. We are working on a study about the use of oil in ser- vice stations. About two billion gallons of oils and lubricants are used in service stations each year. Given the eneroy problem in the United States today, it is important to find out in as much detail as possible the use of all petroleum products. The Environmental Protection Açency of the United States Government is sponsorIng an area—wide study in the Pittsburg area. Please be assured, however, that your name and individu3l answers will be kept in strictest confidence by Response Anal- ysis, and that only statistical compilations will be made available to the spon- sers of this study. 1. To begin with, we would like to get some idea of the amount of oil that you buy... a. How meny gallons of oil can you store In your station? _____________________ b. And how many gallons of oil do you order each time you get a delivery? _____________________ C. And how often is oil delivered to you? _____________________ 2. When you buy oil, is it always in quart cans ol QUARTS (GO TO Q.4) or d you buy sote in gallons or in other ways? 2 GALLONS 3 OTHER -- SPECIFY: L 3 _ 3. Over the last year, what percent of the total voluir.e of oil you have bought has been in cans, other than quart cans? k’ O- %( O.k. 27T PERCEUT 4. Next, I would like to discuss some of the ways you sell oil... a. First, what percent of the oil you sell is added on right at the island? That is, to mike up for oil that is burnt off? b. And what percentaçje is used by you for oil changes? C. Are there any other ways in which you sell oil? For instance, in bulk or in small amounts for use outside the station? d. Could you tell me about them, please? ti ki 4LL 9t3 r 3\ 7 t fl c 4 /!Jr. ‘, ijr 131 YES 2 MO (GO TO Q.5) Lf 5 ) 175 ------- 5. About ho i many oil changes on cars and other vehicles (such as a sno imobile) do you do at this station? _________________________ INTERVJE ?ER NOTE: IF RESPO DEUT DOESN’T KNOW, PROEE. IF RESPONDEUT GIVES A NU BER, SUCH AS 2 OR 3, ASK IS THAT PER DAY, ETC. PLEASE BE SURE TO NOTE BQIE( TUE t4U BER AND THE TI E PERIOD. IF ZERO, GO TO Q.13. 6. Do you use a rolling storage tank when doing a. 1 YES an oil change? 5 2 NO (Go TO Q.lO) O- 1L ,s 7. What is the capacity of the rolling storage 6-jr tank in gallons? i& - 6ALLo . C , ‘.c 8. How often do you empty the tank? 1 EVERY OIL CHANGE ‘o 2 EVERYDAY 3 WHENEVER IT IS FULL 4 OTHER -- SPECIFY: ALL Ar f’i’ o i 1 ’,1 S 9. About how many gallons of oil do you empty from the tank each time? _________________________ 10. When you chanoe oil, how often do you change 34-i EVERY hUE the oil filter? 2 EVERY OTHER TI 3 OTHER -— SPECIFY: 11. Aside from the oil filter, what do you estirate is the average nu—ber of quarts of oil you put into a car during an oil change? ft-V ’I E vi 7 • ave 12. Again, aside from the oil filter, what do you estirate is the averaae nwrber of quarts of oil you take out of a car during an oil ‘ r C change? 45 3g7 3 a1J r 13. Do you ever change oil on trucks? 1 YES 2 NO (GO TO Q.19) DO (flO ( i 1 ’ - 6 14. About ho;, many truck oil changes do you do per week? ___________________ 15. Do you always change the truck’s oil filter? c 5 1 YES (GO TO Q.l9) j3 2 NO 16. About what percentage of the time do you change the oil filter on a truck? __________________ 176 ------- 17. 18. 19. 20. 21. I IIO al/ flv— . Aside from the oil in the filter, what would you estimate is the average num- ber of quarts of oil you put into a truck during an oil change? Aside from the oil in the filter, what would you estimate is the average num- ber of quarts of oil you take Out of a truck during an oil change? Do you ever take waste oil from individ- 5 1 YES uals, for instance, oil they have drained 1,52 N .) (GO TO Q.22) from a car or snowmobile themselves? About how much waste oil do you take from individuals (in gallons) per month? Now I ’d like to talk for awhile about some other products, such as diesel oil, greases, solvents and transmission fluids. First, about how much do you buy a year wholesale of each of the following: a. Solvents Ij 1.,5 ‘7 o l / r b. Greases 3cD . i c £2( t r- c. Transmission fluids ‘ 744 -3 riJ Lf d. Brake fluids ‘1p nI ‘i r e. Diesel oil 0 f. Antifreeze - J (, 17 Is there anything else of a similar type that you buy in quantities of fifty gallons or more per year? Please describe them, and the amounts purchased of each one: 177 ------- 22. On the 0th estimate t a. b. c. d. e. f. g. er hand, how many gallons of each of these sane products would you hat you remove from cars each n onth? c&\j i C Solvents j p Greases Transmission fluids 1 (9 Brake fluids L I Diesel oil Antifreeze Others (mentioned in 21) ( 23. Do you have any agreerents with any indus- (Dl YES trial plants or others to store wastes they 2 UO (GO TO Q.25) may develop? 24. Could you tell tie about them, especially the quantities involved? 25. What storage facilities do you have for waste 1O l WD€RGROUND TA lK oil? 2 A8OVEGROU: D T K 3 3 UO E (GO TO Q.45) 4 OTHER ‘-— SPECIFY: O- reo & r o. $ 7 26. How .tnany gallons is the capacity of the tank? a :tC.-. CO i ’ o 4t..? g ov CS— 27. Of what material Is it made? 1 IRON OR STEEL 2 OThER f ETAL 3 FIBERGLASS 4 OTHER -- SPECIFY: 28. Do you happen to know how old the tank is? 3 ‘ i ’ ’q r-,r ts r ec i..t .4 jC,?T , 29. Do you have ar y special storage facilities 3 1 YES for waste products other than oil? 71 2 HO (GO TO Q.31) 178 ------- 30. Could you describe them please? 31. a. What do you do with waste solvents and greases? 1 SAlT STORAGE TANK AS OIL ‘1 941 ( r- c. Iec re 2 STORAGE FACILITIES CESCRIBED IN Q.30 MOVE i 3 NOT E;;OUGH TO MATTER 4 SOAK INTO kAGS, ETC. FOR DISPOSAL Lj 5 DWP ON GROUND OR IN SEWER uaco1)ec+€i 6 OTHER -— SPECIFY: _________________________ b. What do you do with waste transmission and brake fluid? 514 1 SA T STORAGE TANK AS OIL 35 / jr. Colc-+ .c 2 STORAGE FACILITIES CESCRIBED IN Q.30 ABOVE 3 3 NOT ENOUGH TO MATTER 4 SOAK INTO RAGS. ETC. FOR DISPOSAL i j 3 aJ/ _ t#U,4I U(sV .* tip. Sn a,. 5 ( ‘ f i • ‘ r r’ . ‘ cr ‘ER 6 OTHER -— SPECIFY: _________________________ c. How about waste diesel oil? L. 1 SN lE STORAGE TANK AS OIL 2 STORAGE FACILITIES CSCRIBED IN Q.30 ABOVE j ,3 NOT ENOUGH TO MATTER 4 SOAK INTO RAGS, ETC. FOR DISPOSAL 5 DUMP ON GROUND OR IN SEWER 6 OTHER -— SPECIFY: __________________________ d. And finally, he .•i about used antifreeze? 3 1 SA STORAGE TANK AS OIL 3 1 r ck 2 STORAGE FACILITIES EESC IBED IN Q.30 P .BO.’E i 3 NOT ENOUGH TO MATTER 4 SOAK INTO RAGS. ETC. FOR DISPOSAL Qijc 1 - c 4_ 5 DUMP ON GROIJND OR IN SEWER .c 4 6 OTHER —— SPECIFY: ___________________________ 179 ------- 32. To change the subject slightly, about how often do you clean your gasoline tanks? (PROBE: IF RESPONDENT SAYS SOt ETH1NG LIKE WHENEVER THEY NEED IT ASK, Well about how often is that?) 1 WEEKLY 3 2 THLY 3 TWICE A YEAR 4 YEARLY c.,5 OTHCR -- SPECIFY: ___________________ Le( 6 NEVER (GO TO Q.34) 33. Could you tell ire how you do it and what you do with the residue? 34. Altogether, about how many gallons of wastes, including oil, wo 1d you estiirate LA)c’61 . that you have a onth? I LO, t n’ 1I r,p $ 35. Do you have so o regular provision for 1 / s ) K picking up the ‘cu. tore? Fe’ 2 NO (GO TO Q.a5) .1. *IIJ Qti% ) f l . .S. ri. regularly with a tank truck? 36. What is the method? 1 1 TRUCK 2 OTHER -- PROBE TO GET AS CO PLETE IUFORrATION AS POSSIBLE, THEN SKIP TO Q. 6 0 ic 7S ’6 .‘ 37. How often does the truck ccme around? U 38. Do you happen to know the name and address of the firm which does the pick up? If so, what is it? ADDRESS ___________________ 180 ------- 39. a. Do they charge you for pick up, or 1 1 QIARGED do you get paid or is it simply free 32 PAID pick up? 46 3 FREE (Go TO Q.40) tORO rn cs p, ir b. How much per gallon are you (charged/ paid)? ( ‘F f c. About how much were you (charged/paid) the last time your waste oil was picked up? _______________________ (INTERVIEWER: ENCOURAGE RESPO 1DENT TO QIECK FIGURES IF HE INDICATES HE i!OLJID LIKE TO) GO TO Q.41. 40. About how many gallons do they pick up P< L’s) each time? •.)c 41. Do you make provision for the pick up tl SE1F yourself, or does __________________ 2 OIL CO PAUY (NAt OF OIL CO PA Y) do it for you? — -‘ 42. How interested does ___________________ (NAME OF OIL CONPA Y) seem to be in this probien ? iouid you say 10 1 very interested ‘ ‘ 2 somewhat interested 3 3 a little interested 4 4 not interested 43. Has there been any change in their 4 1 YES interest in the past year? 1,5 2 NO (GO TO Q. 6) L( LDi 44. in what way has there been a change? Please describe this change for me. GO TO Q;46. 45. How do you dispose of your waste oil? (INTERVIEWER: IF RESPO D NT IS HESITA4T OR NERVOUS, EMIMD HIM THAT THE INTERVIEW IS CONFIDENTIAL.) 46. Have there been any changes in your ( 1 YES disposal procedures in the past year, -, 2 NO (GO TO Q.48) including any changes in the cost to you? 181 ------- 47. Could you describe these changes to me please? 48. Finally, I would like to ask you just a few background questions. Is this station privately owned, or owned by ____________________ 3 l PRIVATE 2 OIL CO PA Y ____________________________________ (NAME OF OIL COr.PAUY) 49. And about how many hours a week are you open? ________________________ L/11D(. • “° 50. And about how many gallons of gas do you - /ti, O j7 ptm a week? o ,2 i ;cun , i J1 AIVe& , . INTERVIEWER, CO •!PLElT THE FOLLOWING IHFOR TIC:: AFTC LEAVi G HE P Z SEZ. 51. TI INTERVIEW EtWED ___________________________ 52. LENGTH OF INTERVIEW IN MINUTES __________________ 53. RESPO;;DENT WAS 3 1 VERY K?:OWLEDa 3LE 36 2 SO: :HAT K C :LrDGABLE 3 NOT IO LED A Lt 5 o 54. RESPONDENT WAS 1 VERY COOPERATI ‘I’L g’ 2 SO WHAT C0O ERATIVE 3 3 NOT COOPERXflVE 4 MTACOUISTIC 54. APPEARANCE OF SERVICE STATIC CLEAN SERVICE BAYS 3’ ) ONLY St .ALL OIL SPOTS MD WASTE IN BAYS ____________ cONSIDERABLE oii SPOTS AND WASTE IN BAYS _____________ FILTHY SERVICE AREA, LARGE A ’.31LNTS OF WASTE OIL AND OTHER WASTE PRODUCTS 55. ANY APPEARANCE THAT OIL AND PETROLEU4 WASTE PRODUcTS ARE DISPOSED OF ON THE PREMISE OF THE STATION OR ADJACENT TO IT? I YES (EXPLAIN AND DESCRIBE EVIDENCE) 14 POSSIBLY ________ NO 182 ------- 56. LOCATION OF SERVICE STATION 3 INNER-CITY, URBAN I / CITY, BUSINESS DISTRICT 3 CITY, INDUSTRIAL AREA / . SUBURBAN, RESIDENTIAL AREA 3 5 SUBURBAN, BUSINESS/INDUSTRIAL AREA _____________ SMALL TOWN OR VILLAGE ______________ RURAL-URBAN FRINGE 57. _____________ VERY BUSY INTERSECT ION ______________ INTERSECTION 41 3 ON A BUSY STREET _____________ ON A QUIET STREET _____________ ADJACENT TO TURNPIKE OR INTERSTATE HIGHWAY 58. STATION IS ADJACENT TO OR NEAR 1 E1 TY LOTS 2 STREAI4 OR CREEK 183 ------- APPENDIX D SURVEY OF WASTE OIL COLLECTION AND PROCESSING TABLE OF CONTENTS WASTE OIL COllECTORS 185 Types and sizes of businesses Sources of waste oil How collected oil is disposed of WASTE OIL PROCESSORS 200 Types and sizes of businesses Fortns of treatment Types of oil produced Disposal of wastes Pollution control practices (water, air) National estimates of the waste oil industry Validity of the national estimates FuTURE INDUSTRY PROSPECTS 222 Trends foreseen by waste oil firms Reasons for them San le design Interviewing experience Questiorrnai re 184 ------- WASTE OIL COLLECTORS • Types and sizes of businesses • Sources of waste oil • How collected oil is disposed of 185 ------- WASTE OIL COLLECTORS THIS STUDY ENCOI ’PASSES BOTH WASTE OIL COLLECTORS M D COLLECTOR/PROCESSORS. -. Collector/processors constitute more than one-third (39%) of firms involved in collecting, storing and processing waste oil (Table 1). Later on we learn those finns Involved in processing feel their business is increasing, while those only collecting feel that their business is either declining or just not expanding. —- Most collectors who do not also process their own waste oil have no storage facilities of their own. They coninonly fill trucks to capacity and then transport the waste oil directly to a processor or user. 186 ------- TABLE D-]. Types of Waste Oil Collectors Q. 6: Do you have your own storage facilities for the oil you collect, or do you only transport the oil to another waste oil collector or processor? Q. 9c: What do you do with the waste oil when you remove it from storage. Do you take it to another collector or processor? Q. 9e: What do you do with the waste oil when you remove it from storage. Do you take It to your r,wn processing or rerefining plant? Total — 100 Collectors Take waste oil to others for storage 36 Have own storage facilities 1 but no processing facilities 25 Collector/Processors Both collect and process waste oil 39* *Although eight of the 39 collector/processors do not have any collection capacity of their own, they do have a working relationship with collectors. 187 ------- SOURCES AND AMOUNTS OF WASTE OIL COLLECTED DIFFER GREATLY BETWEEN COLLECTORS AND COLLECTOR/PROCESSORS. —— While service stations/car dealers and industries are collectors’ most comon sources of oil, car and truck fleets, marine sources and railroads are also significant. Nearly 60% of all oil they collect comes from one source —- stations and dealers, as shown In Table 2. -— Five types of waste oil sources are found among 40% or more of collector! processors, while only three of these are sources for 40% or more of the collectors. —— One point of contrast involves collector-to-collector waste oil. While only 13% of collectors get any waste oil from other collec- tors (which represents only 2% of their total gallonage), 41% of collector/processors get waste oil from other (presumably smaller) collectors. -— There are other differences as well. While only 10% of collectors list pipelines as a source, more than one—third of collector/pro- cessors list pipelines as a source. And somewhat higher percentages of collector/processors use railroad, marine and oil spill sources. 188 ------- TABLE D—2 Amounts of Waste Oil Collected from Sources (With Estimate of Total Waste Oil Collected) Q. 4: We would like to know what types of businesses you collect waste oil roni. Do you collect waste oil from ( TYPE OF BUSINESS) ? IF YES -- How many gallons oer month do you collect from ( TYPE OF BUSINESS)? Collectors Collector/Processors Sources % Who Gallons 4 % Who Gallons Collect Month Collect Month (6l (I ,62l,000) (39) (16,172,300) Service stations and new car dealers 58% 18 Pipelines 10% * 38% 8 Car or truck fleets 8 4 Railroaos 28% 4 36% 1 Marine sources 36% 2 6 •Industrial users 26 39 Other waste il collectors 13% 2 23 Oil spills 7% * 10% * Other’ -- 13% * *Less than .5% 1 Totai gallons reported was 3,531,000 gallons month. The sources of only 1 ,521 ,000 gallons/month could be broken down. 2 Total gallons reported collected was l9,i 4,3OJ gallons/month. The sources of only 16,172,000 gallons/month could be broken down. 3 Such as; fire department, oil company, airlines, foundries. 189 ------- COLLECTOR/PROCESSORS OPERATE MUCH LARGER-SCALE COLLECTION BUSINESSES ThM COLLECTORS DO. Collector/processors, on the average, maintain larger fleets of trucks. —— Nearly 40% of all collectors have only one truck, and less than half of collectors have two or more trucks (Table 3). —- The average number of trucks per collector is three. -— By contrast, 41% of collector/processors have five or more trucks, and no collector/processors have only a single truck, although 2l rely entirely on outside contractors for their oil collecting. The average number of trucks per firm is seven. The same trend is also seen in data measuring total truck capacity of firms from the two groups. —— Nearly 60% of all collectors have a total truck capacity of 5,000 gallons or less. Only 13% of collectors have capacity exceeding 10,000 gallons. —— Again, the collector/processors are much greater in their collection capacity. Only lO have total truck capacity of 5,000 gallons or less (none have less than 2,500), and more than 50% have a total truck capacity exceeding 10,000 gallons. The average collector/processor, then, has more trucks and more truck collection capacity (in gallons) than does the average collector. 190 ------- TABLE D-3 Trucks and Truck Capacity Q. 3: How many trucks do you use to collect waste oil and how many gallons does each truck hold? Number of Collector,’ Trucks Collectors (61) Processors (39 ) 5ormore 21% 3 -4 23 28 2 18 10 I 0 211 Average nurrber of trucks per firm 3 7 Total Capacity Trucks Gallons ‘ of Trucks C/P*(31) Collectors (61) JP* Collectors (In thousands (957,000) (469,000) of gallons) Over 20 23% 74% 45% 15.1 - 20 13 8 10.1-15 19 5 8 8 5.1 - 10 35 30 9 30 2.5-5 10 21 1 9 Under 2.5 36 9 *C/P denotes Collector/Processors. 1 Although eight of the 39 collector/processors do not have any collection capacity of their own, they do have a working relationship with collectors. 191 ------- MOST COLLECTORS AND COLLECTOR/PROCESSORS PICK UP WASTE OIL FROM SOURCES WITHIN 100 MILES OF THEIR PLACE OF BUSINESS. Widest ranging collector/processors usually exceed a collection range of 200 miles while widest ranging collectors cover 100 - 200 miles range. -— 64% of all collectors pick up waste oil at distances of from 26 to 100 miles from their place of business: one-third pick up oil at distances exceeding 100 miles. (Table 4) —— 51% of collector/processors pick up waste oil at distances of from 26 to 100 rnfles; 41% from distances exceeding 100 miles. At collection ranges over 100 miles differences between the two groups appear, While collectors and collector/processors differ greatly in their scales of operations, such as number and capacity of trucks and breadth of sources, only minor differences exist in area range they collect from. 192 ------- TABLE D—4 Collection Radius Q. 1: What approximate radius, in miles, does your ftrm collect oil in? Collectors (61 ) Percent of firms who collect in each radius zone. Collector/P races so rs 39 ) Percent of firms who collect in each radius zone. 200 193 ------- WASTE OIL COLLECTORS OPERATE MAINLY INTRA-STATE -- COLLECTOR/PROCESSORS TEND TO COLLECT 4JLTI-STATE. —— About two-thirds of all collectors offer intra—state collection only, and only 3% collect waste oil from five or more states (Table 5). -- Of those collector/processors with their own trucks, more than three-quarters of them collect in three or more states. As In the cases of other indices, collector/processors run larger collection services than do collectors. Collector/processors, on the average, collect waste oil from more states than do collectors -— a statistic that also corre- lates with the greater number of trucks and truck capacities which the collec- tors/processors have. 194 ------- TABLE D—5 Intra-and Inter-State Collection Q. 2: Please tell me the names of the states in which ,you collect waste oil. Collectors (61) Collector/Processors (31 )* Collect in 5 or more states 3% 3 or 4 states 15 32 2 states 18 13 Intra-state collection only 64 6 *AIthough eight of the 39 collector/PrOCeSS0rS do not have any collection capacity of their own, they do have a working relationshiP with collectors. 195 ------- MOST OF THE STORAGE FACILITIES OF WASTE OIL COLLECTORS WHO HAVE THEM, HOLD LESS THAN 500,000 GALLONS OR LESS CAPACITY. —- 72% of all collectors with storage have a total storage capa- city of 500,000 or less gallons and 4% have capacity of more than 1.5 million gallons (Table 6). —- Storage facilities of collector/processors are somewhat larger as would be expected considering their greater need for storage tanks. One-third have storage capacity exceeding one million gallons, although nearly half of all collector/processors store 500,000 gallons or less. —- While a small proportion of collector/processors refused to give out any data on their storage capacities, no collectors refused to supply this data. 196 ------- TABLE D—6 Storage Facilities of Collectors Q. 8: What is the total capacity of your storage facilities in gallons? Total Capacity of Storage Collectors with Collector! Facilities (in gallons) Storage (25) Processors (3 j Over 1,500,000 4% 13% 1,000,001 - 1,500,000 -— 18 500,001 - 1,000,000 24 15 2,001 - 500,000 72 49 Under 2,000 Refused 5 197 ------- NOT ALL STORED WASTE OIL IS PROCESSED OR REREFINED -- SEVERAL ALTE 1ATIVE USES ARE FOUND FOR IT, PARTICULARLY BY COLLECTORS. Although a majority of collectors do transport some of their waste oil to other collectors or processors, much of the waste oil is disposed of in other ways. Co.m ents of collectors indicate that alternative uses become feasible if: (1) Suitable economic incentives are available from alternative uses. (2) Transporting waste oil to other collection or processing facilities is particularly time consuming and expensive. —— Collectors sometimes use their waste oil for road oil or dust control, even though several states now have outlawed this practice (Table 7). —— Half of collectors also use waste oil as fuel, while only 16% use a settling tank without any further treatment. —- Out of all the waste oil picked up by collectors, though, 45% is usually taken to another collector or processor —- 29% is used for fuel and another 22% is used for road oil or dust control. A clear implication emerges —— most of the waste oil which is eventually processed and/or refined is oil which is collected by collector/pro- cessors and not by collectors. -- A far smaller percentage of collector/processors use their waste oil for non—processed applications. Only 36% use any of their oil for fuel, representing only 7% of total oil gallonage and only 21% of the firms use their waste oil for road oil or dust control. —— In addition, only 3% of collector/processors use waste oil as motoroll. 198 ------- TABLE D-7 Uses of Stored Waste Oil, in Gallonage Q. 9: What do you do with the waste oil when you ren ve it from storage? First, do you use it for road oil or dust control? Q. 10: How many gallons per year do you (USE)? Collectors wi thStorage Collector/Processors %Who %Who Use Gallons/Year Use Gallons/Year (25) (3,106,000) (39) (5 1,480,000)* Use for road oil or dust control 22% 1% Use for fuel 48% 29 36% 7 Take to another collector or processor 56% 45 8% Put in settling tank -— that is settling without any other treatment 16% 15% 2 .Take to your own processing or rerefining plant 100% 88 Use for motoroil 3% 2 Other 12% 3 10% *Ir this table, as in similar tables, gallonage bases are often smaller than percent-of—user bases. Many waste oil firms are sure of techniques and pro— ducts used, but are unsure or unwilling to supply figures related to amounts. 199 ------- WASTE OIL PROCESSORS • Types and sizes of businesses • Forms of treatment • Types of oil produced • Disposal of wastes • Pollution control practices (water, air) • National estimates of the waste oil industry • Validity Gf the national estimates 200 ------- WASTE OIL PROCESSORS MOST WASTE OIL PROCESSORS ARE ALSO WASTE OIL COLLECTORS. -- Of the processors studies, 79% collect as well as process waste oil (Table 8). —— Most processors who only process and do not collect, mentioned that they use the services of many collectors and that most of these are small collection firms, with only one or perhaps a few trucks. 201 ------- TABLE D—8 Types of Waste Oil Processors Processors (39 ) Process oil but do not collect 21%* Both collect and process waste oil 79% *Although eight of the 39 collector/processors do not have any collection capacity of their own, they do have a working relationship with collectors. 202 ------- WASTE OIL PROCESSORS DURING 1973 PROCESSED MORE THAN ONE MILLION GALLONS OF WASTE OIL. —- Forty-nine percent processed between one and 24 million gallons during 1973 (Table 9). —— Nearly one-third of all processors either refused to give out their 1973 processing figures or maintained they could not give an accurate figure. This question prompted a very large refusal rate. 203 ------- TABLE D—9 Amount of Waste Oil Processed in 1973 Q. 12: How much waste oil would you estimate you processed in your facilities in 1973? Estimated Amount of Waste Oil Processed in 1973 (in gallons) Processors (39 ) Over 24,000,000 3% 18,000,001 - 24,000,000 6,000,001 - 18,000,000 8 1,000,001 - 6,000,000 38 25,000 - 1,000,000 21 Under 25,000 3 Don’t know 21 Refused 8 204 ------- THE AVERAGE PROCESSING CAPACITY AMONG PROCESSORS IS APPROXIMATELY THREE MILLION GALLONS OF WASTE OIL PER YEAR. -- One-third of al capacity in the three-quarters between 25,000 1 processors have a total annual processing one—to-six million gallon range. More than of all processors have an annual capacity and 24 million gallons (Table 10). - — Fewer processors refused to provide capacity information than actual 1973 gallonage, but still 13% refused to give this information, or said they did not know their processing capac- i ty. 205 ------- TABLE D—1O Total Processing Capacity Q. 11: What is the total capacity of your processing facilities in gallons per year? Total Capacity of Processing Facilities (in gallons/year) Processors (39 ) Over 24,000,000 8% 18,000,001 - 24,000,000 8 6,000,001 - 18,000,000 13 1,000,001 - 6,000,000 31 25,000 - 1,000,000 26 Under 25,000 3 Don’t Know 5 Refused 8 206 ------- MANY PROCESSORS APPEAR TO BE UTILIZING THEIR PROCESSING FACILITIES AT 90% OF CAPACITY OR BETTER. —- Actual processing in 1973 related to total processing capacity could not be coniputed for one-third of the pro- cessors in cases whether either of the two figures were refused (Table 11). - - However, two in five are running their processing facili- ties at 90% or more of total capacity. 207 ------- TABLE D—1]. Estimated Processing (1973) Related to Total Processing Capacity Q. 11: What is the total capacity of your processing facilities in gallons per year? Q. 12: How much waste oil would you estimate you processed in your facilities in 1973? Percent of Capacity Processors (39 ) 90% or more 38% 75 - 89 50-74 5 25-49 13 Under 25 13 Not computable 31 *These figures were con uted by dividing the mean within a total capacity range by the mean within the 1973 processing range. For this reason percentages-of-capacity figures are subject to some variation. 208 ------- FILTRATION, SETTLING TANK, CLAY, DISTILLATION BATCH AND ACID ARE THE MOST COMMON OF ELEVEN TYPES OF WASTE OIL TREATMENT. Of eleven types of waste oil treatment asked about specifically, each is used by at least 10% of the processors (Table 12). —- In proportion to overall waste oil processed, filtration technique leads (16%), followed closely by acid and clay methods (each 15%), and flash drying and distillation batch (each 14% of total processing). —— These treatments are used by 40% or more of the processors: • 69% Filtration • 56% Settling Tank • 46% Clay • 44% Acid • 44% Distillation Batch 209 ------- TABLE 0—12 Processing Treatments Used Q. 13: 1 am going to read you a list of processing methods. For each one could you please tell me whether or not you use this type of processing? Q. 14: About how many gallons did you process using ( TREATMENT ) during 1973? Processors Gallons Processed Treatments Percent Who Use in 1973 (39) - (125,575,000) Filtration 69% 16% Settling tank 56% 12 Clay treatment 46% 15 Acid treatment 44% 15 Distillation batch method 44% 14 Caustic treatment 26% 5 Chemical treatment 23% 10 Flash drying 23% 14 Centrifuge 18% * Silicate treatment 10% Continuous vacuum distillation 10% * Other methods 1 13% * *Less than .5% 1 Such as: deep injection well, steam Incinerate. 210 ------- WHILE MOST PROCESSORS CAN NAME ThE TYPES OF OILS THEY PRODUCE, VERY FEW HAVE KNOWLEDGE OF THE NUMBER. OF GALLONS OF EACH THEY ACTUALLY PRODUCE. —- #4 or #5 fuel oil, lube and road oils are the principal products of waste oil processors. Although other types of oil products are produced by fewer processors, all types are produced by at least 12% of the processors (Table 13). -— Eighteen processors either refused to supply gallonage figures for each product they produce, or stated that they had no records available. Several other processors were able to supply gallonage figures for only a few of the products they produce. 211 ------- TABLE D—13 Types of Processed Oils Produced Q. 15: Next, I am going to read you a list of products. Please tell me whether or not you produce each type. First, take #2 fuel oil, do you produce #2 fuel oil? Q. 16: How many gallons of ( PRODUCfl did you produce in 1973? Processors Gallons Produced Oils Produced Percent L4ho Produce in 1973 (39) -- (5O,942,OOO) Z #4 or #5 fuel oil 59% 29% Lube oils 49% 39 Road oils 41% 7 #2 fuel oil 33% 3 Process oil 26% 8 Journal box oil 21% 4 #6 fuel oil 18% 7 Asphalt flux 13% 1 Farm oil 13% * Other methods 1 18% 2 *Less than .5% 1 Such as: rerefined oil mix with crude, grinding oil, edible, and burn it. 2 The base for this question is 21, as 18 out of 39 processors did not supply the relevant data. 212 ------- MOST PROCESSORS DISPOSE OF WASTE MATERIALS BY DUMPING THEM IN A LAND FILL. —— The only disposal method used by more than one-fourth of processors is dumping wastes into land fills -- and just over half of all processors say they use this single tech- nique (Table 14). —— Only two processors dispose of wastes by injection into a deepwell, but this represents their only disposal technique and the gallonage is considerable on an annual basis. —- Of those processors who rely on biological treatment, nearly twice as many utilize public treatment rather than their own private biological facilities. Burning of wastes is also used by 23% of processors. 213 ------- TABLE D—14 Methods of Disposing of Processing Wastes Q. 17: How do you dispose of wastes, such as tank bottom, acid or caustic sludge, spent clay or distillation residue that develop in the course of processing? Processors Method Who Use (39 ) Dump it in a land fill 56% Use a public biological treatment 23% Burn it 23% Use your own biological treatment 13% Dump it in a deepwell 5% Dun it in the ocean Other methods 1 23% 1 Such as: road oiling, take to special processor, give it to a trucking firm, sold for dust control, sell it, disposal service. 214 ------- OIL-WATER SEPARATION AND SKIMMING ARE THE MAJOR FORMS OF WASTE WATER TREAT- MENT USED BY PROCESSORS. -— Both oil-water separation and skiming are used by half of those processors questioned (Table 15). —— Emulsion breaking, filters, biological treatment, and other methods (including silica sand, amonia, and acid treat- ment) are each also used by at least 20% or more of the processors. -- Many processors did not reply to this question and others were defensive. Several qualified their replies by outlin- ing the regulations of their state pollution agencies. Three processors even stated that no waste water pollution was possible from their operation and that, for this reason, they perceived no rationale for fo11 ing j y protective course of action. 215 ------- TABLE D—15 Waste Water Treatment Methods Q. 18: What about waste water treatment? Processors Method Who Use (39 ) Oil-water- separation 49% Skimming 46% Filters 36% Emulsion breaking 23% Biological treatment, such as trickling filter or activated sludge 21% Centrifuge 13% Activated carbon 5% Other methods 1 21% No answer 2 15% Refused 5% 1 Such as: ammonia, take to special processor, silica sand, acid treat- ment. 2 Three of these six processors insisted their industry causes no water pollution and do not, therefore, use any waste water treatment method. 216 ------- PROCESSORS WERE EVEN MORE DEFENSIVE WHEN ASKED TO DESCRIBE THEIR AIR POLLUTION CONTROL SYSTEMS. —— Scrubbing (33%) and incineration (33%) are the major forms of air pollution control utilized by waste oil processors (Table 16). —— Other methods are seldom used. Those in the ‘other category (10%) include: ammonia, wet scrubbing, coils, complete air- pollution enclosures. - — More than one—third of all processors asked this question either did not answer or stated that they use no air pollu- tion control techniques. Again defensive on this topic, seven processors stated that their type of business creates no form of air pollution and that, therefore, no control methods are in fact needed. 217 ------- TABLE D-16 Methods of Air Pollution Control Q. 19: What about air pollution control? Processors Form of Control Who Use (39 ) Scrubbing 33% Incineration 33% Bag fIlters 5% Electro-static precipitator —— Other methods 1 10% No answer 2 38% 1 Such as: amonia, wet scrubbing , coils, complete air pollution enclosure. seven of the fifteen processors insisted their industry causes no air pollution, therefore no controls are needed. 218 ------- COMPUTATION AND VALIDITY OF THE NATIONAL ESTIMATES On Table 17 are our national estimates of the waste oil industry, on several important dimensions. Although each has been arrived at by means of an ob- jective statistical procedure, the reader should keep in mind various factors affecting the national estimates. All estimates are based on the data we collected for waste oil firms within our national probability sample areas. The information from these 103 areas was weighted up to represent a national estimate. While the Response Analysis probability sample is based on demographic statistics from the 1970 Census, the waste oil industry nay not totally coincide geographically with overall population distributions, although our sample is drawn heavily from urban areas where waste oil firms seem to locate. Data were weighted in other ways as well. Although Response Analysis devel- oped lists of waste oil firms from telephone yellow page directories, many firms may not have phone listings and directories are only published annually. For this reason, we weighted up the number of firms on the basis of additional names we got from the licensing agencies of three states - - Massachusetts, Texas and Maryland.* We also weighted the estimates to account for differences among the areas which each sample area represents and also to account for different completion rates among the respondents contacted in each area. These weighting systems are explained in detail in the Appendix. The reader should also bear in mind that only a small number of firms agreed to participate -- 61 collectors and 39 collector/processors, and that the validity of national estimates based on this small number of cases is reduced. The reader should also realize that the validity will decrease with time. As stated earlier, the waste oil industry is affected by many external factors, and many changes and fluctuations are probable in the future. While our na- tional estimates may be valid for a short period of time, no projection of their accuracy can be stated for extended periods of time. National estimates of amount of oil processed in 1973 and the capacity of processing facilities were computed in terms of ranges, although we also compute a median “best estimate.” In each case, we multiplied the estimated number of firms of a certain size or capacity times the minimum and maximum production or capacity figures within that firm’s answer category. Data for all firms were then summed to provide the estimated total minimum and maximum figures. We then computed the median of the two figures as the best overall estimate. The final mean estimates are calculated to the nearest one thou- sand gallons. In the case of unbounded answer categories (“over 24 million” and “under 25,000”), we used the anchor figure for one extreme and a figure of plus-or-minus 10% as the other extreme figure for the answer category. *We were only able to calibrate the differences between the phone list and state license lists for these three states. This weight was then applied to all states. Massachusetts officials were able to supply us with the names of 17 additional waste oil firms -- Texas supplied seven more, and Maryland supplied only one. 219 ------- TABLE D—17 NATIONAL ESTIMATES OF THE WASTE OIL INDUSTRY Ni er of CollectorS 260 N er of Collector/Processors 163 Gallons Collected Per P’onth 136,681.925 w t Processed During 1973 (in gallons) (STIMATU) NLI ER OF FIRMS MINIU SUB-TOTALS W .XflUt SUB-TOTALS Over 24,000,000 8 24.000.001 192,000,000 26.400,000 211,200,000 18.000 ,000 - 24.000.000 0 18.000.001 W3ME 24.000.000 hONE 6.000.001 - 18,000.000 15 6,000,001 90.000.000 18,000,000 270.000,000 1,000.001 - 6.000,000 1.000.001 86,000,000 6,000.000 516,000.000 25 .000 - 1,000,000 45 25.000 1,125,000 1,000,000 45,000,000 der 25,000 9 22,500 202,500 24.999 224,991 $1*IPUI TOTAL 369.327,000 MAX1NWI TOTAL • I ,042,425 ,000 I(DIAII E.STIIIAT( • 705,877,000 CapacIty of Processing facilIties (in gallons) Over 24,000,000 13 24,000,001 312,000,000 26,400,000 343,200,000 18,000.001 - 24,000,000 1 1 18,000.001 198,000,000 24,000.000 264,000,000 6.000.001 - 18.000.000 16 6,000.001 96.000.000 18,000,000 288,000,000 1,000,001 - 6,000,000 82 1,000.001 82,000,000 6,000,000 492,000,000 25.000 - 1,000.000 34 25,000 850.000 1.000,000 34.000,000 I.Mder 25.000 7 22 ,500 157,500 24,999 174.993 MINDJI TOTAL • 689,008,000 MXIIILI4 TOTAL • 1,421,375,000 COIM ESTIMATE • l .0S5.192. 220 ------- In making a national estimate of the amount of waste oil processed during 1973, the following method of computation was used: -- We first estimated the number of firms in each size category. The number of firms in each category from our sample was weighted up to a national estimate of firms. -- For each processing category, the estimated number of firms was multiplied times both the minimum and maximum processing figures for that category. For instance -- we estimate there are eight firms which processed more than 24,000,000 gallons of waste oil during 1973. Eight was then multiplied times 24,000,001 gallons (the minimal figure for the category) and T o times 26,400,000 (24,000,000 plus l0 ) for the maximum amount. -- We then summed total estimated minimum and maximum production for 1973. We then took the median of these two figures as our best estimate of waste oil processed during 1973. The same method of computation was also used in estimating national waste oil processing capacity. 22]. ------- FUTURE INDUSTRY PROSPECTS • Trends foreseen by waste oil firms • Reasons for them 222 ------- FUTURE INDUSTRY PROSPECTS Collectors and collector/processors were asked at the conclusion of the interviews to discuss the growth or decline of their business, to specu- late on the causes of the growth or decline, and to predict future trends fn the industry. Growth and Decline in the Waste Oil Industry Half of all collectors (49%) feel there has been no change recently in their business, while nearly one-third (28%) feel their business has ac- tually been declining. By contrast, two-thirds (67%) of collector/processors say they have growing businesses, and only one in five (21%) report declining business. Thus, market share within the waste oil industry is changing. Most col- lector/processors are growing, at the expense of collectors who are expe- riencing either no growth or actual decline. TABLE rY—18 Q. 20: During the last year or so has your business been growing, declining, or has there been no major change in your size? Collectors (61) Collector/Processors (39 ) Growing 23% 67% Declining 28 21 No change 49 13 The vefbatim comments of company spokesmen were recorded. Although these coments are provocative, and illustrative of trends in the waste oil in- dustry, they were elicited from unstructured questions and have not been quantified to statistically represent the entire universe of waste oil collectors and collector/processors. The verbatim comments, grouped typi- cally, are presented on pages 46, 47 and 48. 223 ------- COLLECTORS VERSUS COLLECTOR/PROCESSORS: THE ISSUES ARE THE SAME BUT PER- SPECTIVES ARE DIFFERENT. Company spokesmen consistently mentioned the same five central issues facing their industry: the energy crisis, environmental pollution and governmental regulations, changes in equipment and technology, internal business factors, and the competition between collectors and collector/processors. But in terms of viewpoint, collectors and collector/processors differ greatly. While most collector/processors feel their businesses are growing and see continued future growth, a majority of the collectors say they are experiencing a decline or period of no growth in their businesses, and they foresee a con- tinued decline for their sector. The two groups also differ oi their viewpoints on specific industry issues, particularly in reference to the energy crisis and environmental pollution and governmental regulation. 224 ------- We enclose the verbatim comments of industry spokesmen to document the five key industry issues and trends. 1. The Energy Crisis It appears that all firms are well aware of some of the impact the oil shortage has had on their industry. But while coUec- tor/processors see the oil shortage as a positive !growthh force on their business, many collectors have been seriously hurt by the shortage. This seems entirely consistent with data pre- viously discussed -- collectors depend on crankcase oil as their major source, while collector/processors have a much wider col- lection base. Business growing Due to the shortage of crude oil, many of our customers who are unable to get new lube oil now buy it from us, whereas they dithi’t before. (C/P)* Business picked up after the energy crisis. Before, we coulàz’t get any money for fuel oil, hut now, with the big demand for fuel oil, we get more money. (c/P) Business will, continue to grow as long as the energy crisis exvsts. You can’t sell recycled oil when new is available. So, if the crisis exists, we will grow. (c/P) The supply of used motor oil will decline, but I think that this will be offset by the use of rerefined oil. I look for a goad future in sales. I an very optimistic. (C/P) Business declining It is the gas shortage. It has depleted our income. There is no longer such a thing as waste oil. Without that we c j.nnot run a business. (C)** In the last two years there has been pretty much the sane pattern of people changing their oil. We have lost some of the service station clients in the city, but we have gotten new accounts at the newer suburban-type garages. The last few years, overoll, have been down from five to ten years ago -- people go longer bei’ een oil changes. (C) *C/P denotes Collector/Processor. ** denotes Collector. 225 ------- 2. Concern Over Environmental Pollution and the Proliferation of Governmental Regulations Covering the Waste Oil rndustry . Many industry spokesmen have seen basic changes in their collec- tion and processing methods. Many others are bothered by the increased role of government in overseeing and regulating their industry. Business growing We cooperate with the environmental, people rather than fight them. We are not scavengers looking for business. (C/P) People are more are that reclamation exists. There is a lot of economic incentive. Ecolo j and economy are big words. (C/P) Great future, depending on rules and regulations and the finan- cial tax incentive. (C) Business declining Because of the new off-the-road tax, and because of labeling. (c/P) I don’t see a bright future; the oil crisis is going to change a lot of things. The ingenuity of the gover vnent will make the whole situation very competitive, hurting the small businesses. (C) It all depends on Uncle Scvn. The biggest problem is disposing of waste. If the County stops us from dwvrping where we do now, we will be out of business. (C/P) 3. New Equipment and Technologies in the Waste Oil Industry . Business growing Good. It is a small company, but I feel with the new processes being developed, we have no place to go but ahead. (C/P) Great future in the recovery of waste oil as lubricating oil. (C/P) An ecx,nomicxzl method to make fuel oil is now available. People can’t take to landfill anymere. (CIP) New processes such as regeneration of acid -- an excellent n process. (C/P) We have a vacuz n truck, which is fairly unknown in the northwest, and once people become mere oware of its capabilities, we see our business growing. (C) Business declining We are running out of Landfills. It is getting too costly to dispose of the materials in the landfills. (C/P) 226 ------- 4. Internal Business Practices and Factors . Business growing Effective manager and the new owner. (C/P) Service -- our business is growing because we give better service. (C) Bexzuse I hustle for my business; I don ‘t sit back and wait for it to come to mo. I go get new business all the time. (C) We work harder. (C) We do ver j good work; we grew three times as much. We are building, buying more equipment and hiring more people. (C) 5. Competition between Collectors and Collector/Processors . Spokesmen’s comments also reveal that a further dimension exists, reflected in the collector-collector/processor dichotomy. This dimension is big business versus the small business. While most collector/processors maintain larger-scale operations with more capital to invest in new equipment, most collectors main- tain much smaller businesses and are less well—equiped to meet Increasing competition within the waste oil industry. Business declining It is going to get tough; less oil and more people out to get it. (C) Business should grow, but the smaller guys will drop out. The energy crisis has helped waste oil products and dealers, but a gw ’ needs a bigger capacity and more clients in the ft ture. (C) Conrpe titive government refineries that have put more co 1 lectors on the street. They borrowed money from the government to in- crease their business, and now they have more collectors out, which is affecting my business. (C) 227 ------- METHODOLOGY • Sample design • Interviewing experience • Questionnaire 228 ------- SAMPLE DESIGN The sample for this study was drawn from the hundreds of waste oil collectors and processors in the coterminous United States. No complete list of all waste oil collectors and/or processors exists froniwhich the sample could be drawn. Only a few states require this type of business to have permits. And no federal registration is re- quired. Therefore, our job was to compile a list of these businesses from which to sample. The sequence of steps used in the development of the sample included: • Selection 0 f a national sample of 103 primary areas, counties or groups of counties, stratified by geographic region, type of community and other population characteristics. • Obtaining all yellow pages telephone directories in all of the counties in the 103 primary areas. • Compiling a list of all waste oil handlers that are listed in the yellow pages directories. Several steps were taken to supplement this list of waste oil businesses which are as follows: • Contacting individuals in and/or involved in some aspect of the waste oil business to obtain additional information. • Writing to all the members of the Association of Petroleum Rerefiners to obtain additional names. • Asking each interviewed firm in the process of interviewing to give additional names. • Obtaining the state lists of waste oil handlers from the Water Quality Resources Offices of Texas, Massachusetts and Maryland. Details on each of these steps is provided in the following sections. 229 ------- Selection of Sample Areas for National Sample Primary areas were selected as follows: The entire area of the coterminous United States was first divided into approximately 1,140 primary sampling units (PSU’s). Each PSU is a well defined geographic unit, usually a county or a group of counties with a minimum population of 50,000 in 1970. PSU’s are of two general types: (1) metropolitan areas, or parts of metropolitan areas; and (2) other areas. Thirty-eight large PSIJ ’s were included in the sample as self-representing primary areas. These include the 25 largest metropolitan areas in the United States. All other PSU’s were grouped into 65 strata, with an average stratum population of approximately 2,000,000 persons in 1970. Basic criteria used In the stratification procedure were: • Geographic division (within a stratum all PSU’s are in the same Census geographic division). • Metropolitan or nonmetropolitan character (with the excep- tion of a few counties, strata consist entirely of metro- politan areas or entirely of other counties). These two stratification features are employed in regional and corTununity— size analysis. Additional stratification criteria included population density, rate of population growth, and industrial characteristics. One PSU was selected with probability proportionate to population size from each of the 65 strata that included two or more PSU’s. Each of the 103 primary areas (38 selected as self-representing areas, plus 65 selected as a result of the stratification procedure) is a rela- tively heterogeneous area. Most include city, town suburban and rural residents. Some are primarily small towns and rural, but are several counties in size. 230 ------- Compiling a List From the Yellow Pages Directories Yellow pages directories were obtained for all counties in the 103 PSU’s. To compile a list of names, several headings in each directory were re- ferred to and names in each section were recorded. Those headings are as follows: Oils - waste Waste - oil Waste reduction & disposal service - industrial Tank cleaning Ecological conservation Every name and telephone number was reviewed and compared with others in each primary sampling unit and any duplicates were removed. Also, each ad- dress was checked to make sure that the waste oil firm physically was located in a sample county. This was done because in many cases yellow page direc- tories cover wider areas than do the white pages. Individuals Contacted to Obtain Additional Information Individuals in the waste oil business and individuals who have dones studies of the waste oil business were contacted to try to supplement the list of waste oil collectors and/or processors from the yellow pages directories. Those contacted were: Several processors in the New Jersey and Pennsylvania areas to ascertain registration requirements or practices of collectors and processors with government agencies or with associations. We found no association exists for this particular group. Regis- tration is required in some states, but not all. The U. S. Department of Interior, Bureau of Mines, who sent us a copy of their study on waste oil recycling. From this a compre- hensive list of rerefiners and contact names of people knowledge- able about waste oil was made available. Messrs. Richard Finocchi and John Williams of Resource Planning Associates in Cambridge, Massachusetts, have done several studies on waste oil and told us which states require registration and permits and from which state office permits are obtained. Contacting Members of Association of Petroleum Rerefiners Response Analysis sent letters to the 45 names of commercial rerefiners on the list received from the Bureau of Mines. This letter asked for their help in building Response Analysis’ industrial sample by providing us with names of waste oil processors and collectors. Five of those letters were returned because the company was no longer in business. Of those forms returned completed, 22 names were given. These names were checked against the list and any additional names were added. 231 ------- Obtaining Lists From State Governments From the Water Quality Control Offices of Texas, Maryland and Massachusetts the lists of registered waste oil handlers were requested. These lists served two functions. The first was to provide additional names for the locations that are in these states. The second and more important function was to compare the state lists of names with the yellow pages di- rectc ry list of names. By doing this, locations could be weighted up in the national projections to compensate for the differences between the two Waste Oil Sample Weighting In developing the national projections, three weight factors were applied to the data: 1. A weight factor equal to the reciprocal of the probability of selec tion of each PSU from its stratum. For self-representing PSU’s (the top twenty-five metropolitan areas) this weight factor was 1. For smaller metropolitan areas and nonmetropolitan PSU’s the weight factors were higher. 2. A weight factor to adjust for the fact that some eligible respon- dents refused to be interviewed or were unavailable after several calls. This weight factor was computed separately for each PSU and was equal to the number of eligible respondents divided by the number of completed interviews in that PSU. 3. A third weight factor to compensate for the fact that some collectors and processors were not listed in the yellow pages. Complete list- ings of collectors and processors were obtained for three states. These listings were compared with the yellow page listings for those states. Based on that comparison, a weight factor of 1.71 was ap- plied to all interviews to adjust for unlisted collectors and pro- .essors. The final weight factor used for each interview was the product of the above three weight factors. 232 ------- INTERVIEWING EXPERIENCE Interviewing was done by a WATS telephone interviewing service, Each in- terviewer who worked on the study was briefed on the questionnaire. Inter- viewers were instructed on the difficulty of reaching many of the respon- dents. They were told to leave a message with the waste oil firm to call Response Analysis collect, if they were unable to directly contact the cor- rect respondent. A letter from Response Analysis explaining the nature of the study and that Response Analysis was conducting the study for the En- vironmental Protection Agency was sent to each organization before inter- viewing began. A sample of the letter is bound in this report. Each re- spondent was assured through the letter and the interviewer that individual answers would be kept in strict confidence and results would be available only as a statistical compilation: The results of the interviewing were as follows: TOTAL NAMES 285 Completed interviews 100 Refused 43 *Do not collect waste oil 32 Direct contact with respondent not made (Response Analysis’ number given —— never called back) 44 No longer in business 32 No answer, six callbacks made 25 Duplicate 9 *Although these firms had listings in the waste oil categories in yellow page telephone directories, they have either changed their operation or else their type of business can be subsumed under no other directory heading. 233 ------- Response Analysis Research park, Route 206 Princetor New Jersey 08540 (609 921 -3.333 March 1 1974 Dear Sir: Response Analysis is a private research organization, specializing in attitude, social, and marketing research. Currently we are con- ducting a nationwide study for the Edison, New Jersey Laboratories of the Environmental Protection Agency on waste oil collection and processing. Your firm is one of a randomly selected group of waste oil collection and/or processing businesses throughout the country who are being surveyed to better understand the contribution being made by such firms to our present energy needs. Your participation will take only a little time by telephone but is essential to the study’s success. Please be assured that your individual answers will be kept in strict confidence. Neither your company’s name or your name will be identi- fied with your responses in any manner. Results will be available to the Environmental Protection Agency only in summary form and not for any individual or company. Our representative will phone you during the next week or so to get your opinions. If you have any questions, please call me at (609) 921-3333, or Leo McCarthy, Assistant Director of the Edison Lab- oratories at (201) 548-3347. Thank you for your cooperation. Sincerely, IZ.Q ! ‘+ — Paul A. Scipione, Ph.D. Researc . Associ ate en c i 234 ------- Time Began:___________ NATIONAL WASTE OIL COLLECTORS AND PROCESSORS SURVEY Hello, I am____________ from Response Analysis Corporation in Princeton, New Jersey. Recently you were sent a letter telling you about a survey on waste oils and asking your cooperation. Did you receive that letter? (IF NOT: USE SCRIPT TO EXPLAIN PURPOSE OF SURVEY) I would just like to ask you sone questions which wifl take only a few minutes. (IF RESPONDENT IS TOO BUSY, MAKE APPOINTMENT TO CALL BACK) 1. What approximate radius, in miles does your firm collect oil in? 1 10 MILES OR LESS 2 11 TO 25 MILES 3 26 TO 100 MILES 4 101 TO 200 MILES 5 OVER 200 MILES 6 OTHER: (SPECIFY):________________ 7 DON t T KNOW 2. Please tell me the names of the states in which you collect waste oil 1 ALABAMA 2 ARIZONA 3 ARKANSAS 4 CALIFORNIA 5 COLORADO 6 CONNECTICUT 7 DELAWARE 8 FLORIDA 9 GEORGIA 10 IDAHO 11 ILLINOIS 12 INDIANA 13 IOWA 14 KANSAS 15 KENTUCKY 16 LOUISIANA 17 MAINE 18 MARYLAND 19 MASSACHUSETTS 20 MICHIGAN 21 MINNESOTA 22 MISSISSIPPI 23 MISSOURI 24 MONTANA 26 NEBRASKA 26 NEVADA 27 NEW HAMPSHIRE 28 NEW JERSEY 29 MEW MEXICO 30 NEW YORK 31 NORTH CAROLINA 32 NORTH DAKOTA 33 OHIO 34 OKLAHOMA 35 OREGON 36 PENNSYLVANIA 37 RHODE ISLAND 38 SOUTH CAROLINA 39 SOUTH DAKOTA 40 TENNESSEE 41 TEXAS 42 UTAH 43 VERMONT 44 VIRGINIA 45 WASHINGTON 46 WEST VIRGINIA 47 WISCONSIN 48 WYOMING 3. How many trucks do you use truck hold? to collect waste oil and tiow many gallons does each NUMBER OF TRUCKS GALL ONS 235 ------- 4. We would like to know what types of businesses you collect waste oil from. Do you collect waste oil from ( TYPE OF BUSINESS) ? IF YES -- How many gallons per month do you collect from ( TYPE OF BUSINESS) ? (IF NO GO TO NEXT TYPE OF BUSINESS) (INTERVIEWER: ASK FOR EACH TYPE A—H) Q. 5 Q• 4 NUMBER COLLECTED FROM BY BY COLLECT FROM GALLONS/MONTH CONTRACT CALL YES NO a. Service stations and new car dealers 1 2 ____________ ________ _______ b. Pipelines 1 2 ___________ _______ _______ c. Car or truck fleets 1 2 ____________ ________ ________ d. Railroads 1 2 ____________ ________ ________ e. Marine sources 1 2 ____________ ________ ________ f. Industrial users 1 2 ____________ ________ ________ g. Other waste oil collectors 1 2 ____________ h. Any other businesses (SPEtIFY): __________ 1 2 ___________ _______ ________ __________ 1 2 ______ ____ ____ ASK Q. 5 FOR EACH TYPE COLLECTED F )M) 15. How many ( TYPE OF BUSINESS ) do you collect from on a contract basis, and how many others on a per-call basis? 6. Do you have your own storage facilities for the oil you collect, or do you only transport the oil to another waste oil collector or processor? 1 HAVE STORAGE FACILITIES -- SKIP TO Q. 8 2 TRANSPORT TO COLLECTOR OR PROCESSOR 7. Could you tell me the name and address of the collector or processor you take your waste oil to? F Q. 7 ASKED, SKIP TO Q. 201 236 ------- 8. What is the total Capacity of your storage facilities in gallons? 1 UNDER 2 ThOUSAND GALLONS 2 OVER 2 THOUSAND - 5 HUNDRED THOUSAND GALLONS 3 OVER 5 HUNDRED THOUSAND - 1 MILLION GALLONS 4 OVER 1 MILLION - 1 MILLION 5 HUNDRED THOUSAND GALLONS 5 OVER 1 MILLION 5 HUNDRED THOUSAND - 2 MILLION GALLONS 9. What do you do with the waste oil when you remove it from storage. First, do you use it for road oil or dust control? (INTERVIEW: READ REMAINING IbETHODS b-f) Q. 10 DON’T Q.11 USE USE AMOUNT Do you: a. Use for road oil or dust control 1 2 b. Use for fuel 1 2 c. Take to another collector or processor 1 2 d. Put in settling tank — - that is settling 1 2 without any other treatn nt e. Take to your own processing or rerefining 1 2 plant f. Are there any other things you do with it? 1 2 SPECIFY:_______________________________ A (ASKQ. 10 FOR EACH USE INDICATED JJO. How many gallons per year do you (USE)? — INTERVIEWER: IF RESPONDENT TAKES ANY OIL TO OWN PROCESSING OR REREFINING PLANT, METHOD e, CONTINUE WITH QUESTION 11. IF RE- SPONDENT DOES NOT TAKE TO OWN PROCESSING OR REREFINING PLANT SKIP TO QUESTION 20. 11. What is the total capacity of your processing facilities in gallons per year? 1 UNDER 25 THOUSAND GALLONS 2 OVER 25 THOUSAND - 1 MILLION GALLONS 3 OVER 1 MILLION - 6 MILLION GALLONS 4 OVER 6 MILLiON - 18 MILLION GALLONS 5 OVER 18 MILLION - 24 MILLION GALLONS 6 OVER 24 MILLION GALLONS 7 DON’T KNOW 237 ------- 12. How much waste oil would you estimate you processed in your facilities in 1973? 1 UNDER 25 THOUSAND GALLONS 2 OVER 25 THOUSAND - 1 MILLION GALLONS 3 OVER 1 MILLION - 6 MILLION GALLONS 4 OVER 6 MILLION - 18 MILLION GALLONS 5 OVER 18 MILLION - 24 MILLION GALLONS 6 OVER 24 MILLION GALLONS 7 DON’T KNOW 13. I am going to read you a list of processing methods. For each one could you please tell me whether or not you use this type of processing. First, caustic treatment, do you use caustic treatment? Q. 13 DON’T Q. 14 USE METHOD AMOUNT PROCESSED Do you use: USE METhOD OR DON’T KNOW IN 1973 IN GALLONS a. Caustic treatment 1 2 __________________ b. Silicate treatment 1 2 _________________ c. Chemical treatment 1 2 _________________ d. Filtration 1 2 _________________ e. Centrifuge 1 2 __________________ f. Flash drying 1 2 ________________ g. Distillation batch method 1 2 _________________ h. Continuous vacuum distillation 1 2 ________________ i. Acid treatment 1 2 _______________ j. Clay treatment 1 2 ______________ k. Settling tank 1 2 _______________ 1. Other methods (SPECIFY): __________ 1 2 _______ __________ 1 2 _______ ASK Q. 14 FOR EACH METHOD USED IN Q. 13 14. About how many gallons did you process using ( TREATMENT ) during 1973? 238 ------- 15. Next, I am going to read you a list of products. Please tell me whether or not you produce each type. First take #2 fuel oil, do you produce #2 fuel oil? Q. 15 DON’T ( 6 PRODUCE PRODUCE AMOUNT PRODUCT PRODUCT PRODUCED IN 1973 a. #2 fuel oil 1 2 ________________ b. #4 or #5 fuel oil 1 2 ________________ C. #6 fuel oil 1 2 ________________ d. Process oil 1 2 ________________ e. Asphalt flux 1 2 ________________ f. Lube oils 1 2 ________________ g. Road oils 1 2 ________________ h. Farmoil 1 2 ___________ I. Journal box oil 1 2 _______________ j. Other (SPECIFY): ____________ 1 2 _______ ____________ 1 2 _______ ASK Q. 16 FOR EACH PRODUCT PRODUCED IN Q. 15 6. How many gallons of ( PRODUCT ) did you produce in 1973? 17. How do you dispose of wastes; such as tank bottom, acid or caustic sludge, spent clay or distillation residue that develop in the course of processing? Do you: USE DON’T DON’T METHOD USE METHOD KNOW a. Dump it in a land fill 1 2 3 b. Dump it in a deepwell 1 2 3 c. Dump it in the ocean 1 2 3 ci. Use your own biological treatment 1 2 3 e. Use a public biological treatment 1 2 3 f. Burnit 1 2 3 g. Use any other method 1 2 3 SPECIFY: _______________________ 239 ------- 18. What about waste water treatment? USE DON’T DON’T Do you use: METHOD USE METHOD KNOW a. Emulsion breaking 1 2 3 b. Oil—water separation 1 2 3 c. Skiming 1 2 3 d. Biological treatment, such as trickling filter or activated sludge 1 2 3 e. Centrifuge 1 2 3 f. Filters 1 2 3 g. Activated carbon 1 2 3 h. Any other method (SPECIFY): _______________ 1 2 3 19. What about air pollution control? USE DON’T DON’T Do you use: METHOD USE METHOD KNOW a. Scrubbing 1 2 3 b. Incineration 1 2 3 c. Electro-static precipitator 1 2 3 d. Bag filters 1 2 3 e. Any other method (SPECIFY): _______________ 1 2 3 Finally a few general background questions to help us analyse the results. 20. During the last year or so has your business been growing, declining, or has there been no major change in your size? 1 GROWING 2 DECLINING 3 NO CHANGE - - SKIP TO Q. 23 240 ------- 21. What is the reason for the (growth/decline) in business? 22. What future trends do you foresee in your type of business? 23. How many terminals or storage facilities do you have in urban areas? How about rural areas? URBAN AREAS ______________________ RURAL AREAS ______________________ 24. How many fullticne employees do you have? 1 LESS THAN 10 2 11 - 50 3 51 — 100 4 101 - 150 5 150 - 200 6 OVER 200 7 DON’T KNOW 25. How many shifts do you operate? 1 ONE 2 TWO 3 THREE 4 OTHER (SPECIFY): _____________________________ 5 DON’T KNOW Thank you very much for your cooperation Time Ended: ________ Length of Interview: 241 ------- Respondent appeared 1 Very knowledgeable 2 Somewhat knowledgeable 3 Not very knowledgeable Respondent was 1 Cooperative 2 Somewhat cooperative 3 Very uncooperative Respondent’s Name: _____________________________________ Title: Company Name: Business Address: __________________________________________ Business Telephone: ______________________________________ Interviewer Name: __________________________________ Date: 242 ------- APPENDIX E INDUSTRIAL SURVEY 243 ------- SIC MAJOR GROUP 01 - Agricultural Production/Crops Annual oil purchases and disposal practices were re- ported for one plant and related field operation. Machine and Repair Shop Service tractors, bulldozers, carts, and other field vehi- cle. Ann u a 1 Type Use Amount Havoline Motor oil 30 100 cases (24 qts/ case) Marfax #1 Grease 50 drums (120 lbs/ drum) Series 3—LA330 oil 12,000 gallons Randol C-hydraulic oil field equip- ment hy- draulic cylinders Series 1—SAE 30 12,000 gallons URSA ED 30 oil 12,000 gallons These oils are changed right in the field and dumped on the ground at the site (45,000 acres). Oils Purchased for In—Plant Usage Annual Type Use Amount Klingfast Special Extra Lubricate 80 drums (420 lbs/ Light Oil main jour- drum) nals Klingfast 265-11W Lube Lubricate 8 drums (440 lbs/ Oil wheels for drum) mills 676—W Brooks Worm Lubricate 13 kegs (115 lbs/ Gear Oil all worm keg) gears Texaco Regal, PC (R+O) Lubricate 120 drums (55 gal/ speed re- drum) ducers 244 ------- Arrnua 1 Type Use Amount Texaco Regal G (R+O) Lubricate 30 drums (55 gall speed re— drum) du cers Texaco Regal A (R+O) 15 drums (55 gall drum) Texamatic Fluid Hydraulic 6 drums (55 gal/ fluid drum) Mart ax MP-#2 Grease caps, 30 drums (120 lbs/ bearings, drum) shafts Crater 2X Fluid Hydraulic 6 drums (415 lbs/ fluid drum) URSA LA3 SAE 40 Oil Special 2 drums (55 gal/ lube oil drum) Meropa #3 Lubricate 1 drum (55 gal/ speed re- drum) ducers Meropa #8 H 50 drums (415 lbs/ drum) The oils from the speed reducers are changed, collected in drums and used without any processing for less demanding lubrication such as chains, gears, etc. The other oils are dissipated in unknown ways, e.g. dripping on floors, getting in product (?), vaporizing, etc. Drips on floors wind up in drains, which used to go to drainage ditches. Presently the company is separating drains which receive pollutants and directing them to an impounding area. SIC MAJOR GROUP 02 — Agricultural Production/Live—Stock The company contacted has seven independent agricultural production (live-stock) operations. One typical operation reported that the only waste oils they generated were from the servicing of pickup trucks and power equipment. The crankcase oils, approximately 20 gallons per month, are collected in 55 gallon drums and used to lubricate high speed roller chains and open drive shafts on conveyer equip— men t. 245 ------- SIC MAJOR GROUP 07 - Agricultural Services The agricultural service company contacted has approxi— rnately 900—1000 employees at their main plant. Waste oils generated from their operations and the means of disposal are: 1. Lube and seal oil in ammonia refrigeration systems. They purchase about 55 gallons per month to makeup that which is disposed of by dumping down the drain. About 150 gallons per month additional are drained, filtered, allowed to vent the dissolved ammonia, and reused. 2. The plant purchases about 300 gallons per month of gear box, motor, compressor, and other drive system lube oils. Most of them leak out onto the ground. An estimated 100 gallons per month are drained off and dumped down the drain. 3. There are very small amounts of transformer oils involved. They are cleaned up and re- used. 4. The fuel oil tank purges about 50 gallons per month of Bunker C or No. 6 oil which goes into a small laqoon. This is caused by a steam leak in a heating coil. Presently there are about 500 gallons of oil in the lagoon arid it is in the company T s interest to recover and use this oil. 5. Sludge from the fuel oil tank is removed once a year and buried in a local dump. 6. There are about 700 gallons per month of crankcase oils generated from the servicing of material haulers and industrial vehicles. These are stored in a 4,000 gallon under- ground tank and hauled away once a month by a local waste oil collector. There is no charge for the disposal service. 246 ------- SIC MAJOR GROUP 79 - Amusement and Recreation Services Except Motion Pictures Machine Shop Generates about 25 gallons per week of waste lube and cutting oils. They collect them in a 1,000 gallon holding tank. Periodically it is picked up by a local waste oil collector. On-Site Vehicles Maintenance Shop Approximately 300 vehicles (trucks, buses, trains, etc.) are serviced (about 25 lube oil changes per week). The waste oils are collected and stored in the same tank as above. Small Engine Maintenance Shop Services lawn mowers, tractors, pumps, etc. Lube and hydraulic oils are put in 55 gallon drums and used for dust control purposes. Very small quantities of waste oils are involved. Company Owned Gas Station Services company cars. They reportedly accumulate less than 30 gallons per month. The oil is collected in 55 gallon drums and is used for fire training programs and dust control at a sanitary landfill site. Central Energy Plant Has two natural gas jet turbines for electricity followed by hot water boiler. The oils purchased for the plant are as follows: 1. Jet Engine Oil-—consumption 40 gallons per year 2. Turbine Oil--consumption 200 gallons per year 3. Air Compressor Oil—-consumption 75 gallons per year 4. Chiller Oil--consumption 100 gallons per year 247 ------- 5. General Lube Oil--consumption 200 gallons per year Any waste oil is collected and put in the main waste oil storage tank to be hauled away. SIC MAJOR GROUP 23 - Apparel and Other Finished Products Made From Fabrics and Similar Materials All company vehicles are serviced at local service stations (40 cars and 20 trucks). An estimated 3,200 gals! year of sewing machine oil is purchased and used on gears in the sewing machines. The oil disappears onto fabrics or into the air, therefore, no disposal is needed. Approxi- mately 600 gallons per year of hydraulic oil and 5 gallons per year of oil from compressors are dumped on an open lot behind the factory. Transformers are serviced under con- tract. There is no process water in this plant. SIC MAJOR GROUP 75 — Automotive Repair Services and Garages The company leases more than 10,000 each of short term rental cars, rental trucks, and long term lease cars. Sixty percent of the cars and all of the rental trucks are serviced at various company owned service areas throughout the U. S. The balance of the cars are leased from auto- mobile manufacturers and serviced under contract. The vehicles that are directly serviced by the company have the oil and oil filter changed every 6,000 miles. The average vehicle is run approximately 15,000 miles per month and is used for rental or lease purposes for 18,000-20,000 miles. It is then sold or returned to the manufacturer. The waste oils generated from the servicing of the vehicles is collected and stored in underground waste oil storage tanks at the various locations. The tank sizes range from 500-2,000 gallons depending on the size of the service area. The waste oils are then hauled away by scavengers. Information on the fees paid for the disposal services or the quantities of waste oils involved were not available. SIC MAJOR GROUP 55 — Automotive Dealers and Gasoline Service Stations Five auto dealers were contacted. They had a combined total sales of 4,000 cars per year. Estimated purchases, 248 ------- totaling 11,400 gallons per year of multi—viscosity SAE1OW- 30 oil were made in 1973. Waste oils are collected at all dealers, however no information on quantities was available. Three of the dealers pay a flat rate (approximately $9.00) every two months to have the waste oils hauled away. The other two dealers do not pay any fee; the oil is just picked up. One of the newer auto dealers has an oil-water sepa- rator unit on the main discharge to the city sewer; the oil recovered is dumped into the same tank with the drain oils and collected. Outside run-off does not enter into this system. SIC MAJOR GROUP 12 — Bituminous Coal and Lignite Mining The company contacted purchased 960,000 gallons of lube oils in 1972. Most of this is used for trucks and other diesel engines. Some oil is used with additional fuel oil to spray coal in coal cars in cold weather; less than 20,000 gallons per year is used for this purpose. Some waste lube oils are used as fuel; however, most is collected by scavengers. The company pays 2 per gallon to have it hauled away. Any fuel oils spilled are impounded, collected, and re- turned to storage tanks. No. 2 oil is used as a frothing agent in those plants which have treatment facilities. This oil, along with coal particles, is returned to a coal pile. A total of 20,000 gallons per year for all plants is used for frothing. SIC MAJOR GROUP 15 - Building Construction/General Con- tractors and Operative Builders The company owns 100-150 trucks throughout the U. S., all serviced at service stations. They claim no waste oils are generated from equipment (all electric) or construction operations. The company is involved mostly in construction of commercial buildings. SIC MAJOR GROUP 73 - Business Services This maintenance and repair company owns three cranes serviced by the factory; 10 leased trucks, serviced under contract; and approximately 30 vans and pick-up trucks which are serviced at local stations. 249 ------- Approximately 30 gallons per year of cutting oils are purchased which go out in the cutting chips. An estimated 350 gallons per year of waste oils generated from various jobs are taken to the town dump for disposal. SIC MAJOR GROUP 28 - Chemicals and Allied Products A single large chemical plant reported the following for their oil usage and disposal. For the year 1973, they purchased 1.2 million gallons of process oils. Of this 500,000 gallons were directly consumed in their products, 10,000 gallons were disposed of by incineration, 600,000 gallons went to landfill, and 75,000 gallons went to the treatment ditch. Purchases of lube oils for the same year totaled 620,000 gallons, 12,000 gallons of which were dis— posed of by incineration, with an additional 50,000 going to the treatment ditch. From the treatment ditch, approximately 62,000 gallons per year is discharged into a river with other wastewater streams. The total wastewater discharge rate is 80,000 gallons per minute. The remaining 63,000 gallons, recovered as sludges and contaminated oil from the treatment ditch, are hauled to a landfill site. The company is studying means to recover oil usable as fuel. SIC MAJOR GROUP 48 - Communication Information was supplied for two typical plants rnanu- facturing component parts for cummunication equipment. Plant A manufactures small electronic parts. They purchase only 5-10 gallons per month for stationery machine lubrication. It is used for lubrication of bearings, electric motors, etc. All vehicles are leased and serviced under contract. The only waste oil that is generated is from the crankcase draining of two diesel powered generators. The oil is changed once per year and disposed of in the trash. Plant B manufactures cable and various types of wire. The reported purchases of oils are as follows: 1. Vehicular crankcase oil for gasoline and diesel engines - 360 gallons per month. 2. Oil for stationary machine lubrication — 2,000 gallons per month. 250 ------- 3. Emulsified oils - 3,000 gallons per month. 4. Other metal working oils - 400 gallons per month. 5. Insulation oils - 800 gallons per month. 6. Hydraulic oils - 3,800 gallons per month. 7. Process oils - 5,000 gallons per month. Plant B reclaims approximately 13,000 gallons per year of their stationary machine, metal working, and hydraulic oils through an outside re—refiner. The balance of the waste oils are disposed of via a local scavenger. A fee of $240 per month is paid for this disposal service. SIC MAJOR GROUP 16 - Construction Other than Building Con- struction General Construction On one major construction site, the company owns and services 22 large diesel driven rigs (cranes, loaders, crawlers, etc.) and 21 pickup type trucks. It also rents 35 larger trucks and vans. The maintenance shop services two vehicles per day. All waste oils that are recoverable are dumped into one of two 1,000 gallon storage tanks. Approximately 8,500 gallons per year of waste oil is hauled away at a cost of 3.5 per gallon. Form oils soak into wooden forms and go out with the scrap wood; 10,578 gallons of form oil has been used. SIC MAJOR GROUP 58 - Eating and Drinking Places The Company contacted has well over 500 restaurants throughout the U. S. Waste oils generated from the restau- rants are beef and vegetable fats and oils, calculated to total 7,488,000 pounds per year. It is collected at each location by local tallow services which pay 1—1 l/2 per pound. All company cars (over 100) are serviced at local ser- vice stations or under- contract agreement with a leasing company. SIC MAJOR GROUP 82 - Educational Services All waste oils from the university’s vehicles (SAE lOW-30), power equipment, and physical plant operations are 251 ------- collected and stored in. 55 gallon drums. It is later blend- ed into No. 6 fuel oil and burned in the main boilers. J n estimated 100 gallons per month is disposed of in this manner. SIC MAJOR GROUP 49 - Electric, Gas, and Sanitary Services The power company interviewed has more than ten generating stations and many hundreds of electrical sub- stations. No serious spillage problems from fuel oil tankage has occurred. The following discussion is, there- fore, limited to other major types of oil used — for transformers, circuit breakers, and turbines. Little cable oil is used by this company. Most generating stations and some substations have a waste oil tank with a capacity of about 10,000 gallons. Some waste oil is sprayed onto coal piles, and some used as road oil, but most is picked up by a collector. Some waste oil used to be applied as weed killer, but this is no longer practiced. No central data was available on oil purchases, or on waste oil collected. As will be discussed, considerable internal recycle (purification) occurs. Transformer Oils Direct purchases of transformer oils is very small, since most is bought with the transformer and used for its life. Purchases are generally limited to spillage makeup. Transformers contain 2 gallons to 31,000 gallons, depending on size. Small transformers are shipped full; while, for large transformers, the oil is shipped separately and filled onsite. Transformer oil undergoes tests for dielectric strength before putting it into service. The oil is treated by means of portable vacuum equipment, primarily for drying. Testing of the full transformers is also done routinely to detect problems, including oil degradation. When oil problems are detected, the oil may be processed by use of vacuum equipment. Fuller’s earth is used only when sludge is present. Transformers may be used for 40 years or more, in progressively less severe service, before discard. Upon discard, oil may be sold to special reprocessing 252 ------- companies, dumped to the waste oil storage tank, or left in the transformer. In the growing power industry, discard has been, infrequent. PCB oils are used for indoor transformers because of their fire resistance. These are handled as a hazardous material in. sealed units. PCB’s are disposed of by returning them to the PCB manufacturer. Circuit Breaker Oils Oil similar to transformer oil is used in circuit breakers for 69 kilovolt service or lower. The oil becomes contaminated by arc products, e.g. gases, such as methane and ethylene, carbon, and water. The useful life of this oil may be four years or more depending on the frequency of operation, which is monitored. Degraded oil is purified in mobile filter presses, or is taken out dirty to central cleaning facilities, and replaced with cleaned oil. Dielectric strength measurements are used to check the oil, which is discarded when it finally cannot be used. About 50,000 to 150,000 gallons per year are purchased. Turbine Oils Turbine oils are generally circulated through cloth filters to remove particles and centrifuged to remove water. The generating plants maintain storage facilities for both clean and dirty turbine oils. During turbine servicing, every two or three years, oil is removed to a tank and then returned. Makeup is required on older units, so that typical plants may purchase 100-1000 gallons per month of turbine oil. However, makeup for new units is negligible, as little as 12 gallons per 1000 service hours. Older plants have oil/water separators and/or oil skimmers on the wastewater pond. Oil is first separated and recovered from a turbine room sump. Water is pumped to the wastewater facility. Little difficulty is encountered meeting 10 ppm oil and grease limits. 253 ------- SIC MAJOR GROUP 36 - Electrical and Electronic Machinery, Equipment, and Supplies Plant A - Approximately 200-300 gallons per year of waste oils were generated in-plant from the servicing of vehicles or industrial equipment, and from stationary machine lubrication and cutting oils. The waste oils are stored in 55 gallon drums and hauled away by a local dis- posal service. Plant B - Waste oils generated in—plant, as described above, are segregated and the less contaminated oils are blended into the fuel supply. The remainder of the waste oils are hauled away. SIC MAJOR GROUP 91 - Executive, Legislative and General Government The information for a government service was collected from several of the agencies as no central source of dat.a was available. The highway department owns and services over 1,000 cars, trucks, and other pieces of equipment. Tt purchased 25,500 gallons of SAE 1OW—30 multi—viscosity oil in 1973 for its service areas. Each service area disposes of its own waste oil by a local collector picking it up. There is relatively little shop oils or hydraulic oils handled. There was no central source of information on names or costs of disposal for the individual service areas. The central motor pool services over 1,000 cars used by various agencies. An estimated 4,000 gallons per year of lube oil is purchased and used at the central maintenance shop. No records of the waste oil quantities have been kept as there is no cost involved. The waste oil is stored in a 500 gallon underground tank and is collected by a local waste oil collector. Another agency estimates they generate 1,100 gallons per year of waste oils from vehicles and equipment. The waste oil is hauled away by a service at no cost to the agency. The police department services its own vehicles (over 1,000) at four different locations. An estimated 11,000 ‘gallons per year of waste oil is generated, and hauled away at each of the four locations by collection services. 254 ------- The buildings department estimates generation of 250 gallons per year of waste oil. This comes from maintenance shops, air-conditioning units, and power equipment. It is blended into the No. 6 fuel oil tank and burned in the boilers. SIC MAJOR GROUP 34 - Fabricated Metal Products, Except Machinery & Transportation Equipment The following information came from one plant with approximately 1,000 employees. Lube Oils Purchased Yearly % Waste Primary For High Speed Pro- Usage, oil Contaminant duction Equipment Gal. Generated or Residue A 2640 0 B 106 0 — C 383 34 Sludge D 990 20 Sludge E 5480 81 Sludge (iron, tin, NH 4 C1, ZnC1 2 ) F 165 40 Sludge (metal, heavy grease) G 165 0 — H 924 71 Sludge I 1096 60 Sludge Lube Oils Purchased For Lift Trucks Motor Oil 1095 30 Sludge Trans. Fluid 218 30 Sludge Miscellaneous Oils Gear Lube 217 0 Sludge Cylinder Oil 106 0 sludge Other Oil 277 24 Varnish 13862 On various occasions the plant has tried oil reclaimed from these wastes. In each instance the trials gave un- satisfactory results. The practice now is to have the accumulated waste oils hauled away by an outside concern monthly (averaging 550 gallons per month). The overall cost for such collection and disposal averages 27 per gallon. 255 ------- This is generally typical of the company’s other manu- facturing locations. At a few of the other locations recent practice has been to add a major portion of these wastes to the No. 6 oil used for space-heating boilers. The sludge is not efficiently separated from the remainder of the waste oil; the “supernatant” liquid is merely “poured off” and added to the fuel oil, with only the remaining sludge hauled away by the scavenger. Such use of a portion of the waste oil for fuel is limited to the few plants equipped with boilers of the type that can handle such wastes without causing an air pollution problem due to the inorganic contaminants in the wastes. SIC MAJOR GROUP 09 - Fishing, Hunting and Trapping A fisherman’s cooperative that services approximately 50 fishing vessels sells 36,000 gallons per year of engine crankcase oil. Sales of other oils are small in quantity (e.g. gear oils, hydraulic oil, etc.). Crankcase oils are usually changed every 200 operating hours or every one to two weeks. The waste oils (approxi- mately 10—20 gallons per vessel) are drained into old 5 gallon containers, which the crankcase oil is purchased in, and disposed of at sea or in trash receptacles at dock side. SIC MAJOR GROUP 20 - Food and Kindred Products A multi—plant meat processing operation was investi- gated. The operation included four types of plants: slaughter, integrated (slaughter plus processing), pure processing, and distribution. About 6Olbs. of offal (blood, trimmings, bone, intestines, etc.) are recovered per animal and sold for various purposes, including edible and inedible tallows, animal feed, etc. About the only loss occurs when emulsified oils escape primary water clarifiers. Wastewater discharge to municipal plants contain 100- 300 ppm hexane solubles (oil + non-oil), attainable in normal clarifiers. Point source discharge requires further treatment, usually aerobic and/or anaerobic digestion to reduce hexane solubles to 5-10 ppm. Most plants discharge to municipal treatment, but some major plants are point sources. 256 ------- Lower oil levels are sometimes achieved by polyelectro- lyte addition and air flotation. Oil recovered from any clarifier operation is processed for use in soaps, command- ing prices of 3—l5 /lb., depending upon quality. About 1% of the meat processed is recovered and sold as oils and fats. Clarifier sludges,containing 4—5% solids,are usually landfilled. Total losses of oil and fat to wastewater and sludges may be on the order of 0.2—0.5% of the meat processed. SIC MAJOR GROUP 54 - Food Stores The following represents information on waste oil generation and disposal practices for all processing, distribution, and sales activities. Approximately 4,000 gallons per month of lubricating, hydraulic, and refrigera- tion oils are purchased. Waste oils are disposed of: a) by burning in plant boilers (approximately 100 gallons per month), b) road oiling or weed control at plant sites (approximately 700 gallons per month), c) collection and. removal via a local scavenger (500 gallons per month). The balance of the oils are consumed in their particular use, lost due to leakage, or are unaccounted for. 257 ------- SIC MAJOR GROUP 25 - Furniture and Fixtures The company contacted manufactures wooden furniture and fixtures. The number of wood working machines in one typical plant averages about 500, with 700 to 750 employees. There are 18 tractor—trailers (diesel), 7 trucks, 3 cars, and 3 fork lifts, all of which are serviced at the plant. Purchases of oil in 1973, for the one plant, totalled over 10,000 gallons of crankcase oil for vehicles and lubrication oils for stationary machines, with an additional 20,000 pounds of grease purchased for lubrication of wood working machinery. All waste oils and greases are collected in-plant and stored in 55 gallon drums. The waste oil is then disposed of at a municipal dump or given away to farmers for lubri- cation of farm machinery. Waste oils were disposed of, in the past, by using them for road oiling. However, this practice has been dis- continued. SIC MAJOR GROUP 53 - General Merchandise Stores The company contacted owns and operates over 100 general merchandise retail stores. Approximately 25% of all the stores have an automotive service center. This is where the bulk of the company’s waste oils are generated. In a survey of 15 representative service centers, an estimated average of 200 gallons per month per location of waste oils are generated from crankcase drainings. These oils are disposed of at all locations via local waste oil collectors. Generally the only other source of waste oils in large quantities is from the company’s fleet of vans and cars. These vehicles are usually serviced at their own automotive service centers, or at local service stations. All other vehicles or transportation equipment are leased and serviced under contract. Most buildings, offices, and warehouses are heated electrically or by natural gas. Little or no fuel oil is handled. Any waste oils that are generated from the rnainten— ance of these buildings would be small in quantity and dis- posed of in the trash. The company does sell some automotive oils, less than 10% of which are sold in. the service centers. They are 258 ------- generally purchased over—the—counter and used by “do-it- yourselfers” who service their own cars. SIC MAJOR GROUP 80 - Health Services The four vehicles owned by the hospital contacted are serviced at local service stations. An estimated 200 gallons per year of waste oils are generated from generators, com- pressors, and shop oils. It is collected by scavengers. However, no formal records are kept on quantities and there is no fee paid for the service. SIC MAJOR GROUP 70 - Hotels, Rooming Houses, Camps and Other Lodging Places The main office of this hotel chain leases more than 100 cars, all serviced under contract. One typical hotel generates waste oil from one car, which is serviced at a local station, lawn mowers, and a central chilling unit (serviced under contract). Vegetable oils from the kitchen are hauled away by a scavenger. SIC MAJOR GROUP 63 - Insurance The company has 200 cars across the U. S. which are serviced in local service stations. All equipment in the office buildings are serviced under contract, e.g. elevators, heating and air—conditioning units and transformers. They claim to generate no waste oils from any operation or maintenance they conduct. SIC MAJOR GROUP 31 - Leather and Leather Products The company contacted purchased approximately 1,800 gallons of various lubrication and hydraulic oils in 1972. They were used for servicing company vehicles, lubrication of stationary machinery, and hydraulic systems. Twenty-five gallons per month of hydraulic oil is recycled using a filtration process, and the remaining quantity of waste oil is hauled away under contract by a local disposal company. SIC MAJOR GROUP 41 - Local & Surburban Transit and Inter- urban Highway Passenger Transportation One bus company that was contacted reported that their buses, either diesel or turbine, are serviced at various 259 ------- company centers throughout the United States. At all locations, waste oils from crankcase drainings, transmission fluids, etc. are collected and stored in underground stor— age tanks. It is then pumped out and hauled away by local scavengers. The quantities of waste oil and the fee or price paid for the disposal service was riot available. SIC MAJOR GROUP 24 - Lumber and Wood Products, Except Furniture No central records were available. One large mill, greater than 500 tons per day, purchased the following for one year: 1. Mi ii lube oils, including paper machines, pumps, turbines and all lubricated systems - 308 drums (55 gal.) = 16,940 gallons. 2. Hydraulic oil - 15-20 drums about 1000 gallons for hydraulic systems and elevators throughout plant. 3. Greases — 14,000 lbs. 4. Mobile equipment lube oil, including compressors- 133 drums = 7315 gallons. 5. Other lubricants, including vacuum oils, insulating oils, cutting oils, and gear compounds - small quantities. Paper machine lube oil is filtered and centrifuged as necessary (water contamination makes oil milky) , with some oil added as makeup. The capacity of a single machine is about 500 to 1000 gallons, which is replaced about once per year. A 2000 gallon waste oil tank is available. The waste oil may be blended with No. 6 fuel oil or removed by a collector. Water removed by the centrifuge goes to wastewater. Used oil from mobile equipment lubrication is drummed and collected, amounting to about 3000 gallons per year. However, some bulldozers are drained in the field over a bed of chips and bark. Leakage from fuel oil tanks to a surrounding water filled berm is a problem, especially because the No. 6 oil density is close to and sometimes exceeds that of water. This leakage and oil from other systems do find their 260 ------- way into the wastewater treatment system, where some oil is skimmed, and finally to a large aerated holding pond, which discharges to a river. Tall oil lost during pulping is also discharged into the wastewater system. The amount of tall oil lost varies with the type of wood processed and with the facilities available for recovery. Most western mills produce little tall oil. No information was available on the amount of oil contained in the wastewater effluent. The holding pond is covered by an oil containing scum which gradually degrades, or is blown away. 261 ------- SIC MAJOR GROUP 35 — Machinery, Except Electrical The machine manufacturing company that was contacted purchases the following types and quantities of oil per month: 1. Crankcase oils used for vehicular gasoline and diesel engines — less than 100 gallons per month 2. Oil for stationary machine lubri- cation - approximately 3,000 gallons per month 3. Soluble and emulsified oils, cutting oils — approximately 3,000 gallons per month 4. Other types of metal working oils- approximately 5,000 gallons per month 5. Hydraulic oils — approximately 5,000 gallons per month These oils are dispensed from a central oil house to the manufacturing operations in 70 gallon containers which have hand pumps. After their specific use, the waste oils are caught in drip pans or sump systems on the metal work- ing machinery and returned to the oil house in 500 or 250 gallon tank carts. Little spillage or leakage occurs in the handling of these oils. Some of the cutting oils become contaminated with a red dye, used to mark metals for cutting. Others contain metal cutting chips, ut most shavings and metal chips are recovered separately and contain virtually none of the cutting oils. Almost all waste oils are disposed of through a waste oil collector. None are used as fuel. The waste oils are stored in either 55 gallon drums or larger storage tanks. An estimated 800,000 gallons per year of oily wastes are hauled away at a fee of 5—10 cents per gallon. There is a small quatity of hydraulic oil being re- cycled, approximately 30 gallons per day. This process in- volves filtration and dehydration. However, no large scale recycling of waste oils is presently being practiced. 262 ------- SIC MAJOR GROUP 38 - Measuring, Analyzing and Controlling Instruments; Photographic, Medical and Optical Goods; Watches and Clocks A typical manufacturing operation (1 of 2 locations) has approximately 25 vehicles which are serviced in the maintenance shop. The drain oil is dumped into a waste oil storage tank. Together with hydraulic oils, gear oils, coolant and water soluble cutting oils, an estimated 72,000 gallons per year of oiiy wastes are hauled away by a local waste oil collection service. Of this, 40% is water from the cutting oils. An unreported fee per gallon is paid for the disposal service. SIC MAJOR GROUP 10 - Metal Mining The mining company contacted supplied the following information for one of their typical open pit mines. It’s production rate is 50,000 tons per day of ore with an over- burden of 200,000 tons per day. The oils purchased for this operation during 1973 were: 111,000 gallons SAE 30 Crankcase oil 72,000 gallons SAE 20 Crankcase oil 41,000 gallons SAE 10 Hydraulic oil 9,000 gallons Transmission fluid 233,000 gallons total The mobile equipment used in the mining operations are: Quantity 150 ton trucks 12 100 ton trucks 119 85 ton trucks 5 7.5 to 20 ton fork lift trucks 10 Bull dozers —D—8 29 Front-end loaders lOyd. 7 6yd. 2 2 yd. 3 Electric shovels S Road Graders 9 Pickup trucks 65 Service truck 1-1/2 — 5 ton 40 Fuel trucks 3 Large low bogs 2 Water trucks 10-12 ton 8 263 ------- Oil used for crusher lubrication in 1973 totalled 46,000 gallons. Oil purchased for miscellaneous usage in 1973 totalled 2,100 gallons. All waste oils, resulting from maintenance of equip- ment, during the winter months are dumped with the discarded overburden. During the summer, about 15% of the waste oil is used for dust control on mine roads. The company claims that none of the waste oils get washed out of the mine or carried away. Two alternative methods for disposal of waste oils are being considered at this time. 1. Re—refining on a toll basis. 2. Use with ammoriium nitrate for blasting (new oil is used presently). SIC MAJOR GROUP 14 - Mining and Quarrying of Non-Metallic Minerals, Except Fuels A multi-plant mining and quarrying operation reported purchasing over 100,000 gallons of lubricating oil and over 150,000 pounds of lubricating grease in 1973. These were used for the servicing of company vehicles and equip- ment, shown below, which required an oil change on the average of 8 times per year. Haul Wagons 44 Cranes 54 Air Compressors 12 Drills 9 Graders & Scrapers 9 Front End Loaders 38 Locomotives 1 Bulldozers & Tractçrs 13 Tugboats 11 Lift Trucks 27 Welders 24 Mixer Trucks 162 Tractor Trailers 2 Dump Trucks 2 Pick-up Trucks 37 Flat-beds 3 Dredges 5 264 ------- All waste oils are stored and. hau.Led away by a local scavenger at each of 15 locations. Approximately 4,000 gallons per month of waste oil, in total, is disposed of in this manner. No fee is involved for the disposal service. 265 ------- SIC MAJOR GROUP 39 - Miscellaneous Manufacturing Industries The main plant of the manufacturing operation contacted has six company trucks which are serviced at local service stations. All other waste oils from the plant are collected and stored in 55 gallon drums; approximately 650 gallons of water soluble cutting oils and 550 gallons per year of hy- draulic oil are hauled away by a waste oil collector for 1-2c /gallon paid to the collector. SIC MAJOR GROUP 76 - Miscellaneous Repair Services Company claims to generate zero waste oils. Vehicles are leased and serviced under contract; construction equip- ment that they lease to contractors generates zero waste oil (equipment has sealed bearings or grease fittings). SIC MAJOR GROUP 89 — Miscellaneous Services The institution contacted leases 5 cars and 17 trucks; all are serviced under contract. Approximately 250 gallons per year of waste oil is generated from the machine shop, maintenance of compressors, or repair of hydraulic systems. This includes all laboratory and office facilities. It is disposed of via a scavenger service. SIC MAJOR GROUP 78 - Motion Pictures Claimed to generate zero waste oils. SIC MAJOR GROUP 42 — Motor Freight Transportation & Ware- housing The cnpany contacted owns and services 260 Detroit Diesel tra’tors. Twelve thousand gallons per year of crank- case lubrication oil is purchased from Mobil. They change oil every 15,000 miles. The crankcase of each engifle holds 11 gallons of SAE lOW—30 oil. All drain oils are hauled away by a local waste oil service, however, no information on quantity or costs were available. The garage where the tractors are serviced uses approxi- mately 1,000 gallons per year of automotive parts cleaner. This is dumped into the drain oil storage tank and hauled away with the waste lubricating oil. 266 ------- SIC MAJOR GROUP 84 - Museums, Art Galleries, Botanical & Zoological Gardens Three facilities were contacted. Zoo —— There was no information available on the amcu ts of oil purchased or their specifications. They service 20 trucks (gas and diesel) and 50 pieces of power equinment. They estimate 350 gallons per year of waste oils are gene— rated from the vehicles and disposed of at the zoo s dump. Little or no other oils are used at the zoo Botanical Garden —- They purchase 600 gallons ncr year of SAE 30 oil and 30 gallons per year of hydraulic oil. Approximately 30 vehicles are serviced. The waste oils are stored in drums and hauled away by a waste oil collector. No fee is paid for the service. Museum —— Five vehicles which are owned are serviced at a local station. The little waste oils generated froo the building go out in the trash. SIC MAJOR GROUP 72 — Personal Services A laundry service operates and services 300 vehicles at one location. They purchase SAE 30 crankcase oil in bulk. However, no information on quantity was available. All waste oils are stored in an underground tank. Approxi mately 2,000 gallons of waste oil is collected every 2-3 months by a waste oil collector. A fee of l per gallon i.s paid to the collector. SIC NAJOR GROUP 29 - Petroleum Refining, and Relatel Industries Discussions with this company covered refinina, marketing, production, and marine losses. Refining Oil losses vary widely from refinery to refinery, hut careful operation may result in the following: 1. Evaporative losses as hydrocarbons to the atmosphere from tanks, flanges, etc. - 0.3% of total throughput. 267 ------- 2. Flare losses via CO 2 and H 2 0 — 0.1% of total throughput. 3. Other losses via liquids and solids (spills and wastewater; caustic, acid, biological sludges; tank bottoms; spent clay and catalyst; offspec polymer; rags and trash) - 0.1%. Total losses in some refineries may be 1% or so, versus 0.5% total above. Potentially recoverable losses (item 3. above)is disposed of in a variety of ways, for example: - tank dewatering—to wastewater - lubes, greases, hydraulic oils, cutting oils from vehicles, compressors, turbines, diesels, gas engines, and central lube systems—picked up by vacuum trucks and deposited in slop tanks, or drained into wastewater system. - tank cleanings and oily dirt from spills - internally or to outside contractors for incineration or landfill — barometric condensers — on way out, but oily water from those remaining to wastewater - flanges leaking liquids - oil picked up by vacuum trucks and deposited in slop tanks, by absorbents and to landfill, or lost by evaporation - tank spills - contained in fire walls and pumped to slop tanks — caustic sludges — sold to companies who recover cresylics and other chemicals, and paper companies — API separator sludges - some to outside contractors and some to “landforming” (oxidation in layers 4 to 6 inches deep using disc cultivators) - slop tank liquids - to special distillation for recovery of crude products - other sludges and solids - to outside contractors, landforming, and fixation (outside contractors add materials which cause reactions resulting in inert fill material) - biological sludges - generally to outside contractors, thence to landfill — oil in wastewater systems — about 85—90% removal to 15 ppm or less (oil recovered to slop tanks) 268 ------- The net result is considerable internal recycle with a very small percentage actually lost. However, even this represents relatively large volumes; for example, 0.1% loss is equivalent to almost 300 million gallons per year nationwide. Marketing Oil losses in marketing operations take place at numerous terminals and bulk plants. The terminals which service pipelines, barges, and tankers all have oil/water separators, but not all bulk plants have such facilities. Oil losses include evaporative and spill losses; pipeline interface and offspec oils; transfer losses; and tank, truck, barge, railroad car, and tanker cleaning residues; tank dewatering losses; and rain water drainage losses. Some of these oils are collected by scavengers (e.g. oils skimmed from separators, tank cleaning residues, oils gathered from vehicle draining, and oils gathered from repair shops) ; some are blended back to products (e.g. Bunker oils recovered from loading area drains, interface oils, and clean spill oils). Slop tanks in terminals are often a depository for oils collected through spill cooperatives. Production Crude oil production almost always leads to oil/water mixtures. Modern facilities use heater—treaters to produce pipeline quality oil. These are baffled tanks where heat and chemicals are used to break oil/water emulsions. The water is subsequently treated by a variety of methods, including oil/water separators, flotation, and. sand filters. These normally reduce oil content to 60-200 ppm, before discharge to wells, waterways, the Gulf, etc. depending upon location. Water quantities are small compared to refinery water systems, and total oil losses are probably on the order of 0.01%, with spill losses being the same order of magnitude. Marine Refineries and terminals receive oil contaminated waters from tanker washinq, and ballast and bilge water. Most of this water is handled at Gulf Coast terminals from U. S. flag product carriers of less than 75,000 tons. 269 ------- Product carriers require relatively little cleaning, perhaps every 2—4 years. When cleaning is necessary, tanks are usually cleaned at sea arid water brought to shore for discharge to holding tanks, though some water may be decanted at sea. Bilge and ballast waters are also brought to shore, requiring tanks which may hold over 100,000 barrels (4,200,000 gallons), although some ballast changes may be made at sea. Oil/water separation occurs in. the receiving tank. Oil is transferred to slop tanks in refineries (the same tanks as previously discussed) for recovery. Water is further purified in separators and/or biox systems. Increases in future crude demand will find considerable crude receipt at Gulf Coast refineries, requiring some changes in marine oil practices. Foreign flag tankers carrying black oil (crude) are generally cleaned only once in 5-10 years, but contaminated water has normally been discharged at sea. 270 ------- SIC MAJOR GROUP 46 — Pipelines, Except Natural Gas Common carrier of petroleum products and crude with a thruput for 1973 of over 200,000 barrels per day. Major types transported include premium gasoline, regular gasoline, #1 heating oil, #2 heating oil, kerosene, naphtha, JP—4 jet fuel and crude. Sources and disposition of waste oils are: 1. Oil recovery from terminals which have oil— water separators -— waste oil is returned to slop tank. 2. Oil resulting from tank cleaning -- hauled away by a contractor. 3. Contaminated water withdrawn periodically from tanks -— hauled away by a contractor. 4. Oil spills -— spills have been on the order of 1% of the total thruput. Recoverable portions of spills are recovered and re- turned to slop tanks, while in some cases a large amount evaporates (gasoline). 5. Virtually no loss of interface oils occur. They are small in quantity and are blended off gradually into suitable products. 6. Slop tank oils are blended gradually into suitable products. 7. Losses are being minimized by shutting down and replacing older lines, and by im- proved preventive measures against line breakage by outside contractors. SIC MAJOR GROUP 33 - Primary Metal Industries One large steel plant might purchase the following yearly quantities of oils and lubricants: 271 ------- Absorbent oils 150,000 gal. Maintenance and hydraulic oils 500,000 gal. Motor oils 4,000 gal. Rust preventative & slushing oils 200,000 gal. Transmission fluids, gear oils & compounds 200,000 gal. + 400,000 lbs. Rolling oils, including animal & vegetable fats and oils 2,500,000 lbs. Open gear compounds 20,000 lbs. Maintenance greases 250,000 lbs. In addition, many plants purchase synthetic oils, and metal working compounds and oils (including those containing fats, sulfur and chlorine). Absorbent oil, used for recovering light oils from coke ovens, is recycled but the makeup quantity leaves the steel plant with a heavy light oil fraction. Considerable recycle of cold rolling oils is practiced, with the quantity of recycle often the same order of magnitude as the purchased oil shown above. Some hydraulic oils and other used oils which can be isolated are re- claimed both within plants and by outside contractors. For example, transformer oil is sometimes recycled by filtering, dewatering, and “active earth” treatment. Reclaiming has expanded with current oil shortages. Some waste oils and sludges are disposed of to con- tractors who landfill or burn them. For example, these include some acid and tar sludges from coke oven operations, waste soluble cutting oils, waste fuels, and other contaminated waste oils. In general, waste oils which are diluted with water, from mills and other operations, are sluiced to sewers and thence central wastewater treatment facilities. Other waste oils are collected in large portable containers to be reclaimed for fuel or other uses. Oil from the wastewater system is often skimmed and reclaimed for rolling oil or fuel use by cooking, acid treating, or other processing. Further treatment of waste— water by lime, aeration, and sedimentation yields waste solids containing some residual oil, which is concentrated to about 30% solids and disposed of by landfill. 272 ------- Lagoonin.g of sludges is being phased out. Sludqes from rolling mills ontain con sideraole iron and anvw iere from traces of oil to 30% oil. Some plans are beine nade to incinerate certain sludges (i.e. to burn the oil nit and vaporize water)before feeding to sinter plants. Not. all steel plants have adequate was-tewater facilities with oil recovery, but these are gradually being updated to meet new standards. SIC MAJOR GROUP 27 — Printing, Publishing, and Allied Industries A fleet of over 100 coir anv owned gasoline engine trucks are self serviced. Waste oil is collected ir. a 250 gallon tank and removed by a waste oil dealer who reprocesses the oil, prorabJaT to fuel use. Some additional diesel trucks are leased and serviced by the leasor, who also transfers waste oil to a collector. About 200 gallons per month of oil find use in gear- boxes, and in drip feed to a compressed air systen for air cylinders. About 5 gallons per month of a viscous emulsified rnoly oil is used for chair. conveyors. Oil is drained and recovered only upon failure of equipment. About 300—400 gallons per veer is so recovered, put into drums, and transferred to a collector. Some oil is lost to rags which are used 1 with soivnnts, to clean presses and machinery. These are returned to a laundry. Another source of oil in high speed letter press print- ing is the oil mist which leaves the presses and is e- covered by a combination vacuum/centrifugal filtr tiTa- system. This oil, which amounts to less than fl : . che ink used, is recycled to the ink (85% minera ail/15% carbon black). Ink oils are eventually last, of course, with the printed paper. Letter presses may use about 35-37 lbs. of ink per ton of newsprint7 letter presses about 2/3 of this quantity. 273 ------- SIC MAJOR GROUP 40 - Railroad Transportation Purchases of lubrication oils and greases totalled 7,249,668 gallons in 1973. The major purchases, by type, are as follows: Over 500,000 gallons diesel engine crankcase oil Over 30,000 gallons SAE 1OW—30 lubrication oil Over 1,000,000 gallons non-additive journal oil About 10,000 gallons SAE 90 gear grease Over 50,000 gallons bearing grease Over 200,000 gallons roller bearing grease Over 10,000 gallons insulation oils Over 50,000 pounds ‘asphalt’ gear grease Over 200,000 pounds flange grease Over 100,000 gallons reclaimed diesel crankcase oil In 1973 over 600,000 gallons of car journal oil and over 160,000 gallons of diesel engine crankcase oils were reclaimed by outside waste oil re—refiners. Proper re- claiming has been a problem. Waste oil reclaiming and disposal practices are: 1. Locomotive diesel engine crankcase oil — usually reclaimed and re—fortified with additives for reuse as diesel crankcase oil (by outside re— ref iner) 2. Spilled or contaminated fuel oil - spillage from refueling operations (over 100 locations) is captured in fiberglass drip pans. It is generally sold to scrap dealers, but some is filtered and returned to storage for the original intended use. The latter is the recommended approach and is being promoted. 3. Mixed scrap oil from oil/water separators — mostly spilled fuel oil, sludges from tank 274 ------- cleanings, or other waste oils that have not been segregated for re-refining. These are usually sold to scrap dealers. Attempts are being made to recover some by filtration or other methods. Small quantities are being blended into No. 6 fuel oil and burned at two locations. The following impurities were mentioned as present in waste oils: 1. Crankcase oil — soot, fuel oil, water, oxidation products. 2. Fuel oil - dirt and water. 3. Mixed scrap oil - dirt, water, detergents. Detergents which contaminate waste oils were noted to in- crease difficulty in reclamation. Detailed information by specific location was unobtain- able. SIC MAJOR GROUP 65 - Real Estate The company contacted provides maintenance services for large office and residential buildings. Their policy, in brief, is to dispose of the small amount of waste oils generated to trash collection. Approximately 3 gallons per year is crankcase oil drained from a back—up diesel gene- rator, and 10-15 gallons per year is lubrication oil from the turbine drive in the central air-conditioning system. All other systems are self—contained or are under a service— contract with the manufacturer (e.g. elevators, cooling towers, and transformers). SIC MAJOR GROUP 30 — Rubber & Miscellaneous Plastics Products The following purchases of oils were reported for the company’s many plants throughout the United States: 1. Crankcase oil used for vehicular gasoline engines - 1,200 gallons per month. 2. Crankcase oil used for vehicular diesel engines - 1,125 gallons per month. 275 ------- 3. Oil for stationary machine lubrication — 620,000 gallons per month. 4. Soluble and emulsified oils — 6,200 gallons per month. 5. Other metal working oils — 1,000 gallons per month. 6. Insulation oils — 1,350 gallons per month. 7. Hydraulic oils — 33,750 gallons per month. 8. Oil used as a raw material in processing — 1,412,000 gallons per month. The general waste oil disposal practice, for all plants, is to use industrial waste oils, excluding crankcase drain— ings and other badly contaminated oils, for fuel. An esti- mated 150,000 gallons per month, 90,000 gallons of which are a by-product from a chemical process, are disposed of in this manner. At one plant alone, 5,000—7,000 gallons per week of waste oils are filtered and added to the fuel supply. Waste oils that are not used as fuel are collected in 55 gallon drums and hauled to landfill sites by conu’nercial disposal services. The fee paid for this service is about 10 cents per gallon. These oils include crankcase drainings from material handlers, oils skimmed from API oil/water separators, and oils that cannot be segregated in—plant and become contaminated, preventing their use as a fuel. Crank- case, transmission, or other oils cOntaining additives seem to cause plating problems in the plant boilers when used as fuels. SIC MAJOR GROUP 32 - Stone, Clay, Glass and Concrete Products Six typical plants of the company contacted reported purchases of lubricating, hydraulic, and process oils of over 40,000 gallons in 1973, for vehicles, mining equipment, etc. A breakdown on the types of oils and their specific applica- tions was not available. All waste oils are collected, stored and, disposed of in one of three ways: a) disposal via a local waste oil collector accounts for the bulk of the waste oils generated in the six plants. 276 ------- b) burning of industrial waste oils in plant boilers (small quantity). c) flushing down pLan t drains, whare oil is later separated (oil/water separators in. waste— water treatment system) and disposed of with the other oils being hauled away by a collector. SIC MAJOR GROUP 21 - Tobacco Manufactures The bulk of waste oils generated from tobacco processing activities are from transmissions, gear motors, and machine tool coolants. Their waste oil disposal and reclamation practices in 1972 were as follows: ?5,000 gallons reclaimed 2,000 gallons given away >78,000 gallons hauled away by a commercial dis— posal company 600 gallons to landfill by commercial disposal service. This totals 86,000 gallons of waste oils accounted for out of 90,000 gallons of lubricating, hydraulic, and cutting oils purchased in 1972. The commercial disposal service previously charged $3.50 per barrel of waste oil and returned the barrel. Now it charges $8.25 per barrel and keeps the barrel. These new costs caused the company to look for new disposal methods, at long-life coolants and self-treating facilities. As a result, the company policy for disposal of waste oils has changed since 1972. Now all waste oils are drained, collected, and given to a subsidiary for use as fuels, ex- cept if the oils are wet, very fouled, or volatile. 277 ------- SIC MAJOR GROUP 45 - Transportation By Air Waste oils are generated both. at airports and central maintenance centers. Some typical airport examples are: 1. Aircraft sumping - 500 gallons per month turbine fuel scheduled and non—routine for maintenance purposes, for one airline at one airport. 2. Facilities and dispensing vehicle sumping - 300 gallons per month turbine fuel for one airline at one airport. 3. Ramp spills — seldom exceeds 35 gallons turbine fuel per spill. However, hydrant failure has, in one known instance, caused an approximate 2,000 gallon spill. No predictable average. Leaks, spills, failures of other fluids from aircraft and ground vehicles are insignificant until total accumulation is washed off by rain. 4. Loading facility spills - with dry type dis- connects, do not expect monthly spills to exceed 20 gallons total turbine fuel. Accidents or carelessness have caused 200 gallon spills. 5. Gasoline — may have occasional small leaks which contribute to ramp pollution, but generally no problem. 6. Petroleum based lubricants (engine and transmission) — 500 gallons per month for one airline at one airport. 7. Heavy petroleum based greases — 160 lbs. per month for one airline at one airport. 8. Deicing fluids - usage varies drastically from year to year and from one location to another, but during one 24—hour period in a major northern airport, 100,000 gallons of fluid were used. 9. Synthetic lubricants - one airline at one airport might use up to 150 gallons per month. Total airline system might use 40,000—50,000 gallons yearly. 278 ------- 10. Aircraft exterior and ground support equipment washing and cleaning compounds - 25,500 gallons per year before dilution, or up to 250,000 gallons per year after dilution with water. Recommended methods for handling fluid spills follows: Type of Fluid Disposition Method Turbine Fuel & Petroleum Solvents Large spills (over 50 square feet of wetted area) - Water flush to a safe collection area where the fuel may be mechanically separated from the water and picked up by refuse collector. Small spills (under 50 square feet of wetted area) - Pick up with filter clay or absorbents and burn or hold for refuse collector. Gasoline Large spills (over 50 square feet of wetted area) - Block the spill area from motorized traffic. Notify airport fire department. Water flush to safe collection area where the fluid may be mechanically separated from the water and picked up by refuse collector. Small spills (under 50 square feet of wetted area) — Pick up with filter clay or absorbents and remove to a safe area to burn or evaporate. Petroleum & Synthetic Pick up with filter clay or Oil & Petroleum other absorbent and burn or Hydraulic Fluids hold for refuse collector. 279 ------- Type of Fluid Disposition Method Synthetic Hydraulic Spills — pick up with filter Fluids clay or other absorbent and hold for refuse collector. Drained — store in 55 gallon drums. Laboratory tests will determine reusability: 1. Reusable: Filter and return to service. 2. Reclaimable: Send to manufacturer for credit on new fluid. 3. Non-reclaimable: Hold for pickup by refuse collector. Chlorinated Solvents Pick up with absorbents and remove to safe open air area for evaporation. Toilet Germicides & Pick up lavatory spills with Toilet Wastes scrub brush-equipped tractor vacuum unit with brushes in raised position. Following removal of waste, brush scrub and revacuum the area. Dis- charge the waste through triturator to sanitary sewer. Deicers & Antifreeze Flush to storm drain with (Ethylene Glycol based) large quantities of water to provide thorough dilution. Contaminated fuels are sold for fuel value, for example, No. 2 fuel oil. Contaminants are minor, but may include aviation gasoline and microbial contamination, but little or no water. Other waste oils are generally picked up by a collector. However, as can be seen from the previous discussion, considerable oil and deicing fluids may enter airport wastewater systems, with proper disposal depending upon the adequacy of those system. Little firm data is available, but discussions with airport officials raise doubts as to the present effectiveness of airport wastewater treatment, usually controlled by independent authorities. 280 ------- The central maintenance facility collects most waste oils from wastewater recovery and other sources in a waste oil tank (about 2000 gallons), but other waste oils from shops, the test cell, and ground equipment is collected in 55 gallon drums. A total of about 1000 gallons per month of oil—type fluids is picked up by a collector at a cost to the airline of $150. per month. About 400,000 gallons per day of wastewater effluent is injected into a high pressure deep well approved for that purpose. 281 ------- SIC MAJOR GROUP 37 - Transportation Equipment The metal fabricating company contacted has had an on- going program of oily waste treatment and recovery for many years. During the past year they reclaimed 19 million gallons of oil. About 40% was used for lubrication and about 60% for fuel. A low quality recovered oil is provided from one source to a public utility which uses it as fuel to generate power. Other plants use recovered oil for fuel in boilers, in forge furnaces, or reconstitute the oil themselves, or through an outside service, for manufacturing operations. They claim not to dispose of recoverable oil to waste. A general description of the waste oil recovery process that is used in several plants follows: An equalizing and holding tank is used as an in-plant col- lection system. The tank is divided into compartments to provide a semi-fill and draw procedure which equalizes the waste. They have a 16 to 24 hour residence time to provide filling and gravity separation of the oil. In some plants new corrugated plate separators have been installed in the raw waste line to remove the bulk of free oil and solids prior to the holding tanks. Influent waters vary in oil content from 2,000 to 5,000 mg/l. About 90% of this oil separates by gravity and can be removed as “free oil.” In some cases this oil can be re- used as cutting oil without further processing. However, the major portion of this oil contains some emulsifier and water which forms an invert emulsion layer. The free oil is pumped to a lead lined evaporator where this emulsion is broken by heat, sulfuric acid, and occasionally de—emul— sifying agents. After settling, a three phase separation occurs — oil, acid water, and a rag or scum interface layer. The acid water is used for pH control of the raw waste or final effluent. The rag layer is recooked. The re- sulting oil is equivalent to No. 4 fuel oil. Some nine million gallons of this oil is recovered annually by the plants employing this type of waste oil treatment. The oil is utilized in general for fuel in boilers and forge furnaces. The oily wastewater in the lower portion of the holding tank is pumped to a mix tank where, after polymer injection at the pump intake, alum is added in dosages of 25-50 mg/l. 282 ------- The treated waste is fed by gravity to a dissolved air flotation cell where the floc formed is removed. The effluent overflows to a third mix tank where pH adjust- ments may be made to dispose of excess acid. The float or scum oil is pumped to a cooker and treated similarily to the free oil. The effluent water is run through a clarifier and discharged. SIC MAJOR GROUP 47 - Transportation Services The company contacted is a conglomerate of smaller trucking firms throughout the United States. One typical company owns and operates 110 diesel trucks. They purchase 2,600 gallons of multi-viscosity SAE 1OW—30 crankcase oil and 40 gallons of hydraulic oil per year. The trucks, which have either Detroit or Cummings diesel engines and have a crankcase capacity of approxi- mately 10 gallons, are serviced every 15,000 miles. The drain oils are stored in a 550 gallon waste oil tank and hauled away every two months by a waste oil collector. They claim to pay 33 per gallon for this service. An esti— mated 1,800 gallons of waste oil per year is disposed of in this manner. Engines and parts are cleaned by steam in a maintenance shop. The wastewater from the cleaning operations is washed down the city sewer. They could not estimate the amount of water or oil and grease content discharged as there is no wastewater pre—treatment involved. SIC MAJOR GROUP 44 - Water Transportation The company contacted owns and operates several turbine driven, containerized cargo ships. Lubrication oil for the turbines (marine oil, non- detergent) is circulated through a ‘Sharples’ oil purifier, which removes water, dirt, and metal particles by fil- tration and centrifuging. The oil is then held in a sump and returned to the turbine as required. Approximately 1,700 gallons per turbine are recycled in this manner. Any other spilled or reclaimable oils from drips, etc , on board ship are returned or added to this system. Oils that are not reclaimable by this purification system (drain oils from back—up generators, air compressor oils, vent traps) are blended into Bunker tanks and burned in the boilers. 283 ------- This amounts to approximately 15 gallons per year per vessel. Cutting oils from the shop are reused or are dis— posed of in cleaning rags that go out with the trash. The bulk of waste oils generated from shore side operations would be from motor vehicles which are leased and serviced under contract. Disposal and reclamation practices for waste or spilled oils on board the vessels are as follows: Oil Pollution Effective July 1, 1974 all vessels will be subject to the “Clean Water Act” while in the continental boundaries and contingency zones of the United States. This area ex- tends fifteen miles off shore and encompasses all waters therein. There is no mathematical designation as to the amount of oil that constitutes pollution. The law states: DISCHARGE OF OIL PROHIBITED The Federal Water Pollution Control Act prohibits the discharge of oil or oily waste into or upon the navigable waters and contiguous zone of the United States if such discharge causes a film or sheen upon, or discoloration of, the surface of the water, or causes a sludge or emulsion beneath the surface of the water. Vio— lators are subject to a penalty of $5,000. It is the company’s desire that all vessels will comply immediately without waiting until the effective date. The following practices will be instituted immediately: Bilge Pumping All vessels will pump bilges dry before entering the contingence zone. No bilges are to be pumped while in port. In an emergency, or due to some unusual circumstances that requires any bilge pumping in U. S. ports, it will be discharged into a slop barge or to a holding tank aboard. Your vessel is permanently piped to take suction from bilges and discharge through the oily ballast system into any tank. The smallest fuel oil tank aboard should be used 284 ------- as the holding tank. It is not the intent that this holding procedure will be used routinely. Any time con- ditions require its use the home office, is to be notified. When this tank is discharged the home office is again to be notified in order to be aware at all times of your bunker capacity. It will be necessary to install an interrupting stop button adjacent to the filling stations to stop the ap- propriate bilge pump that is piped to discharge to the filling line. A separate directive will cover this in- stallation. Upon departure from U. S. Ports if the Watch Engineer desires to pump bilges he shall call the Bridge to ascertain that the vessel is outside the contingence zone and shall log the fact in the Engine Room Log. If your vessel is equipped with automatic bilge pumps they shall be secured at all times the vessel is within the contingency zone. Cargo Oil If your vessel is fitted with cargo oil tanks, the U.S. Coast Guard Certification of these tanks is being withdrawn and the tanks henceforth will be classed dry cargo or ballast. Bunkering The new laws covering transfer of oil from dock to vessel or from vessel to vessel are very explicit as to the steps to be taken. It is not the intent to paraphase them at this time. The laws are contained in U. S. Coast Guard publication CG-257 titled “Rules and Regulations for Cargo and Miscellaneous Vessels”, Subchapter 1 dated April 1, 1973. Some of the interpretation follows: Oil shall be taken under the supervision of “Person in Charge”. This shall be the Chief Engineer. 1. Declaration of Inspection Attached are copies of the “Declaration of Inspection” based on 33 CFR 156.150 and 46 285 ------- CFR 35.35—30. This check list is to be jointly checked off and signed by the receiver and deliverer who will be respon- sible for the areas each has checked. The person signing the “Declaration of In- spection” becomes the “person in charge” as defined by the law. This shall be the Chief Engineer. This certificate shall be held on board for thirty (30) days. 2. Containment of Vents, Overflows and Filling Lines On vessels constructed prior to July 1, 1974 it will be acceptable by the U. S. Coast Guard when bunkering to have a bucket of at least five gallon capacity secured to each vent. While the law states they shall be eighteen inches high it has been clarified with the U. S. Coast Guard that paint buckets will suffice even though they do not meet the required height. On filling stations and where the dianieter of the vent does not make it practicable to use paint buckets it is suggested that thirty or fifty gallon barrels be adapted. While it is not required, the company suggests that all goosenecks from fuel tanks and a ship set of containment buckets be painted red and that the ship’s set of buckets be used for no other purpose. It is recognized that on some vessels the arrangement of the vents on deck are such that a containment bucket can not be affixed. When this condition is found, structural changes can be made prior to July 1, 1974. 3. Transfer Procedure Manual Transfer Procedure Manuals for each class of vessels are being prepared and will be forwarded to your vessel. This manual shall be kept in the Engine Room log desk. 286 ------- 4. Required Personnel and Their Duties Specific duties and required personnel are required during any transfer of oil, dock to vessel or vessel to vessel. Chief Engineer — “Person in Charge” who shall fill out and sign the Declaration of Inspection. Second Engineer — In Engine Room in charge of all manifolds. I One (1) Engine Department member at filling station to communicate with deliverer. On Deck one (1) Officer and one (1) seaman to tend lines. In addition to the five required personnel such other ship’s personnel as may be deemed necessary by the “Person in Charge”. Placard Your vessel is being furnished with two (2) decals with wording required by law to be affixed to a metal plate and permanently mounted. In the Engine Room, one shall be ad- jacent to the bilge and ballast pump control station and one at a convenient location on the Bridge. Plugging Scuppers Nothing in the above mentioned regulations relieves the requirement that all scuppers and deck drains be plugged. Reporting Oil Spills or Pollution In the event of any pollution while in port,the U. S. Coast Guard in the port you are in is to be immediately notified. While the above touch upon pollution through fixed piping it should be borne in mind that anything ernminating from the vessel that causes “a film or sheen or discolo- ration” is considered by law to be pollution from the vessel. 287 ------- SIC MAJOR GROUP 50 - Wholesale Trade/Durable Goods The company contacted leases 50 vehicles which are all serviced under contract. They claim to generate no waste oils from their buildings, maintenance or other operations. SIC MAJOR GROUP 51 - Wholesale Trade/Non-Durable Goods The bulk of waste oil generation is from motor vehicle maintenance. Eight trucks (gas and diesel) are owned and serviced by the company. The waste oils are drained and stored in 55 gallon drums to be hauled away be a scavenger, at a fee of 2—3 per gallon. The company claimed to generate no other waste oils from maintenance or manufacturing operations. 288 ------- APPENDIX F WASTE OIL MATERIAL BALANCE METHODOLOGY 289 ------- FIGURE F—i U.S. CRUDE OIL DISTRIBUTION + Crude Oil Imports 25,800”’ Crude Oil Production 145, lOO ’ (Millions of Gallons Per Year) Re-refined Oils From Figure F-3 2, 1, 2, 944 7 487 ‘ _____ 2, 23 4L9) To gure F-2 1, 365 To Figure F—2 * By difference 4- See Table F-i for key to data sources Crude & Refined Products Exports 3.431’ 2) 0 Liquid Oils Consurnptioi as Fuel & Chemicals* 224,i53 ’ “ Sales of Lubricating & Process Oils 2, 72l ’ Refined Products Imports 34. 300 Total Petroleum Liquids 231, i0O 2 2 Oil Spills — Mar in e 22 Natural Gas Liquids Produced 25 ,90d” s I Oil losses in Produc- tion, Refining, Trans portation, and Use 1, l56 ------- FIGURE F—2 WASTE OIL GENERATION * (Millions of Gallons Per Year) 2.23 4( From Figure F-: 3. Other Industrial Oil Sales 377(2 3) 1. Automotive Lubricating Oil Sales l,O86 ‘ 6l6 ’) dlO ri 148 B 3 19 142 105 202 D 1 C 1 2. Industrial & Aviation Lubri- cating Oil Sales 734(2 2 J 394(27 ) 340 41 A 2 112 - B 2 25 C, ic _ 130 ; 2 F 2 - 290 41 I 25 3 E 3 28 4. U.S. Government Lubricating Oil Sales 37(2 ¼) 19 A 3 B 4 D — ;i 4 4 3 E 4 F 4 1.365@ From Figure F-i 5. Oil Losses & Spills 1, 365 ’ 365 0 690 Bc 66 D 5 199 it E,. 399 -, Fç 4 -I A Consumed as lubricating oil, fuel or other use by the original purchaser/user. B = Potentially discharged to the environment (land or water) C = Used as road or dust control oils D = Used as fuel or for other purposes E = Sent to lubricating oil re-refiner F = Sent to waste oil processor * See Table F—l for key to data sources 291 ------- FIGURE F-3 WASTE OIL DISPOSAL * A 1 470 (Millions of Gallons Per Year) A 2 340 290 1.119 Consumption 19 (31) B 1 148 _______________________ b 2 112 ______ — 2 ‘ 25 _________________ B 5 690 978 To The Environment 4 ( 2 B 4 3 1,331< C 1 142 28l( C 3 6 _____________ 25 243 Road Oiling, Dust C 4 4 ________________ ( 33J Control, Asphalt 3 9(3I C5 66 ________________________ 19 _______________________ 111 Fuel & Other Uses D 3 358 D 4 1,o28 ’° ) D c gg ______________________ 105 ________________________ E2 16 Lubricating Oil ____ E3 138 Rerefiners 1 83’ ° E4 3 — (2 ) 138 ’ E 5 _____________________ 202 _______________ 763 Waste Oil Processors 763’ _ f3 - _____ ___ 4 (ii) 763( ) 399 ______________________ 83 Rerefined Auto 1 erefined Indus- j tRerefined Indus— i s ‘ubricating Oils L Lubricating L 7O(52 _________________ jtriai Other Oils 2 11 (S 3) __ 8 3(SS) I I To Figure F-i * See Table r—1 for key to data sources 292 ------- TABLE F-i. KEY TO SOURCES OF DATA IN FIGURES F-i, F-2, F-3 Data Item No. Source of Data Item Table F—2 2 “ F—2 F—2 F—2 F—2 6 Figure F-3 By difference 8 By difference Table F-4 1 0 F—5 11 H F—6 12 “ F—2 11 By difference Table F-3 1 “ F—4 16 “ F—5 1 “ F—6 18 ‘ F—3 By difference, Table F-3 20 By addition 21 Table F—3 22 F—3 23 F—3 2’+ “ F—3 2 By addition 26 Table F-7 27 “ F—9 28 “ F—lO 29 ‘I F—li 30 By addition 31 By addition, F-12 32 By addition By addition By addition Table F-14 36 ‘ F—15 F—12 38 “ F—22 By additiOn By addition 293 ------- TABLE F-i (Continued) Data Item No. Source of Data Item 41 Table F-14 42 “ F—15 F—22 F—18 F—14 46 F—18 F—18 48 “ F—14 F—14 50 “ F—14 5’ ‘ F—15 52 “ F—14 F— 14 F—14 F—14 A 1 By difference A A 3 H - Table F-21 B 2 “ F—19 B, “ F—20 B “ F—li B 5 “ F—17 C 1 “ F—21 C 2 “ F—19 C, “ F—20 C “ F—li C “ F—17 F—21 F—19 F—20 F—il D 5 “ F—17 E “ F—14 E 1 “ F—14 E 2 “ F—14 E “ F—14 E F—14 F 5 “ F—16 F’ “ F—16 F—16 F “ F—il F 5 “ F—17 294 ------- TABLE F-2. SALIENT STATISTICS OF CRUDE PETROLEUM, REFINED PRODUCTS AND NATURAL GAS LIQUIDS IN U. S.-1971 PRELIMINARY DATA 86 Thousands of 42 Gal Barrels Crude Petroleum Production 3,453,914 Crude Petroleum Imports 613,417 Refined Products Imports 817,204 Natural Gas Liquids Production 617,800 Total Liquids ( t1 Oi1s’ ) Produced and Imported ______ Crude Petroleum Exports Refined Products Exports _________ Total Liquids ( t1 Oils”) Exported Millions of Gal/Yr 145,100 25,800 34,300 25,900 5,502 ,335 503 81,182 81,685 231, 100 21 3,410 3,431 295 ------- TABLE F-3. ESTIMATED LUBRICATING AND INDUSTRIAL OIL SALES IN THE U.S. - 1970_7128 Millions of Gal/Yr Automotive Lubricating Oils 1086 Commercial engine oils — fleet sales 200 Commercial engine oils — retail sales 90 Factory fills, automotive and farm 60 Private automobiles*, automobile fleets, other 736 1086 Aviation Lubricating Oils B Industrial Lubricating Oils 726 Hydraulic and circulating system oils 325 Metalworking oils 150 Railroad engine oils 60 Gas engine oils 62 Other 129 726 Other Industrial Oils 377 Process oils 310 Electrical oils 57 Refrigeration oils 10 377 Federal Government 37 Exports 487 2721 * Approximately 600 million gal/yr. (45% = service stations; 17% = car dealers; 10% = garages, auto supply stores; 28% = mass marketers) •87 296 ------- TABLE F-4. ESTIMATED MARINE OIL SPILLS — U.S. — 197288 Coast Guard reported oil spills in 1972: 8013 reports of 16.5 millions of gallons Assume only 75% of spills were reported: Estimated total marine spills 22 millions of gallons 297 ------- Total % of Total Proj ect ions to National Basis TABLE F-S. ESTIMATED MARINE OIL LOSSES - U. S. 1971* Port Millions of Gallons/Xear of Oily Waste Cargo Cargo Tanker Bilge Ballast Washings Ballast Waters Tanker Washings New York 22.3 141.1 891.3 19.8 Totals 1078.0 3.5 Hampton Roads Galveston Texas City Houston 14.2 6.7 1.0 25.2 86.4 23.1 0.6 66.2 0.0 0.0 0.0 0.9 0.0 0.0 272.0 1303.2 1.7 0.0 38.8 5.6 102.3 29.8 312.4 1401.1 San Diego San Francisco San Juan 2.2 7.1 3.6 11.6 63.5 58.7 0.0 0.0 0.0 0.0 524.7 14.4 0.0 2.5 13.0 13.8 597.8 89.7 I ” Miami Cleveland St. Louis 1.3 205.8 1.3 22.0 9.0 0.0 0.0 0.0 2.0 0.0 0.0 0.0 0.0 0.0 0.0 23.3 214.7 3.3 290.7 482.2 6.4 3005.6 81.4 3866.2 7.5 12.5 0.17 77.73 2.1 100.00 14,888 * Harris Report ------- Table F-5. (Continued) Bilge Cargo Ballast Cargo Washings Tanker Ballast Tanker Washings _______ * In Ports Surveyed ** Nationally - By Applying %‘s Estimates of Oil content of the % Of Oil.. Bilge Cargo Ballast Cargo Washings Tanker Ballast Tanker Washings Total: Millions of Gal/Yr. Of Oily Waste Water** 1117 1861 25 11572 313 14,888 to National Total oily waste waters: Content Source Harris Report Above, p. 4—18 As sumed Assumed (1) + (2) Harris Report Above, p. 4-18 Although Frederic R. Harris, Inc. is unwilling to make the following calculations, RECON will do so as a tlguesstimatetl: Projections of Above Data to National % of Total* 75 12.5 0.17 77.73 2.1 100.00 1.0 0.0 0.0 0.5—2.0 10 . 0 299 ------- Table F-5. (Continued) (1) Harris Report above, p. 4-18 indicates 2%. (2) Esso Report for Norfolk reports 0.1-1.0% — assume average 0.5%. Application of oil content to oily waste quantities: Millions of Millions of Gal/Yr Gal/Yr Waste Water % Oil Waste Oil Bilge 1117 1.0 11 Cargo Ballast 1861 0.0 0 Cargo Washings 25 0.0 0 Tanker Ballast 11572 l.25(avg.)145 Tanker Washings 313 10.0 31 14888 187 300 ------- TABLE F-6. ESTIMATE OF OIL LOSSES AND SPILLS ON LAND, AND LOSSES FROM PROCESSING 197l* Assume 0.5% of Total Liquids (“Oils ’ 0.005 (231,100) 1156 Millions of Gal/Yr. * Includes oils in waste waters. + See Table F-2 301 ------- TABLE F—7. ESTIMATED LUBE OIL SALES AND WASTE OILS GENERATED AT AUTOMOTIVE SERVICE CENTERS* 1970—1971 Sales Waste Waste Oil Millions Oil Millions of Gal/Yr. Factor± of Gal/Yr . Automobiles in service stations 270 0.63 170 Automobiles in garages & auto supply stores 60 0.63 38 Automobiles at new car dealers 102 0.90 92 Retail sales for commercial engines 90 0.63 57 Automotive fleet and other lube oil uses ÷ 136 0.50 68 Sub—Total 658 425 Factory fills, auto- motive and farm 60 0.90 54 Oil bought at discount stores 168 0.22 37 Sub—Total 886 516 Commercial engine Fleets 200 0.5 100 Totals 1086 616 ± See Table F-8 for estimates of waste oil factors. * Includes motor oils, transmission oils, hydraulic oils, etc. + Marine, agricultural, etc. 302 ------- TABLE F-8. ESTIMATE OF FACTORS FOR CONVERTING AUTOMOTIVE SALES TO WASTE OIL QUANTITIES Service Stations 2 70% of oil sold is used for changes. Oil drained is 90% of filled capacity. 70% x 90% = 63% of oil sold — waste oil generated. Garages and Auto Supply Stores Assume average is same as service stations (63%). New Car Dealers 100% of oil sold is used for changes. Oil drained is 90% of filled capacity. 100% x 90% = 90% of oil sold = waste oil generated. Retail Sales for Commercial Engines Assume same as service stations (63%). Automotive Fleet and Other Lube Oil Uses Assume 50%, allowing for two—cycle engines and internal use, e.g. fuel, by commercial and governmental fleets. Factory Fills, Automotive and Farm Assume 90% recovery as in automotive service centers. Oil Bought at Discount Stores Assume same as service stations (63%). Assume 35% of waste oil generated finds it way to service stations . 63% x 35% = 22% of oil sold = waste oil generated at service stations. * Estimated by RECON SYSTEMS from information obtained by Teknekron’ 303 ------- TABLE F-9. GENERATION OF INDUSTRIAL LUBRICATING WASTE OILS Sales* Waste Oil Lubricating Oils MM gal/yr. Factor MM gal/yr . Hydraulic & circulating 325 0.42 137 system oils Metalworking oils 150 0.7 105 Railroad engine oils 60 0.53 32 Gas engine oils 62 0.9 56 Aviation and other 137 0.47 ___ Totals 734 394 * Sources: See Table F—3. 304 ------- TABLE F-l0. GENERT TION OF OTHER INDUSTRIAL WASTE OILS Sales* Waste Oil MM gal/yr. Factor MMgal/yr . Process oils 310 0.1 31 Electrical oils 57 0.9 51 RefrigeratiOn oils 10 0.5 5 Totals 377 87 *gource: See Table F-3 305 ------- TABLE F-li-GENERATION OF U.S. GOVERNMENT LUBRICATION WASTE OILS Sa les* Waste Oil MM gal/yr Factor MM gal/yr 37 0.5 18 Assume following distribution of the waste oil: To the environment 3 For road oils & dust control 4 For fuel 4 To re—refiners 3 To reprocessors 4 18 * See Table F-3 306 ------- TABLE F—12. CONSUMPTION OF LUBRICATING OILS - AS LUBRICATING OIL, FUEL, OR OTHER USES BY ORIGINAL PURCHASER/USER Assume Consumption = Sales — Waste Oil Generated Sa les* — Waste Oil = Consumption Auto Lubes 1086 — 616 = 470 Industrial & Aviation 734 - 394 = 340 Lubes Other Industrial Oils 377 — 87 = 290 U.S. Government Lubes 37 - 18 = 19 2234 — 1115 = 1119 * From Table F-3. + From Tables F-7, 8, 9, 10, 11. 307 ------- TABLE F-13. WASTE LUBRICATING OIL REREFINERS 1973 PRODUCTION - RECON SYSTEMS SURVEY * MGPY Other Total Total MGPY MGPY Auto MGPY Industrial Industrial MGPY Company GPD c 250D Lube Oils Lube Oils Oils Fuel 1 7,000 1,750 1,575 0 0 175 2 10,000 2,500 2,250 250 0 0 3 12,000 3,000 2,850 150 0 0 4 8,000 2,000 200 1,800 0 0 5 20,000 5,000 5,000 0 0 0 0 6 6,500 1,625 1,625 0 0 0 7 25,000 6,250 6,250 0 0 0 8 5,200 1,300 520 780 0 0 9 1,800 450 450 0 0 0 10 27,000 6,750 500 0 0 6,250 11 2,000 500 450 50 0 0 12 8,300 2,075 1,971 0 0 104 13 12,000 3,000 2,700 300 0 0 ------- TABLE F_13.(Cofltiflued) MGPY Other Total Total MGPY MGPY Auto MGP? Industrial Industrial MGPY Company GPD @ 250D Lube Oils Lube Oils Oils Fuel 14 12,000 3,000 3,000 0 0 0 15 40,000 10,000 9,000 1,000 0 0 16 2,000 500 25 0 0 475 17 22,000 5,500 4,950 0 270 280 18 8,000 2,000 1,800 0 100 100 19 25,000 6,250 5,625 625 0 0 20 6,000 1,500 1,500 0 0 0 21 8,000 2,000 1,800 200 0 0 22 3,000 750 75 0 0 675 23 2,500 625 593 32 0 0 24 4,000 1,000 1,000 0 0 0 25 4,000 1,000 1,000 0 0 0 26 2,000 500 500 0 0 0 27 Strictly a fuel processor ------- Total _______ GPD 4,000 6,000 6,000 5,000 12,500 5,000 1,900 10, 000 333,700 Assuming 90% coverage of the industry: 371,000 Total MGPY @ 250D 1,000 1,500 1,500 1,250 3,125 1,250 475 2,500 83,425 0 1,350 0 2,969 0 0 125 62,653 MGPY Other Industrial Oils 0 0 150 0 0 1,250 475 0 2,245 MGPY Fuel 0 0 0 625 0 0 0 0 8,684 * G D = gallons per day; GPY gallons per year; MGPY = thousands of gallons per year. 250 D = 250 days per year. company 28 29 30 31 32 33 I -i 0 34 35 TABLE F—13 (continued) MGPY Auto MGPY Industrial Lube Oils Lube Oils — 1,000 0 1,500 0 625 156 0 0 2, 375 9,843 93,000 70,000 11,000 2,000 10,000 ------- TABLE F-14-- ESTIMT TE OF FEEDSTOCKS TO WASTE LUBRICATING OIL REREFINERS * A. Product: Rerefined Auto Lubes 70 MM GPY Assume plant yield = 65% Feed 108 MM GPY (assume 3 MM GPY from U.S. government, 105 MM GPY from other auto sources) B. Product: Industrial Lubes 11 MM GPY Assume plant yield = 70% Feed = 16 MM GPY C. Product: Other Industrial Oils 2 MM GPY Assume plant yield = 70% Feed 3 MM GPY D. Product: Fuel 10 MM GPY Assume plant yield = 90%, and also Feed = 11 MM GPY SuznmarI : Auto Lube Oils 105 MM GPY u.s. Government Lube Oils 3 MM GPY Industrial Lithe Oils 16 MM GPY Other Industrial Oils 3 MM GPY Spills & Losses 11 MM GPY Total Feed 138 MM GP Less Products (A,B,C) 83 MM GPY Less Internal Fuel Use 11 MM GPY Less Fuel Sales (D) 10 MM GPY To Environment MM GPY * MM GPY = Millions of gallons per year Product quantities from Table F-13 311 ------- TABLE F-15 . ESTIMATION OF TOTAL FEEDSTOCK TO REPROCESSORS From Tables F-8 thru F-12, Total Waste Oil = 1115 MM GPY From A. D. Little Report 2 , about 45% of Auto and indus- trial waste oils is estimated to be reprocessed. Reprocessed Oil = 0.45 (1115) = 502 MM GPY From Table F-14, Feedstock to Rerefiners = 138 MM GPY Feedstock to Reprocessors from these sources = 502 - 138 = 364 MM GPY From Table F-17, Feedstock from Spills & Losses = 399 Total Feedstock to Reprocessors = 763 MM GPY 312 ------- TABLE F-16. ESTIMATION OF INDIVIDUAL FEEDSTOCKS TO WASTE OIL PROCESSORS From Table F-15, Feedstock from auto , industrial, U.S. Government, waste oils = 364 MM GPY From Table F-li, Waste oil from U. S. Government 4 MM GPY •. From auto, industrial = 360 MM GPY Assume same proportion of oil from each of these sources goes to reprocessors Waste Oil to Waste Oil % to Reprocessors auto lube oils 616 56.2 202 industrial lube oils 394 35.9 130 other industrial oils 87 7.9 28 1097 100.0 360 MM GPY 313 ------- TABLE F-17. DESTINATION OF SPILLS AND LOSSES From Tables F—4,5,6, Spills and Losses = 1365 MM GPY It is speculated that 80% of marine oil spills remain in environment. 88 Assume 0.8 (22) = 18 MM GPY. Recon guesses that 50% of land, marine, and processing losses and land spills (see Tablet F’5,6) are entering the environment = 0.5 (187 + 1156) = 672 MM GPY From Table F-14, amount to rerefiners = 11 MM GPY .. By difference, assume balance goes to reprocessors road oils, and directly to fuel 664 MM GPY 1365 MM GPY Of the 664 MM GPY, assume: To Road Oils , asphalt 10% 66 MM GPY To Fuels 30% 199 MM GPY To Waste Oil Processors 60% 399 MM GPY Total 100% 664 MM GPY 314 ------- TABLE F-18.ESTIMATION OF PRODUCTION OF WASTE OIL PROCESSORS 80% of production to fuel sales 0.8 x 763 10% of production for road oil and asphalt 5% of production for internal fuel use 5% of production to the environ- ment * From Table F-15. Assume : = 611MMGPY = 76MMGPY = 38MMGPY = 38 MGPY 763 MM GPY* 315 ------- TABLE F-19- ESTIMATE OF DESTINATION OF INDUSTRIAL LUBRICATING WASTE OILS From Table F-12, Total industrial lubricating waste oil = 394 MM GPY From Table F16, Amount to Reprocessors 130 MM GPY From Table F-14, Amount to Reprocessors 16 MM GPY .. Amounts to environment, road oils, and fuel 248 MM GPY Guess at distribution : ___ MMGPY To Environment 45 112 For Road Oils, Asphalt 10 25 For Fuel 45 111 100 24B 316 ------- TABLE F-20. ESTIMATE OF DESTINATION OF OTHER INDUSTRIAL WASTE OILS MM GPY From Table F-12, total other industrial waste oil = 87 From Table F—16, amount to reprocessors = 28 From Table F—14., amount to re—refiners = 3 Amount to environment, road oils, and fuel = 56 Guess at Distribution: % MMGPY To Environment 45 25 For Road Oils , Asphalt 10 6 For Fuel 45 25 100 56 317 ------- TABLE F-21. ESTIMATE OF DESTINATION OF AUTOMOTIVE LUBRICATING OILS From Table F-l2., total automotive waste oil = 616 MM GPY From Table F-16, amount to reprocessors = 202 From Table F-14, amount to re—refiners 105 .. Amount to environment, road oil and fuel = 309 From A. D. Little Report 2 , it is estimated that about 23% goes for road oil and dust control =142 .. To the environment and fuel = 167 . .Froin A. D. Little Report 2 , assume 24 o total auto waste oil is uncollected and goes to the environment = 148 • .Axnount directly to fuel = 19 318 ------- TABLE F-22. ESTIMATE OF WASTE OIL POTENTIALLY ENTERING THE ENVIRONMENT MM GPY From Table Source Amount F-21 Auto lube oils 148 F—19 Industrial lube oils 112 F—20 Other industrial oils 25 F-il U.S. Government lube oils 3 F—17 Losses & Spills 690 F-14 Lube oil rerefiriing 34 F-18 Waste oil reprocessing 38 Figure F—3 Road oils (O.88*x 319) 281 Total 1331 MM GPY * Estimated from EPA tata. 33 319 ------- APPENDIX G HEALTH AND SAFETY ASPECTS OF RE-REFINING PROCESS EFFLUENTS Page Acid Sludge 321 Spent Clay 325 Caustic Sludge 326 Distillation Bottoms, etc. 32 Volatiles, Vapors 326 Noise 327 Other Safety Considerations 327 320 ------- HEALTH AND SAFETY ASPECTS OF RE—REFINING PROCESS EFFLUENTS Although the following discussion deals with health and safety aspects of re—refining effluents, much of the data is applicable to the waste oils directly. In additions, some industrial waste oils, e.g. chlorinated bipheny]. type transformer oils are inherently hazardous. The Occupational Safety and Health Standards, Sax’s “Dangerous Properties of Industrial Materials”, and other suitable references 81,82,63 should be consulted for specific situations. ACID SLtJDGE In general, acid sludge exhibits the same health and safety aspects as does virgin sulfuric acid. Specifically, it is corrosive, carries a white label (Coast Guard, ICC, and IATA Classifications), and has the following Hazard Analysis: Toxic Hazard Rating: Acute Local: Irritant 3; Ingestion 3; Inhalation 3. Acute Systemic: U. Chronic Local: Irritant 2; Inhalation 2. Chronic Systemic: U. TLV: ACGIH (recommended); 1 milligram per cubic meter of air. Toxicology: Contact with the body results in rapid destruction of tissue, causing severe burns. No systemic effects due to continual ingestion of sn ail amounts of this material have been noted. There are systemic effects secondary to tissue damage caused by ccntact with it. However, repeated contact with dilute solutions can cause a dermatitis, and repeated or prolonged inhalation of a mist of sulfuric acid can cause an inflammation of the upper respiratory tract leading to chronic bronchitis. Sensitivity to sulfuric acid or mists or vapors varies with individuals. Normally 0.125 to 0.50 ppm may be mildly annoying and 1.5 to 2.5 ppm can be definitely unpleasant. 10 to 20 ppm is unbearable. Workers exposed to low concentrations of the vapor gradually lose their sensitivity to its irritant 321 ------- action. Inhalation of concentrated vapor or mists from hot acid or oleum can cause rapid loss of con- sciousness with serious damage to lung tissue. In concentrated form it acts as a powerful caustic to the skin destroying the epidermis and penetrating sane distance into the skin and subcutaneous tissues, in which it causes necrosis. This causes great pain and if much of the skin is involved, it is accom- panied by shock, collapse and symptoms similar to those seen in severe burns. The fumes or mists of this material cause coughing and irritation of the mucous membranes of the eyes and upper respiratory tract. Severe exposure may cause a chemical pneumonitis; erosion of the teeth due to exposure to strong acid fumes has been recognized in in- dustry. Fire Hazard: Moderate, by chemical reaction; a power- ful oxidizer; can ignite upon contact with combus- tibles. Disaster Hazard: Dangerous; when heated, it emits highly toxic fumes; will react with water or steam to produce heat; can react with oxidizing or re- ducing materials. Countermeasures are described in “Dangerous Properties of Industrial Materials.” 82 Due to the complex composition of the acid sludge, there are other noteworthy aspects: Combustibles The 30-42 wt.% concentration of combustibles in- dicates that the sludge should be treated with apprcpriate caution, but due to the low concentration of volatiles (0.8%), this is probably a minor hazard. Lead Because the concentration of lead ranges from 1,000 ppm (as elemental lead) from treating waste diesel oil to 20,000 ppm from treating crankcase waste oils, the sludge prctably presents significant potential for lead poisoning, since 1. The lead may be partially present as organo- lead compounds which can enter the body through the skin. 322 ------- 2. The lead is probably present partially as lead sulfate, one of the most toxic forms (due to high solubility). 3. The concentrations of lead in blood in cases of poisoning are equivalent to about 0.27 grains (6 x lO— lb) of sludges 4. The concentration of lead is comparable to that in lead paint which has been banned or restricted in some areas. The complete writeup in Sax on lead, lead compounds, and tetraethyl lead should be consulted. 82 Organcineta is No data has been found to indicate the presence of or absence of compounds of the metals with organic constituents of the oils. However, the following hazard analysis from Sax may be appropriate: Organ ome t a is General Information: Description: Compounds containing carbon and a metal. Ordinary metallic carbonates (calcium carbonate etc.) are excluded and also metallic salts of common organic acids. Examples of organic metal compounds are Grignard compounds such as methyl magnesium iodide (CH 3 MgI) and metallic alkyls such as butyilithiuin (C 4 H 9 Li). Hazard Analysis: Toxicity: This group of compounds is constantly growing in importance but there is relatively little toxicological information on most of them. Alkyl compounds of lead, tin, mercury and aluminum are known to be highly toxic. Less is known about other organornetals, but for the most part they are highly reactive chemically and therefore dangerous if only on direct contact. Until specific toxicological data become available, it is prudent to exercise great caution in handling organometals, particularly the alkyl forms. Su if ona tes No data has been found to indicate the presence or absence of sulfonates in the acid sludge, although 323 ------- it can be speculated that they are present. Sax indicates that the toxicity varies for different compounds. Toxic fumes of sulfur oxides may be emitted on decomposition. Cal ci urn The toxicity of calcium compounds generally is slight; in fact many calcium compounds are used medicinally. Phosphorus Organic phosphate compounds are considered poisons by ICC (Poison B Classification) and IATA (Poison B Classification). Most inorganic phosphates, except phosphine, have low toxicity, but in large doses m y cause serious disturbances particularly in calcium metabolism. Meta phosphates may be highly toxic, causing irritation and hemorrage in the stomach as well as kidney and liver damage. No data has been found on the hazards of the low concentrations present in th€. acid sludge. Sodium Sodium compounds in general are not tcxic unless the anion is, because the sodium ion is practically non — toxic. Z in c Zinc is not inherently a toxic element, and zinc compounds generally are of low toxicity. Carcinogenicity Some polycyclic hydrocarbcns, which may be resent in some oils, have carcinogenic properties. These include 3,4-benzpyrene, l,2,3,4—dibenzphenanthrene, 3,4,8,9 dibenzpyrene, arid 3,4,9,10 dibenzpyrene. Possible toxicity and carcinogenicity of lubricants and additives has also been investigated. 85 324 ------- Other Metals In addition to the above, acid sludge also contains copper and chromium in minor amounts. EPA has in- cluded these elements in the list of substances which, on the basis of initial analyses are believed to have potential for producing serious public health and environmental proflems when contained in wastes for disposal. Asbestos, arsenic, beryl- lium, cadmium, cyanides, lead, mercury, halo— genated hydrocarbons, pesticides, selenium, and zinc are also on the list. The other known constituents cf the sludge do not appear to present any obvious hazard potentials. SPENT CLAY No analyses of spent clay have been found. Spent clay for petroleum refining contains 1-45% oil. It should be pointed out that it is possible that the adsorped oil con- tains lead and other potential hazards, as outlined in Section VIII, and care should be taken to prevent entry in- to the body of the oil laden clay. The Material Safety Data Sheets received from clay suppliers claim that: 1. Attapulgus clay is not considered a hazardous material under current Department of Labor definitions. Source: Englehard Minerals & Chemicals Division. 2. Bentonite clay is considered an irritant due to its particulate nature; with a 15 ppm (for respirable fraction of inert dust) threshhold limit value. Safety glasses and gloves and protective equipment, and water flushing for e e and skin contamination, and vomiting in- ducing for internal contamination are recom- mended. Landfill is suggested for waste dis— posal. Source: Ashland Oil, Inc. Since the clays contain major portions of silica (e.g. Georgia Kaolin “Clarolite T—60” contain 64.6% S10 2 ) Sax’s writeup on silica should be consulted. OSHA limits on mineral dusts should also be consulted. 81 325 ------- Based on our understanding of the function of the clay (to remove odor and color bodies), we expect that the ad- sorbed compounds include nitrogen and oxygen containing organics. Sax’s writeups on nitro compounds of aromatic hydrocarbons, sulfur compounds, aldehydes, esters, and ketones should be consulted. 82 Due to the oil content, the spent clays may present a fire hazard. CAUSTIC SLUDGE Caustic sludge resulting frcm oil treating should be treated with the same precautions as virgin caustic. Specifically, it is corrosive, carries a white label (in solution), and has a “hazardous material” Coast Guard Class i— fication. Consult Sax for writeups on caustics and alkalies. 82 Lead, other metals and metal compounds, and combustible oils present in the sludge would appear to present the same potential health and safety problems as the acid sludge. Sodium silicate is known to be present, but this com- pound, commonly referred to as water glass, has a “slight” hazard rating according to Sax. Sodium compounds in general are not toxic unless the anion is, because the sodium ion is practically non—toxic. DISTILLATION BOTTOMS, RAW OIL SPILLS, TANK SLUDGES, PROCESS RESIDUES, AQUEOUS WASTE Previous and subsequent discussions on lead, cc mbus— tibles, organometals, other metals, volatiles, and car- cincgenicity would appear to apply to these waste products. Phenols may be found in wastes from distillation over- heads. Consult Sax for hazard analysis of phenols. 82 VOLATILES, VAPORS Volatiles and vapors from effluents, spills, and pro- cessing steps present health or safety problem potentials if TLV (threshhold limit value in air) is exceeded, cr if concentrations reach the flammability range. No data is available on work area concentrations, but TLV data on ex- pected compounds follow: 326 ------- TLV NO 25 ppm NO 2 5 ppm SO 2 5 ppm NH 3 50 ppm Consult Sax for hazard analyses for NO, NO 2 , SO 2 and NH 3 . In addition, attention is again called to Sax’s write- ups on aldehydes, ketone, esters and nitro—aromatics, and writeups on paraffins and olefins. 82 NOISE It should be noted that noise problems of re-refiners are similar to those of petroleum refineries (e.g. pumps, valves and burners). OTHER SAFETY CONSIDERATIONS Safety hazards of re—refining are noteworthy, but normal as compared to refinery operations, except that less instrumentation and more manual operations are involved. Fewer volatile combustibles are present in re—refining. 327 ------- TECHNICAL REPORT DATA (Please read I s.t,uctions on the reverse before completing) L REPC’ T NO. 12. EPA-670/2-74-052_— I 3. RECIPIENTS ACCESSION .NO. 3. T TLE ND SUBTITLE 5. REPORT DATE WASTE OIL RECYCLING AND DISPOSAL August 1974;Issuing Date 6.PERFORMINGORGANIZATIONCOD E 7. AL ORIS) 8. PERFORMING ORGANIZATION REPORT NO. Norman J. Weinstein 9. PERFORMING ORGANIZATION NAME AND ADDRESS 10. PROGRAM ELEMENT NO. 1 BBO41 Recon Systems Inc. Cherry Valley Road Princeton, New Jersey 08540 ROAP 21AVJ/TASKS 09 & 21 11. CONTRACT/ F 1 NO. 68-01-1870 and 68-03-0394 2. SPC SORING AGENCY NAME AND ADDRESS 13. TYPE OF REPORT AND PERIOD COVERED National Environmental Research Center Office of Research and Development Final 14.SPONSORINGAGENCYCODE U.S. Environmental Protection Agency Cincinnati, Ohio 45268 5. SUPPLEMENTARY NOTES 1 i, A6ST9 CT This study has developed information on sources and quantities of waste oils, current and potential recycle and disposal methods, and the environmental impact of these methods. In addition to an extensive literature search, surveys (of rerefiners, collectors and processors, the Pittsburgh Pennsylvania Metro area and Standard Industrial Classi- fication groups) were conducted to develop information reported. 17. KEY WORDS AND DOCUMENT ANALYSIS DESCRIPTORS *Waste disposal, *WaSte treatment, *Ojl recovery, * ubrjcating oils, Fuel oil, Wastes, Pollution, Collection b.IDENTIFIERS/OPEN ENDED TERMS C. COSATI Field/Group *Waste oil, *011 pollution, *Recycling, *Waste crankcase oil, *Waste oil re—refining, *Waste industrial oil, Waste lube oil, *Waste oil collec- tion, Recovery and reuse 13B 13DISTRIBUTION STATEMENT 19. SECURITY CLASS (This Report) UNCLASSIFIED RELEASE TO PUBLIC 20SECURITY CLASS (Thispage) 1JNCLASS IF lED 21. NO. OF PAGES 342 22.PRICE EPA F’orm 2220-1 (9-73) 3 2 8 U . 1%I$ Ifl P I%TIIIG OfilCi 197 J 1 - 1 57581 4 /5335 Region No. 5-Il ------- |