2003 Solid Waste Management Plan (SWMP) for Shushufindi Industrial Complex

8/7/2019 2003 Solid Waste Management Plan (SWMP) for Shushufindi Industrial Complex

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OLADE Project OfficeCalgary, AB Canada

UNIV ER SIT Y O F CALGARY

Solid Waste Management Plan (SWMP) for Shushufindi Industrial ComplexSucumbios Province - Ecuador

b y

Denisse Katherine Quispe Alvarado

A Masters Degree Project submitted to the Faculty of Graduate Studies in PartialFulfillment of the Requirements for the Degree of Master of Science in Energy and

Environment

Faculty of Graduate Studies

Quito, EcuadorAugust, 2003


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CERTIFICATE OF COMPLETION OF INDIVIDUAL PROJECTFOR THE UNIVERSITY OF CALGARY/OLADE

MASTER OF SCIENCE DEGREE IN ENERGY ANDTHE ENVIRONMENT

The undersigned certifies that he has read, and recommend to the Faculty of GraduateStudies for acceptance, the Individual Project Report entitled "Solid Waste ManagementPlan (SWMP) for Shushufindi Industrial Complex, Sucumbios Province - Ecuador"submitted by Denisse Katherine Quispe Alvarado in partial fulfillment of therequirements for the degree of Master of Science inEnergy and Environment.

7, , , , . , ' .Supervisor:Dr. Dixon Thompson Date

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ABSTRACT

The following Individual Project develops a Solid Waste Management Plan (SWMP)for Shushufindi Industrial Complex, which belongs to PetroEcuador that is the OilNational Company of Ecuador.

The study starts with a revision of the main concepts that are associated to solid wastemanagement, including a description of how to carry out an Environmental Audit underthe context of solid waste.

A methodology to identify solid waste sources generated by refineries as well as criteriafor classifying them in hazardous and non-hazardous compounds are provided. Adescription of the current disposal and treatment methods of the solid wastes generatedby the petroleum industry is also presented.

An assessment of the current handling of the solid wastes generated by the Complex ispresented for then suggest a SWMP. Also, stakeholders, driving forces and barriers areanalyzed in order to suggest strategies for the best implementation of the SWMP.

The study closes with a set of conclusions and recommendations based on the interest ofthe stakeholders.

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ACKNOWLEDGEMENTS

I would like to start thanking to PetroIndustrial, which was the oil company thatsponsored my Individual Project, especially to my unconditional advisor, MSc. JulioSalazar. Also, I would like to thank to Eng. Luis Martinez and Shushufindi' s workerswho help me in the collection of data during my site visit at the installations.

Thanks for my supervisor, Dr. Dixon Thompson, who helped me with his sound advice,careful guidance and useful information.

I would also like to thank those who agreed to be interviewed, without your time andcooperation, this project would not have been possible.

A special thanks to Latin American Energy Organization (OLADE) and CanadianInternational Development Agency (CIDA) for their assistance with the scholarship toparticipate in this Masters Program.

Finally, I would like thank to all my classmates of this Masters Program whosegenerosity will be remembered always.

To each of the above, I extend my deepest gratefulness.

DenisseAugust, 2003

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TABLE OF CONTENTSApproval page " , , '" 11Abstract '" '" .iiiAcknowledgements '" '" '" , '" .ivDedication , '" , '" , '" .vTable of Contents '" viList of Tables '" '" '" '" viiiList of Figures '" '" '" '" '" .ixAbbreviations , '" xCHAPTER ONE: INTRODUCTION '" '" ., '" '" 1General Context , '" '" '" 1Definition of the Problem '" " , , 2Purposes and Objectives '" '" .. , '" '" '" 3Methodology , 4Summary of Content. '" '" ., '" , 6CHAPTER TWO: SOLID WASTE MANAGEMENT LITERATURE REVIEW 8Overview '" '" '" 8Solid Waste Definition '" '" '" 8Solid Waste Management , '" 9

Fundamental Philosophy of Solid Waste Management.. '" , '" '" 10Solid Wastes Sources '" ., '" , '" 12Solid Waste Classification '" '" '" '" 13Solid Waste Plan '" '" '" '" '" 14Functional Elements ofa Solid Waste Management System '" 14

Hazardous Solid Waste '" 15Characteristics '" '" '" '" 16Environmental Auditing '" '" '" 19

CHAPTER THREE. - ANAL YSIS OF CRITERIA TO BE USED IN THEPREPARATION OF A SOLID WASTE MANAGEMENT 21Overview '" '" '" 21Methodology to identify solid waste stream in oil and gas industry .21Classification of solid waste generated at SIC 22Criteria of Hazardous Solid Waste described by Basel Convention .24

Hazardous solid waste in a petroleum refinery 29Treatment Technologies '" '" '" '" '" .31Gravity Pretreatment 31

Mechanical Dewatering '" '" '" .32Sludge Stabilization '" ., , '" .32Disposal Methods , '" '" 32Landfill '" , '" 32Land-farming '" '" '" '" ,. '" 34Incineration , '" '" , '" '" 36Composting '" '" '" 38Other routes '" '" 40Summary 40

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CHAPTER FOUR - SOLID WASTE MANAGEMENT PLAN TO SHUSHUFINDIINDUSTRIAL COMPLEX '" '" '" '" 41Overview " 41Description of the City of Shushufindi , , " 41Shushufindi Industrial Complex (SIC) '" '" '" '" '" '" 44The Amazonas Refinery .44

The Shushufindi Gas Plant , , .50Evaluation of the current responsibilities related to the handling of the solid wastes atSIC , '" '" '" , 51Evaluation of the current handling of the solid wastes '" 54Proposal of Solid Waste Management Plan '" 61

Responsibilities '" '" , , 62Identification of solid wastes '" 63Quantification, Characterization and Classification 67Temporary Storage '" '" '" 69Labelling '" '" 72Collection and Transportation , '" 73Disposal. " 75

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CHAPTER FIVE.- IMPLEMENTATION STRATEGY OF A SOLID WASTEMANAGEMENT PLAN TO SHUSHUFINDI INDUSTRIAL COMPLEX 78Overview , '" '" '" '" '" 78Stakeholders, Driving Forces and Barriers analysis in the implementation of the SWMPto SIC '" '" '" , ,. '" 78

Identification of stakeholders '" .. , '" '" 78Driving Forces Analysis '" 81Barriers Analysis , '" '" 86Environmental Strategies to be used in the implementation of the SWMP SIC '" 88

CHAPTER SIX .- CONCLUSIONS AND RECOMMENDATIONS '" 92Conclusions '" '" '" '" '" 92Recommendations '" '" 94

REFERENCES '" '" '" ,. '" '" 97ANNEX 1 '" '" '" '" '" : '" 101ANNEX 2 '" 102


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LIST OF TABLESTable 2.1- List of Regulated Toxic Characteristics Leaching Procedure Constituents ..17Table 3.1- Solid waste sources in petroleum refinery or up-grader plant 22Table 3.2- Solid waste streams in a petroleum refinery or up-grader plant 23Table 3.3- Categories of wastes to be controlled - Annex I of Basel Convention 24Table 3.4- List of Hazardous Characteristics - Annex III of Basel Convention 26Table 3.5- List of Hazardous and Non-Hazardous - Annex 2, Table 8 of the EcuadorianEnvironmental Rule: Decree 1215 '" '" 28Table 3.6- Hazardous waste in petroleum refineries from non-specific source .30Table 3.7- Hazardous waste in petroleum refineries from specific sources 31Table 3.8- Matrix for Comparison of disposal options .40Table 4.1- Characteristics of the distillation units '" , '" '" .45Table 4.2- Equipments of the Wastewater Treatment Plant - Amazonas 1 46Table 4.3- Characteristics of the water. .. '" '" .49Table 4.4- SIC production and yield, 2002 '" '" '" '" '" 51Table 4.5- Solid waste sources '" '" 64Table 4.6- List and description of solid waste streams generated in SIC '" 64Table 4.7- Rate of production of each solid waste stream '" '" '" ..67Table 4.8- Classification of solid waste generated at SIC '" 68Table 4.9- Estimation of solid wastes generated by waste sources '" '" 69Table 4.10- Proposal of colour ofthe barrels '" 70Table 4.11- Comparison among tanks cleaning technologies 74

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LIST OF FIGURES

Figure 2.1 Functional elements ofa solid waste management system 15Figure 2.2 Process to be followed to determine if a solid waste is hazardous or not 18Figure 4. 1 Location of Shushufindi Complex 42Figure 4.2 Transportation Options .43Figure 4.3 Organization ofthe Shushufindi Industrial Complex .52Figure 4.4 Organization of the Environmental Protection and Industrial SecurityDepartment (UPASI) '" .53Figure 4.5 Current drums used for temporary storage of solid wastes , .55Figure 4.6 Non treated oily sludge in pond with geo-membrane .56Figure 4.7 Oil Separators - API separator located inside the installations of SIC 57Figure 4.8 Open dumps without geo-membrane located inside the installations ofPetroProducci6n , '" '" , , '" 58Figure 4.9 (a) Special Landfill where it is disposed food wastes - inefficient separation,(b) Sanitary Landfill- inefficient separation '" .59Figure 4.10 Labels to grey, green, blue, brown and red barrels '" '" 72Figure 4.11 Labels to hazardous solid wastes '" '" 73Figure 4.12 Example of Manifest Document 75Figure 5.1 SWMP is a part of an EMP 88

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ABBREVIATIONSAPI : American Petroleum InstituteBOD : Biochemical Oxygen Demand

CONCAWE : Oil Companies' European Organization for Environment, Health andSafety

CPEOCPIDAFDINAPAEMPEMSESPFCUDGWPHFIAFLPGMSWNETLOASOLADEOSWPACEPBBPCB

: Center for Public Environmental Oversight: Corrugated Plates Interchange Separator: Dissolved Air Flotation: Environmental Protection National Direction: Environmental Management Program: Environmental Management System: Electrostatic Precipitator: Fluid Catalytic Cracker Unit: Global Warming Potential: Hydrofluoric Acid: Induced Air Flotation: Liqued Petroleum Gas:Municipal Solid Waste: National Energy Technology Laboratory: Organization of the America States: Organizacion Latinoamericana de Energia: Office Solid Waste: Petroleum Association for Conservation of the Canadian Environment: Polybrominated biphenyls: Polychlorinated biphenyls

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PCTQODRCRASICSSSWMPUNEPUPASIU.S EPA

: Polychlorinated terphenyls: Chemical Oxygen Demand: Resource Conservation and Recovery Act of the United States: Shushufindi Industrial Complex: Suspend Solids: Solid Waste Management Plan: United Nations Environment Programme: Unidad de Proteccion Ambiental y Seguridad Industrial: Environmental Protection Agency of the United States

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1CHAPTER ONE.- INTRODUCTION

Capacity

1.1 General ContextPetroEcuador is the National Oil Company in Ecuador, which has the followings threemain subsidiaries: PetroProducci6n, PetroComercial and PetroIndustrial. The latter isthe subsidiary in charge of the crude oil transformation by using refining processes inorder to get oil derivates products (PetroEcuador, May 2002). Those oil derivatesproducts should satisfy the internal demand as well as the demand for exportation.

Petrolndustrial transforms crude oil into oil derivates products, such as: LPG, Gasoline,Kerosene, Jet Fuel, Diesel, Solvents, Fuel Oil and Asphalts in three refineries and onegas plant, which are (PetroEcuador, May 2002):

Refinery / Gas Plant100000BPD45000BPD20000BPD25MMSFC

Esmeraldas RefineryLa Libertad RefineryShushufindi Industrial Complex - Amazonas RefineryShushufindi Industrial Complex - Shushufindi Gas PlantSource: Petrolicuador, May 2002.

Due to the strict Ecuadorian environmental regulations, PetroIndustrial had to start inthe 90's with the implementation of Environmental Management Systems (EMS's) intheir refineries. In 1993, Petrolndustrial started the implementation of an EMS in theEsmeraldas Refinery and in 2002 started the implementation of an EMS in La Libertadrefinery. Related to the Shushufindi Industrial Complex (SIC), some environmentalactions have been carried out, which represent the initial steps of the implementation ofan EMS to this plant. However, a lack of economic resources is slowing this process(Julio Salazar, personal comm., January 10,2003).

Additionally, it is important to mention that the Environmental Protection ManagementDepartment of PetroEcuador is in charge of providing economic resources to all of thedepartments of PetroEcuador for the development of environmental programs (MauricioMier, personal comm., May 21, 2~03). Hence, the role that this department plays in the


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2implementation of environmental management programs, IS important to discussfurther.

1.2 Definition of the ProblemThe SIC is located in the northeastern Sucumbios province, inside the city ofShushufindi, which is in the Ecuadorian Amazon region.

This complex consists of a gas plant and the Amazonas refinery. Both plants supplyrefined products, such as: LPG, gasoline, jet fuel, and residual; to the people of Amazonregion (petroEcuador, May 2002). This implies that sets of operation units are usedwhich include petroleum treating, gas conversion, petroleum conversion, feedstock andproduct handling. Those operation units produce air emissions, wastewater andpollutant solid wastes, which impact on the environment and the human health ofworkers and neighbouring inhabitants.

Due to the above concerns, the Environmental Protection and Industrial Security Unit(UPASI) of SIC has begun to perform "actions" which attempt to manage in anappropriate manner the pollutants generated by the complex. Some of those actions,which have a certain advance, are related to the handling of solid wastes generated bythe complex. These actions include the disposal of solid waste considered to be similarto municipal solid waste (MSW) in a sanitary landfill, the burning of organic solid

. materials, the disposal of food waste in a landfill and the storage of oily sludge in opendumps (Julio Salazar, personal comm., January 10, 2003).

However, the aforementioned actions have not been documented in a systematic manner(e.g. a Solid Waste Management Plan) so that self-regulation can guarantee that solidwastes are being handled and disposed of in a proper way. For instance, the spacedesignated for the oily sludges I S not always the same; sometimes oily sludges aredisposed of in an open dump placed into the PetroProducci6n area, which is next toPetroIndustrial. That open dump does not contain a permeable membrane, which is usedto prevent the mobility of contaminants into the subsurface (SIC, site visit, April, 2003).Therefore, there is not proper handling of solid hazardous waste due to its deposition inopen dumps, becoming a dangerous source of pollution.


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3Since an Environmental Management Program {EMP)l is part of the EMS, which canbe defined as a "system that anticipate and avoid or solve environmental and resourceconservation problems" (Thompson, 2002, pp.5), the suitable development of a SolidWaste Management Plan (technical program) will avoid environmental liabilities,protect human health and the environment, and comply with the environmentalregulations.

In this regard, this research is focused on developing a Solid Waste Management Planfor SIC, which takes into account all actions related to good management of solid wastegenerated by the complex. Also, this plan will subsequently allow the access to an EMS.

1.3 Pu rposes and ObjectivesPurposesThe purpose of my Master's Degree Project is to perform a pre - solid waste audit inorder to know and evaluate the current handling of the solid wastes generated by theSIC in order to suggest a Solid Waste Management Plan (SWMP), which will enhancethe current actions. In addition, this SWMP will assist PetroIndustrial managers tocomply with the Ecuadorian environmental regulations as well as to achieve thePetroIndustrial policies' goals. Another purpose of this project is to make an integratedanalysis, which involves identification of stakeholders, driving forces and barriers inorder to develop recommendations that will assist PetroIndustrial managers in theimplementation of this SWMP.

ObjectivesTo accomplish these purposes, ten objectives were identified:1. To gain a basic understanding of solid waste management and how an

Environmental Audit related to solid wastes generated in gas and oil industries iscarried out.

2. To identify and define the solid waste .sources generated in a gas plant and apetroleum refinery.

3. To review literature in order to know how to classify the solid wastes as hazardousor non-hazardous.

1 E :t\ .1 Pis d ef in ed a s a p rogr am th at i nc lu d es te chn ic al d eta il s.


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44. To undertake research in order to know the current treatment technologies anddisposal methods of solid wastes generated in oil and gas industries.

5. To review SWMP's of other oil and gas industries in order to gain a basicunderstanding of how to develop a similar SWMPfor the SIC.

6. To review and analyze pertinent Ecuadorian Environmental Regulations related tosolid waste management with a focus on gas plants and refineries.

7. To identify the driving forces and barriers encountered during the implementation oftheSWMP.

8. To analyze why those driving forces and barriers exist and what they signify.9. To identify and evaluate the different approaches available to overcome the barriers

associated during the implementation of this SWMP.10. To develop recommendations that will assist to Petrolndustrial managers in how to

best proceed with the implementation of SWMP. .

1.4MethodologyLiterature ReviewSpecific sources for the literature review include journals, books, guidelines, manuals,regulations, websites, previous MDP of OLADE and private organization reports anddocuments. These documents were obtained from OLADE, the University of Calgaryand PetroIndustrial libraries. This literature review provided a theoretical frameworknecessary to develop an Environmental Audit, to identify solid wastes sources in gasplants and petroleum refineries, to understand current treatment technologies anddisposal methods of solid waste. Accordingly, this provided enough information todevelop a SWMP for the SIC. It also provided the information necessary to conductinterviews, site visits and how to develop checklists. Additionally, it provided moreinformation for the identification of stakeholders, driving forces and barriers to beencountered during the implementation of the SWMP and how to overcome thosebarriers.

Topics reviewed included solid waste management, solid waste minimization,hazardous solid wastes, environmental audit and environmental strategies.The main literature reviewed included the following:


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6ChecklistThe methodology of checklist was used for the identification of the solid waste sourceas well as for the quantification of them, during the sitevisit.

Site VisitOne site visit was conducted at the installations of the complex.

First Site Visit - an inspection was performed at the installations of the gas plantand Amazonas refinery in order to identify solid waste sources, quantify them,using checklists and assess the current handling of the solid wastes generated bythe SIC.

The information collected from the site visit was used for the development of theSWMP by suggesting the principles of reduce, reuse and recycling techniques,treatment technologies and disposal methods to solid waste generated in SIC.

Formulation of RecommendationsAnalysis of the information gathered from the literature review, interviews and site visitallowed the development of a SWMP. Additionally, this analysis will also provide theidentification and evaluation of different approaches that could assist in the SWMPimplementation to PetroIndustrial managers.

1.5 Summary ofContentThe objectives of this research, which have been established in this IntroductionChapter, will be further developed in the following chapters:

CHAPTER TWO.- A review of the main concepts related to solid waste management ispresented in this chapter. It includes, solid waste definition, philosophy of solid wastemanagement, solid waste sources, solid waste classification, solid waste plan, hazardoussolid waste and the current management practices of hazardous waste, such asenvironmental audit.


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7CHAPTER THREE. - It provides information related to the solid waste generated byrefineries. It includes identification of solid waste sources, hazardous solid waste inrefineries, treatment technologies and disposal methods.

CHAPTER FOUR.- An in-depth study of the SIC is conducted to identify the solidwaste sources, quantify and classify those solid wastes generated, and subsequentlydevelop the SWMP. Also, it includes recommendations of treatment technologies anddisposal methods.

CHAPTER FIVE.- An integrated analysis is made in this chapter, which encompassesthe identification of stakeholders, driving forces and barriers. It allows the developmentof environmental strategies for the implementation of the SWMP to SIC.

CHAPTER SIX. - A set of conclusions and recommendations are presented in thischapter.


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8CHAPTER TWO.- SOLID WASTE MANAGEMENT LITERATURE REVIEW

2.1 OverviewThis chapter is going to provide general information of a solid waste management issue.It includes definitions, explains the hierarchy of solid waste management, identifies thesolid waste sources as well as discusses the classification of them as hazardous or non-hazardous compounds. Finally, it will discuss how to carry out an Environmental Auditunder the context of hazardous solid waste as current practical management.

2.2 Solid Waste DefinitionFirst, "waste" is defined by the Petroleum Association for Conservation of the CanadianEnvironment (PACE) as "any material for which the owner/generator has no furtheruse and which he discard" (PACE, 1986, pp. B-1). Therefore, under this definition,waste may be in the form of a liquid, gas, or solid, in its pure form or in a complexmixture. However, this research approaches all concepts related to solid waste.

It is important to define solid waste in order to know what materials are included underthis term. The U.S. Resource Conservation and Recovery Act (RCRA) of 1976, definessolid waste as "garbage,' refuse, sludge from a wastewater treatment plant, watersupply treatment plant. or air pollution control facility, and other discarded materialincluding solid, liquid, semisolid, or contained gaseous material resulting fromindustrial, commercial, mining, and agricultural operations, and f rom communityactivities" (U.S CODE, 2003).

According to this concept solid waste is the material arising from human and animalactivities (municipal waste, industrial waste, commercial waste, agricultural waste andothers) which is normally solid and is discarded by two reasons, useless and/orunwanted. Solid waste does not include solid or dissolved materials in domestic sewage,and it does not include solid or dissolved materials in irrigation return flows orindustrial discharges (Shah, 2000). T n addition, solid wastes based on its functionalproperties (e.g. corrosivity, ignitability, toxicity and reactivity), it may be consideredeither a hazardous or a non-hazardous waste, this issue is going to be expand in thesection 2.4.


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9After knowing the concept of solid waste, readers will realize that solid wastes have thepotential to cause environmental and human health problems if they are stored, handled,transported and disposed in an inappropriate manner (Hettiaratchi, Class notes, June2002). Itcould be recognized that many cases, which occurred in the last century, weredue to poor solid waste management practices, including the Love Canal landfill site atNiagara Falls, New York and the spreading of dioxin contaminated oil, as a road dustsuppressant, in Times Beach, Missouri (PACE, 1986).

These cases indicate the importance of using proper management when consideringsolid waste. However, there are other concerns which worry governments, such aspopulation and urban area growth. Due to these concerns, the availability of adequatespace, cost involved, impact on the environment and human health risk must beconsidered (Shah, 2000).

PACE contemplates four other aspects and concerns that have to be considered whendealing with solid waste:

'The large numher and increasing volumes of different waste materials beinggenerated by a society as whole " (PACE, 1986,pp. B-I0).

"Sorting through a variety of options for dealing with these wastes, not all ofwhich are economical" (PACE, 1986, pp. B-10).e "The environmental consequences of many of these treatment and disposal

options are asyet, not very well understood" (pACE, 1986, pp. B-10). "Public fears and their reluctance to have hazardous waste treatmentfacilities

located in their communities" (PACE, 1986, pp. B-10).

In fact, appropriate management of solid waste generated by humans and animals willhelp to protect human health and the environment. The following section attempts toexplain what aspects should be taken into account to carry out a satisfactory solid wastemanagement plan.

2.3 Solid Waste ManagementSolid Waste Management describes all the activities related to dealing with solid wastegenerated by human and animal activities in a proper fashion which minimizes the


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10environmental and human health risk associated with solid waste (Hertiaratchi, Classnotes, June 2002).

Those activities encompass the planning, design, financing, construction and operationof facilities for the collection, transportation, processing, recycling , resource recoveryand final disposal of residual solid waste materials (Shah, 2000).

As was mentioned in the above section, a poor waste handling practices could impactthe environment and human health, but it also could result in adverse social, legal,political and economical repercussions against the polluting company.

Good solid waste management requires the knowledge of the in-plant solid wastesources, the type of solid wastes generated, acceptable industrial practices and corporatewill to carry out an agreed upon program. In this regard, the following sections areprovided to assist in order to known:

what is the fundamental philosophy in which solid waste management is based,4& how to identify solid waste sources, what mechanism use to decide whether a solid waste is hazardous or not and,e how to develop a site specific solid waste management plan.

2.3.1 Fundamental Philosophy of Solid Waste ManagementAccording to the principles described in the U.S. Environmental Protection Agency'sAgenda for Action, municipalities and industries should use the following hierarchy toreduce the solid waste management problem most effectively (Shah, 2000): SourceReduction, Reuse, Recycling, Treatment & Disposal. The first three address "wasteprevention" and try to reduce the amount of solid waste material. The last two involvethe transformation, destruction or disposal materials once they enter the waste stream, inorder to reduce the risk of the materials. Some literature called those integrated steps"Waste Minimization".

The American Petroleum Institute (API) & U.S. Environmental Protection Agency(EPA) define these concepts as follows:


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112.3.1.1 Source reductionSource reduction, often called waste prevention, refers to the reduction(consuming and throwing away less) or elimination of waste generation at thesource, usually within a process (API, 1991). According to EPA, sourcereduction includes purchasing durable, long-lasting goods and seeking productsand packaging that are as free of toxics as possible (EPA, 2003). Sourcereduction implies prevention of the generation of solid waste in the first place; itis considered as the most preferable method of waste management, which aimsto protect the environment.

2.3.1.2 ReuseReuse refers to using a product more than once, either for the same purpose orfor a different purpose. According to EPA, reuse includes the reparation ofthem, donation of them to charity and community groups, or selling of them(EPA, 2003).

2.3.1.3 RecyclingRecycling refers to the use or reuse of a waste as an effective substitute for acommercial product, or as an ingredient or feedstock in an industrial process(API, 1991). Itmeans the recycling turns solid waste to valuable resources andgenerates a host of environmental, financial and social benefits. Recyclingimplies use, reuse, or rec1amation of a waste either on-site or off-site after it isgenerated by a particular process.

2.3.1.4 TreatmentSome solid wastes need a treatment to reduce their risks to human beings and theenvironment and some of those treatments recover energy which could be usedby the communities and industries. Treatment refers to methods, techniques orprocesses that are designed to change the physical, chemical. or biologicalcharacter of hazardous waste in order to render the waste non-hazardous or lesshazardous. Treatment implies actions that render waste safer to transport,dispose or store (API, 1991).


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122.3.1.5 DisposalReduction, reuse and recycling help to divert significant portions of the wastestream from final disposal, however not all materials are recyclable;consequently they should be located in a proper fashion (Hettiaratchi, Classnotes, June 2002). In this regard, disposal refers to the discharge, deposit,injection, dumping, spilling, leaking, or placing of any waste into or on land orwater, which minimize the human health risks and environment (API, 1991).

2.3.2 Solid Wastes SourcesThe sources of solid waste in a community are generally related to land use and zoning.The literature groups those solid waste into three general categories: municipal solidwaste, industrial solid waste & agricultural solid waste (Gordon, 1977).

2.3.2.1 Municipal Solid Waste (MSW)MSW includes waste from household, commercial, municipal sites (Shah, 2000).This category could be grouped into two sub-categories:

A. Residential Wastes: This waste includes the rejected solid materialform single-family, multifamily, and high-rise dwellings. This wasteconsists of:

Garbage: Type of waste result from food preparation,packaging, consumption and associated activities. This wasteis putrescible.

Rubbish and Trash: Type of waste which consist of paper andpaper products, cans, bottles, old clothes, leather products,metal products, glass, ceramics, dirt, dust, garden wastes andothers.

C D Bu1ky Waste: Type of waste which inc1ude heavy and largewastes, such as appliances, furniture, mattresses, toys andothers.

Ash: This waste is the end product from burning firewood,coal, and others.

B. Municipal Service Wastes: This waste includes the solid residue frommunicipal functions and services, such as: dead animals, old


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14important to understand concepts associated with hazardous wastes before explainingthe process. This issue of hazardous solid waste will be expanded in the section 2.4.After knowing the concepts related to this issue, it will be explained the methodologysuggest by PACE in the determination whether a solid waste is hazardous or non-hazardous.

2.3.4 Solid Waste PlanThe objectives of the solid waste management plan is to:

Practice resource conservation and recovery. Reduce plant waste disposal cost.o Comply with regulatory requirements. Protect the environmental integrity of soil, surface and groundwater in the

immediate vicinity of the plant site.o Avoid transferring a waste disposal problem into an air pollution problem, e.g.

through improper application of incineration. Prevent migration of harmful waste components in off-site landfills or other

third party treatment facilities that are directly attributable to processing of plantwastes.

Avoid future costly clean-up and decontamination during plantdecommissioning stage.

2.3.5 Functional Elements ofa Solid Waste Management SystemAs was mentioned in the definition of solid waste management, several activities arerelated to solid waste management. These activities associated with management ofsolid wastes from the point of generation to the final disposal have been grouped intothe six functional levels. These are illustrated in Figure 2.1.

According to Shah, four of them are considered to be essential for any satisfactorySWMP. These include the following: waste handling and storage at site, collection,transportation and disposal (Shah, 2000).

Therefore, this research is going to develop a SWMP for SIC based on these functionalelements.


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15Figure 2.1 Functional elements of a solid waste management system

Solid 1-vastegeneration

Separation,processing, andtransformat ionofsolid waste.

Source: Shah, 2000.

2.4 Hazardous Solid \VastcTheEPA defines a waste as being hazardous if" it ItUW cause or significantly contributeto an increase in mortality or serious irreversible. or incapacitating, reversible illness,po,


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161. The waste is declared hazardous by the generator.2. The material exhibits any characteristics of a hazardous waste.3. Itis specifically listed as such by the EPA

The EPA has established four hazardous wastes characteristics: ignitability, corrosivity,reactivity, and toxicity (Shah, 2000). The definition of those characteristics areexplained as follows:

2.4.1 Characteristics2.4.1.1 Ignitability: A flammable solid is one that is readily ignitable, burnsvigorously or causes fire or contributes to fire (Hettiaratchi, Class notes, June2002). They may cause fire during transport, storage, or disposal (Shah, 2000).

2.4.1.2 Corrosivity: Corrosive wastes can react dangerously with other wastes,dissolve metals or other materials, or bum the skin Waste rust removers, wasteacid or. alkaline cleaning fluids, and waste battery acid are examples ofcorrosivity waste (Shah, 2000). These are wastes exhibiting a pH ofless than 2.0or greater than 12.5 (Hettiaratchi, Class Notes, June 2002).

2.4.1.3 Reactivity: Reactive wastes are unstable or undergo a rapid or violentchemical reaction with water or other materials. Cyanide plating wastes, wastebleaches, and other waste oxidizers are examples of reactive waste (Shah, 2000).

2.4.1.4 Toxicity: Toxic wastes are considered to be hazardous because of thepresence of toxic constituents in the wastes at greater than the establishedregulatory levels. Metals, insecticides, herbicides and others organics are someof these constituents. Some of them are listed in Table 2.l(Shah, 2000). Also,test methods are used to determine if a waste displays a toxicity characteristic.

2.4.1.5 Other characteristics: Some literatures include other characteristics forthe determination if a solid waste is hazardous. These include: explosivity,radioactivity and infectiousness. However, as was mentioned, the EPA suggeststhe four above characteristics are the determinants characteristics.


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17Table 2.1: List of Regulated Toxic Characteristics Leaching ProcedureConstituents

u .s Original ~'P1'(-,a Regulatory U.S Original ~'P1C RegulatoryEPA EPACode Constituent levels (mg/I.) Code Constituent levels (mg/l.)1)004 Arsenic 5.0 1)018 Benzene 0.5D005 Barium JOO.O D019 Carbon tetrachloride 0.5D006 Cadmium 1.0 D020 Chlordane 0.3D007 Chromium 5.0 D02J Chlorobenzene JOO.OD008 Lead 5.0 D022 Chloroform 6 . 0D009 Mercury 0.2 D023 o-Cresol 200.01)010 Selenium 1.0 1)024 m-Cresol 200.0DOll Silver 5.0 D025 p-Cresol 200.0DOl2 Endrin 0.02 J)026 Cresol 2 {) O . ( )D013 Lindane 0.4 D027 l .s -dichtorobenzene 7.5D014 Methoxychlor 10.0 D028 1,2-dicholoroethane 0.5DOl5 Toxaphene 0.5 D029 I.l-dichloroethane 0.70D016 2,4- 10.0 D030 2,4-dinitrotoluene 0.13Dichlorophenoxy

acetic acid(2,4-D)DOll 2,4,5- Trichloro- 1.0 D031 Heptachlor (and it'> O'( )O8phenoxypropionic oxide)acid (2,4,5-TP,

Silvex)a RP toxicity contaminantsSource: Adapted from Shah, 2000. pp. 397.

Now that the concept of hazardous waste has been covered, it could be possible toexplain the methodology used by PACE for determination if a solid waste is hazardousor not, such as was mentioned in section 2.3.3.

The diagram that PACE used is illustrated in Figure 2.2. First, it should be determinedwhether the waste is on the federal or the pertinent provincial list of hazardousmaterials. Next, using the criteria for ignitability, corrosivity, reactivity and toxicity, adetermination is made as to whether the waste falls within the hazardous definition. Inaddition, there is generally a small volume exemption, which if below this limit, thewaste is deemed to be non-hazardous, even though it meets the other criteria forhazardous waste.


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Figure 2.2 - Process to be followed to determine if a solid waste is hazardous or not

GAS AND OILlNDUSTRY WASTE

T.FACHATEEXTRACT

I*I - : : : ; I IS \VASTE~LI ___~(_)_R_R_O_S_I\_I~_:?_ ~I . NOII o t a

Y I - : : : ; IS WASTEREACTIVE?

. N()

YE S ~ NU 1IS WASTE OR _"f'LEACIIATE ....-EXTR. . I\ .CT TOXIC?

.IS_WA~TE. IHhLOW SMALL l__VOLUME I I I

~WASTE TSNON-lLQ/:JillOUSWASTErs~\zARDOUS

Source: Adapted from PACE, 1996.

18


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192.5 Environmental AuditingEPA defines Environmental Auditing as a "systematic, documented, periodic andobjective review of facility operations and practices related to meeting environmentalrequirements" (EPA, 1997). In addition, EPA identifies the following objectives forenvironmental audits:

To verify compliance with environmental requirements; To evaluate the effectiveness of in-place environmental management systems;

and To asses risk from regulated and unregulated materials in practices.

Some types of environmental audits are: Compliance audit: is merely a "snapshot of plant operations and procedures,

identifying instances of either compliance with regulations or violation of them.A compliance audit is quantal and superficial (LaGrega, Buckingham, & Evans,2001).

Management Audit: is used to look at the strengths and weaknesses of facilityenvironmental management systems (EMSs) (EPA, 1997). Management Auditsdiffer from a compliance audit in that a management audit evaluate the overalleffectiveness of an environmental management program. Liability Audit: these are typically done for prospective buyers of real state andfor proposed mergers and acquisitions. Such audits identify environmentalproblems that cold reduce the value of a property or expose the buyer to liability.

Waste Contractor Audit: uses features of both a compliance audit and a liabilitydefinition audit to analyze commercial facilities used to store, treat, and disposeof hazardous waste.

Risk definition audit: analyzes the operation of facilities that handle hazardousmaterials and substances. These audits serve to help in obtaining insurancecoverage and are required by some governments as part of catastropheprevention planning (LaGrega, Buckingham, & Evans, 2001).

e Specialty Audits: is related to a specific environmental topic area, such as wasteaudits, air quality, water, energy, and greenhouse gas emissions reduction,"whichfocuses only on the generation, handling, storage, and disposal of wasteproducts and may address compliance, management practices and due


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20diligence" (Thompson, 2002. pp. J 29). Some authors include inside thisclassification the waste minimization audit, which examine wastes generated bya facility with the objective of identifying viable actions to reduce, reuse, recycleor otherwise reduce the quantity and toxicity of each waste stream (LaGrega,Buckingham, & Evans, 2001).

An Environmental Audit is an environmental management tool which has shown toprovide significant benefits to organizations which have environmental impacts or aresubject to environmental regulations.

This research attempts to develop a solid waste management plan to the SIC. In thisregard the initial step to a solid waste management plan is to conduct a wasteminimization assessment, for instance a solid waste minimization audit. WasteMinimization audits involve identifying and characterizing waste streams.


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22In this regard, PACE in its report N 86-2 has identified 55 solid waste streamsgenerated in petroleum refineries or up-grader plants, which have been grouped togetheraccording to functional sources. There are basically five major source groupings ofwastes in a petroleum plant. These are shownin Table 3.1.

Table 3.1 - Solid waste sources in petroleum refinery or up-grader plantCode PACE Waste Sources

I Storage and Products Handling OperationsII Process UnitsII I Utility Plant - Steam Generation - Cooling WaterIV Wastewater Treatment FacilitiesV Miscellaneous, which include: maintenance, laboratory andadministrative office building.

Source: PACE, 1986.The solid waste streams are illustrated in Table 3.2. In addition, ARPEL, in its guidelineof Management solid waste generated by refining industries, Annex 1, has includedanother 14 solid waste streams (ARPEL, 1992).

Although PACE does not include solid waste streams generated by a gas plant, themethod for grouping thesolid waste sources could be adapted to find the solid wastestreams of this plant. Infact, some interviews will be necessary to conduct by talking toengineers and operators in order to identify those solid waste streams.

3.3 Classification of solid waste generated at SICChapter two described in general terms the criteria used by EPA to classify waste ashazardous or non-hazardous compounds. However, a more in-depth criteria systemwillbe developed in this research. Therefore, this section will develop two additional criteriato be taken into account during the classification of the solid waste streams to beidentified.


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~cd0-'-(l)-0CdI-


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243.3.1 Criteria of Hazardous Solid Waste described by Basel ConventionDue to the fact that Ecuadorian environmental regulations related to wastes are based onthe Basel Convention, the criteria of hazardous characteristics described in Annex III ofthis convention will be taken into account in this research. The Basel Convention, inarticle 1, paragraph 1 (a) considers as hazardous waste any material that belongs to anycategory contained in Annex I, unless they do not posses any of the characteristiccontained in Annex III (Basel Convention, 1992).

Table 3.3 shows Annex 1 of Basel Convention in which the categories of wastes to becontrolled are illustrated. Table 3.4 shows Annex 3 of the Basel Convention, in which alist of hazardous characteristics is described.

Table 3.3 - Categories of wastes to be controlled - Annex I of Basel ConventionCode Waste StreamY l Clinical wastes from medical car in hospitals, medical centres and clinics.Y 2 Wastes from the production andpreparation of pharmaceutical products.Y 3 Waste pharmaceuticals, drugs and medicines.Y 4 Wastes from the production, formulation and use of biocides and

Iphytopharmaceuticals.Y 5 Waste from the manufacture, formulation and use of wood preservingchemicalsY 6 Wastes/rom the production, formulation and use of organic solvents.Y 7 Waste from heat treatment and tempering operations containing cyanidesY 8 Waste mineral oils unfit fqr their originally_ intended use.Y 9 Waste oils/ water, hydrocarbons/water mixtures, and emulsions.

Waste substances and articles containing or contaminated withY l O polychlorinated biphenyls (PCBs) and / or polychlorinated terphenyls

(PCTs) and/or polybrominated biphenyls (PBEs)Y l l Waste tarry residues arising from refining, distillation and any pyrolytictreatmentY 1 2 Wastes from production, formulation and use of inks, dyes, pigments, paints,

lacquers, varnishY l 3 Wastes from production, formulation and use of resins, latex, plasticizers,glues/adhesives

Waste chemical substances arising from research and development orY 1 4 teaching activities which are not identified and/or are new and whose effects

on man and/or the environment are not known.Y l 5 Wastes of an explosive nature not subject to other legislation.

Source: Basel Convention, 1992.


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25Table 3.3 - Categories of wastes to be controlled - Annex I of Basel Convention (Cont.)Code Was te S tr eamYI6 Wastes from production, formulation and use of photographic chemicals andprocessing materials.YI7 Wastes resultingfrom surface treatment of metals and plasticsYI8 Residues arising from industrial waste disposal operations


Table 3.3 - Categories of wastes to be controlled - Annex I of Basel Convention (Cont.)Code Was te s hav ing a s consti tu en tsYI9 Metal carbonylsY20 Beryllium; beryllium compoundsY2I Hexavalent chromium compoundsY22 Copper compoundsY23 Zinc compoundsY24 Arsenic; arsenic compoundsY25 Selenium; selenium compoundsY26 Cadmium, cadmium compoundsY27 Antimony; antimony compoundsY28 Tellunum; tellurium compoundsY29 Mercury; Mercury compoundsY30 Thallium, thallium compoundsY3I Lead; lead compoundsY32 Inorganic fluorine compounds excluding calcium fluorideY33 Inorganic cyanidesY34 Acidic solutions or acids in solid formY35 Basic solutions or bases in solid formY36 Asbestos (dust andfibres)Y37 Organic phosphorus compoundsY38 Organic cyanidesY39 Phenols; phenol compound'} including chlorophenolsY40 EthersY4I Halogenated organic solventsY42 Organic solvents excluding halogenated solventsY43 Any congener polychlorinated dibenzo ..uranY44 Any congener ofpolychlorinated dibenzo-p-dioxinY45 Organohalogen compounds other than substances referred to in this Annex.(e.g. Y39, Y4I, Y42, Y43; Y44)



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26Table 3.4 - List of Hazardous Characteristics - Annex III of Basel ConventionUN Class Code Characteristics(*)

Explosive. - An explosive substance or waste is a solid or liquidsubstance or waste (or mixture of substances or wastes) which is1 HI in itself capable by chemical reaction ofproducing gas at such atemperature and pressure and at such speed as to cause damageto the surroundings.

Flammable liquids. - The word "flammable" has the samemeaning as "inflammable". Flammable liquids are liquids, ormixtures of liquids, or liquids containing solids in solution or3 H3 suspension (for example, paints, varnishes, lacquers, etc., but notincluding substances or wastes otherwise classified on account oftheir dangerous characteristics) which give off a flammablevapour at temperatures of not more than 60.5C, closed-cup test,or not more than 6 5 . 6 C , open-cup test.

Flammable solids. - Solids, or waste solids, other than those4 . 1 H4.1 classed as explosives, which under conditions encountered intransport are readily combustible, or may cause or contribute tofire throughfriction.

Substances or wastes liable to spontaneous combustion. -4.2 H4.2 Substances or wastes, which are liable to spontaneous heatingunder normal conditions, encountered in transport, or to heatingup on contact with air, and being then liable to catchfire.

Substances or wastes, which, in contact with water emit4 . 3 H4.3

flammable gases. - Substances or wastes which, by interactionwith water are liable to become spontaneously flammable or togive offflammable gases in dangerous quantitiesOxidizing. - Substances or wastes which, while in themselves not

5 . 1 H5.1 necessarily combustible, may, generally by yielding oxygencause, or contribute to, the combustion of others materials.Organic Peroxides. - Organic substances or wastes which

5 . 2 H5.2 contain the bi-valent -0-0- structure are thermally unstablesubstances which may undergo exothermic self-acceleratingdecomposition.Poisonous (Acute). - Substances or wastes liable either to cause

6 . 1 H6.1 death or serious injury or to harm health if swallowed or inhaledor by skin contact.Infectious substances. - Substances or wastes containing viable

6 . 2 H6.2 microorganisms or their toxins, which are known or suspected tocause disease in animals or humans.(*) Corre sp on ds to th e h az ar d c la ssific atio n sy ste m In clu de d in th e U nite d N atio ns R ec omm en da tio ns onth e T ra ns po rt o f D a ng ero us G ood s ( ST IS gIA C.1 0IR ev .5 , U nite d N atio ns , N ew Y ork , 1 98 8).Source: Basel Convention, 1992.


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27Table 3.4 - List of Hazardous Characteristics - Annex III ofBasel Convention (Cont.)UN Class Code Characteristics(*) Corrosives. - Substances or wastes which, by chemical action,

will cause severe damage when in contact with living tissue, or,8 H8 in the case of leakage, will materially damage, or even destroy,other goods or the means of transport, they may also cause other

hazards.Liberation of toxic gases in contact with air or water. -9 HiO Substances or wastes, which, by interaction with air or water, areliable to give off toxic gases in dangerous quantities.Toxic (Delayed or chronic). - Substances or wastes which, ? f they

9 Hll are inhaled or ingested or if they penetrate the skin, may involvedelayed or chronic effects, including carcinogenicity.Ecotaxic. - Substances or wastes which if released present or

9 Hi2may present immediate or delayed adverse impacts to theenvironment by means of bioaccumulation and/or toxic effectsupon biotic systems.Capable, by any means, after disposal, of yielding another

9 Hi3 material, e.g., leachate, which possesses any of thecharacteristics listed above(* ) Corresponds to the hazard classification system mcluded In the United Nations Recommendations onthe Transport of Dangerous Goods (STISgIAC.10IRev.5, United Nations, New York, 1988).Source: Basel Convention, 1992.

In addition, the Basel Convention in its annexes VIII and IX, has developed two lists,which include:

LIST A (Annex VIII),which contains all waste classified as hazardous under theArticle1, paragraph 1 (a) of the Convention, and their designation on this Annex .does not preclude the use of Annex ill to demonstrate that a waste is nothazardous.

e LIST B (Annex IX), which contains all wastes classified as non-hazardous,unless they contain Annex I material to an extent causing them to exhibit anAnnex II characteristic.

Some of those wastes contained in both lists (LIST A and B) have been considered inthe Ecuadorian Environmental Rule (Republic of Ecuador, February 2001). in order toprovide a list of hazardous and non-hazardous compounds. This list is described inAnnex 2, Table 8 of this Rule, and illustrated in this project by Table 3.5. Article 28,


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28paragraph (b) of the Environmental Rule points out that the classification should bedeveloped according to this list.

Table 3.5 - List of Hazardous and Non-Hazardous - Annex 2, Table 8 of theEcuadorian Environmental Rule: Decree 1215

A) Waste Classified as Dangerous(In conformance with danger waste classifications of the Basle Agreement (concerningthe control of cross-border movement of dangerous waste and its elimination, validsince 1992:Code Type 0/ WasteAOOI0 Radioactive waste from detectors.A0046 Infectious sanitary waste.A0046 Infectious sanitary waste.AIOI0 Metallic waste or waste containing metals such as antimony, arsenic,beryllium, cadmium, lead, mercury, selenium, tellurium, and/or thallium

Including, among others, incinerator ash inertness, solidification,controlled di5posal.

AI040 Waste that has a constituent metal carbonyl and/or hexavalent chromiumA2030 Catalyzed waste Regeneration and retailization waste whenever possibleA3010 Waste resultingfrom production or treatment of petroleum coke and

asphaltA3020 Mineral oil waste that was not suitable for the use for which it was

destined Adequate recovery, treatment, and reuseA3021 Filtered oil waste, filtered hydraulic waste, etc.A3070 Phenol waste and waste containing phenolic compounds, includingchlorophenol in a liquid form or in mudA3140 Non-halogenated organic solvents.A3150 Halogenated organic solvents.A3190 Tarring residue waste (with the exclusion of asphaltic cement) resulting

from refining, distillation, or any other pyrolyitic treatment of organicmaterials

A4020 Clinical and related waste.A4030 Waste resulting from the production, preparation and use of a biocide,A4060 and phyto-pharmaceuticals, including pesticide and herbicide waste thatA4070 does not correspond with the specifications, are expired or are not

suitable for the originally contemplated useMixed waste and emulsionsof oil and water or hydrocarbons and waterWaste resultingfrom theproduction, preparation, and use of dyes, colorants, pigments, paints,lacquer, or varnish.

A4080 Waste of an explosive nature.A4091 Acidic solution waste with pH 11.5A4100 Wastefrom the use of industrial control devices for gas purification.Source: Republic of Ecuador, February 2001.


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29A) Waste Classified as Dangerous (cont.)Code Type 0/ WasteA4I20 Wastes that contains, consists of, or is contaminated with peroxides.A4I30 Bottles or containers of waste that contain substances or materials

included in this list.A4I40 Waste consisting of or containing chemicals products that do notA4I50 correspond with the specifications or have expired corresponding to theA4I60 categories included in this list Waste from chemical substances that are

unidentified or new resultingfrom research, whose effect on humanbeings or the environment is unknown Activated carbon waste, exceptthat resulting/rom the treatment of potable waterSource: Republic of Ecuador, February 2001.

B)Non-Hazardous wastesCode Type of WasteBOO45 Inorganic domestic waste.BOO46 Organic domestic waste.B2011 Cuttings Glass waste.B2020 Formation water.B2041 Contaminated drilling and bottom sediments from storage or non-

dangerous waste warehousing.B300I Soil with hydrocarbons.B3002 Mud and sands contaminated with hydrocarbons Bioremediation, land

farming.B3003 Hydrocarbons recovered in the production flow and/or effluent treatment

Re-incorporation in the production process.B3004 Crude oil waste Re-incorporation in the production process.B3005 Gases withdrawn from production flow such as: hydrogen sulfite and

carbon dioxide and other volatile hydrocarbons Recovery and treatmentwithin the production processes.

B3006 Drilling fluids and mud Prioritization of drilling mud on the basis ofwater content, recycling of mud, treatment of sedimentation, decantation,liq~uidre-injection, controlled disposition of solids.

B3010 Plastic waste Classification; recyclable.B3020 Paper, carton, paper products waste Classification; recyclable.B3030 Textile waste Classification; recyclable.B3I50 Other inorganic industrial waste not classified as dangerous specify.Source: Republic of Ecuador, February 2001.

3.3.2 Hazardous solid waste in a petroleum refineryThis section will provide information related to those wastes considered as hazardous inthe refining industry. According to the EPA, the petroleum refining industry waspreviously studied by OSW in the 1980s, which involved sampling and analysis of a


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30number of residuals belonging to 180 refineries of 19 different sites (EPA, 1996). Theresults of this study culminated in the promulgation of two hazardous waste listingsfocused on wastewater treatment sludges. Those lists are F037 and F038, which areshown in Table 3.6.

Table 3.6 - Hazardous waste in petroleum refineries from non-specific source

Waste N" Ha za rd ou s Wa steF037 Petroleum refinery primary oil/water/solid separation sludge. Any sludge

generated from the gravitational separation of oil/water/solids during thestorage or treatment of process wastewaters and oil cooling wastewatersfrom petroleum refineries. Such sludges include, but are not limited to,those generated in oil/water/solids separators; tanks and impoundments,ditches and other conveyances; sumps; and storm waster units receivingdry weather flow sludges generated from non-contact once throughcooling waters segregated for treatment from others process or oilycooling waters, sludges generated in aggressive biological treatment unitsas defined in Sec. 261.31 (b) (2)) including sludges generated in one ormore additional units after wastewaters have been treated in aggressivebiological treatment units) and K05I wastes are not included in thislisting. This listing does include residuals generated from processing orrecycling Oil-bearing hazardous secondary materials excluded underSec.261A (aj(l2Jfi), if those residuals are to be disposed of.

F038 Petroleum refinery secondary (emulsified) oil/water/solids separationsludge. Any sludge and/or float generated from the physical and/orchemical separation of oil/water/solids in process wastewaters and oilycooling wastewaters from petroleum refineries. Such wastes include butare not limited to, all sludges and floats generated in: induced air flotation(IAF) units, tanks, and impoundments, and all sludges generated in DAFunits. Sludges generated in storm water units that do not receive dryweather flow, sludges generated from non-contact once-through coolingwaters segregated for treatment from other process or oily cooling waters,sludges and floats generated in aggressive biological treatment units asdefined in Sec 261.31 (b) (2) (including sludges and floats generated inone or more additional units after wastewaters have been treated inaggressive biological treatment units) and F037, K048 and K051 wastesare not included in this listing. Dissolved airflotation (DAF) float from thepetroleum refining industry. Slop oil emulsion solids from the petroleumrefining industry. API separator sludge from the petroleum refiningindustry. Does not include inert support media

Source: EPA, 1996.


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31Table 3.7 - Hazardous waste in petroleum refineries from specific sources.Waste N Hazardous WasteK048 Dissolved air flotation (DAF) float from the petroleum refining industryK049 Slop oil emulsion solidsfrom the petroleum refining industryK050 Heat exchanger bundle cleaning sludge from the petroleum refining

industry.K05I API separator sludgefrom the petroleum refining industryK052 Tank bottoms (leaded)from the petroleum refining industryKI69 Crude oil storage tank sedimentfrom petroleum refining operationsKI70 Clarified slurry oil tank sediment and/or in-line filter/separation solids

from petroleum refining operationsKI7J Spent Hydro Treating catalyst from petroleum refining operations,

including guard beds used to desulfurize feeds to other catalytic reactors(this listing does not include inert support media)

KI72 Spent Hydro Refining catalyst from petroleum refining operations,including guard beds used to desulJurize feeds to other catalytic reactors(this listing does not include inert support media)_Source: EPA, 1996

On the other hand, the EPA proposes a specific list of hazardous solid wastes for thepetroleum refining industry. Table 3.7 shows the specific hazardous waste generated ina petroleum refinery.

To sum up, the criteria discussed in these sections 3.3.1 and 3.3.2 will be used toclassify the solid waste streams to be identified at SIC as either hazardous or non-hazardous.

3.4 Treatment TechnologiesThis section will provide information on the treatment technologies applied to oil andgas industries.

3.4.1 Gravity PretreatmentAlthough settling of sludges can be used as a passive form of gravity thickening, thereare thickeners specifically designed for this purpose. Chemical flocculants and heat canalso be used to improve performance. With good operation, thickened sludge can reach6-10% suspended solids, depending upon feed properties (CONCA WE, 1995).


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33pre-existing depressions in the ground or specially prepared sites above ground. Afterdeposition, the wastes are covered with soil and the land is rehabilitated (CONCA WE,1995).

ClassI (secure landfills)II (monofills)III (sanitary landfills)

Designed to HandleHazardous wasteDesignated wasteMSW (Municipal Solid Waste)

It is now common practice, before filling, to line the bottom with an imperviousmembrane of either compacted clay or polymer, or both. This serves to stopcontaminants leaking out of the landfill. A similar impervious layer is also often used toprevent the ingress of rain water (Shah, 2000).

Waste is often pre-treated before disposal to landfill, e.g. by dewatering orsolidification. While dewatering reduces the volume of waste, solidification is designedto bind the constituents together and prevent leaching.

Landfill ClassificationLandfills have been classified in different ways, the following of which is used in thisresearch (Shah, 2000):

This classification will be useful to suggest what type of landfill will be suitable for thesolid wastes generated in the SIC.

Amenable Wastes to LandfillAccording to PACE, some materials should not be disposed of in this manner (PACE,1996). These would include:


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34In fact, an environmental engineer when considering landfill, either on-site or off-site,should be thoroughly aware of the degree of containment, which an individual landfillsite provides. Some other type of disposal should be considered when there is a risk ofcontaminating the leachate and surrounding groundwater.To sum up, only certain hazardous solid wastes may be disposed of in a landfill, sincethis type of disposal method results in some negative environmental impacts, such as:

,( the mitigation of the leachate to the groundwater, and,( the generation of methane gas, which is flammable and explosive and can have

undesirable environmental impacts (it contribute to Global Warming).

Hence, this practice has a high risk, since the landfill must have good protection in orderto avoid the migration of contaminant leachate to the groundwater and comply with theregulations. Also, it requires of well-qualified operators, which may mean that localhiring may not be possible. PetroIndustrial must characterize the oily sludges generatedby SIC before deciding whether this practice is suitable.

Related to cost, CONCAWE reports that the cost of landfill varies widely - around of58$/tonne (CONCA WE, 1995). However this considered to be an acceptable cost.

3.5.2 Land-farmingCONCA WE defines land farming as " the treatment of oily or biological sludges bycontrolled application to specially prepared area of soil so that the microorganismspresent can biodegrade the organic components of the sludge as rapidly as possible"(CONCAWE, 1995, pp.14).

Land farming utilizes natural soil microorganisms to break down oily or biologicalsludges, which use the organic part of the waste as a food, producing carbon dioxideand additional bacteria cells in the process (pACE, 1996). Land farming is also knownby other names such as land-spreading, soil biodegradation, etc. but should not beconfused with landfilling.Operating ParametersAccording to PACE, the following parameters should be taken into account to get agood performance during the operation of the land-farming:


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35


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37hazardous materials to simple, non-hazardous byproducts (NETL, 2000). Therefore,heavy oily sludges can be burned through this practice.

In modem incineration systems, four major types of combustion chamber designs areused: liquid injection, rotary kiln, fixed hearth, and fluidized bed (NETL, 2000).

In these designs, waste material is combusted in the presence of a relatively large excessof oxygen (air) to maximize the conversion of the hydrocarbon based wastes to carbondioxide and water (50% to 200%). Sulfur and nitrogen in the feedstock are oxidized toform SOx and NOx . Halogens in the feedstock are primarily converted to acid halidegases such as HCI and HF and exit the combustion chamber with the combustion gases(NETL, 2000). Often scrubbers filters are required to remove or reduce theconcentration of these contaminants to acceptable limits to meet air regulations,therefore treated flue gas is discharged to the atmosphere (PACE, 1986). Ash solids arealso eliminated.

Some incinerators recover the heat and gases (C02 & H2O) generated by thecombustion in order to produce heat and electricity, otherwise known as incinerationwith heat recovery. Since oily sludges can be burned in incinerators, it is possible torecover energy from the waste.

Additionally, Dr. Amir Badaksham, Professor of Engineering Department DofCrecommends a 99.999% incinerator for burning oily sludges as the best option todispose this kind of solid waste. In fact, incineration must be with heat recovery toreduce costs by generating heat and electricity (Amir Badaksham, personal comm., June26,2003).

For all above mentioned, incineration practice has the following advantages over theothers, for the followings reasons:

./ Reducing volume of waste.,f Reducing air pollution (treated flue gas is discharged to atmosphere, which

complies with air regulations. It means a clean practice).


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38./ Acceptable by community (since it is a cleaner practice than landfarrning andlandfill, this practices could be preferred instead of others) .

./ Complying with environmental regulations .

./ Reducing risks (unlike landfill and landfarming, it does not produce pollutantleachate) .

./ Recovery of heat and gases (C02 & H2O), which allows the generation of heatand electricity.

However, according to CONCAWE, one disadvantage of this practice is its high capitalcost (on-site treatment). The average cost to treat raw oily sludges is the most expensivecompared to landfill and landfarming. This cost is around of 127$/tonne (CONCAWE,1995). A lack of knowledge and skills is another disadvantage for the implementation ofthis practice, since very well-qualified operators are needed.

It is important to add that INCINEROX, an enterprise with experience in incinerationpractice; it is currently operating at the Shushufindi community by incinerating metalwastes (Manuel Rivera, personal comm., June 13,2003). Also, the Esmeraldas Refineryhas an incinerator, which is currently out of service, since the Esmeraldas communitythought that the incinerator was to be used to bum clinical wastes. The Esmeraldasmunicipality forbade any type of incineration practice inside the community (MauricioMier, personal comm., May 21,2003).

PetroIndustrial must investigate these alternatives in order to bum the oily sludgesgenerated by SIC.

3.5.4 CompostingAccording to EPA, "composting refers to the controlled decomposition of organicmatter by microorganism (mainly bacteria and fungi) into a stable humus material thatis dark brown or black and has an earthy smell. The process is controlled in that it ismanaged with the aim of accelerating decomposition, optimizing efficiency, andminimizing any potential environmental or nuisance problems that could develop"(EPA, 1994, pp. 2).


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39Composting decomposes organic matter such as kitchen, leaf, food, paper, cardboard,wood products, and yard materials. It is important to indicate that since yard materialsconsist of relatively clean, biodegradable materials, landfilling them simply wastesspace and burning them wastes energy (Shah, 2000).

The end products of a well-run composting process are a humus-like material, heat,water, and carbon dioxide (C02) (EPA, 1994). Unlike landfills, compo sting producesC02 instead of methane (CH4), which has a considerable effect in the Global Warmingconcern. (Global Warming Potential (GWP): GWP (CH4) = 21; GWP (C02) = 1)(Pembina Institute, 2002). The humus (compost material) is used primarily as a soilamendment by farmers, horticulturists, landscapers and residents. This materialenhances the appearance of soil, increases soil fertility, increases the ability of the soilto retain water and nutrients and moderate soil temperature, reduces erosion and plantdisease. Due to these characteristics, these materials could generate revenues to thecommunity by its purchasing.

Composting can be managed by people of the community, who must be trained in orderto gain knowledge and skills before operating it, meaning the possibility of creating newjobs (labor).

According to the EPA, the capital cost of composting depends on the type of technologyto be used, the characteristics of the material to be composted and the quality ofcompost material to be obtained (EPA, 1994).

For all above mentioned, composting can offer several potential economic benefits tocommunities, such as:

./ Extended landfill longevity .

./ Avoided costs from reducing or eliminating the need for soil amendmentpurchases .

./ Reduction in the volume of waste to be incinerated or landfilled

./ Production of beneficial material - humus-that improves the productionpotential of soil.

./ Revenues from selling the finished product.


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40./ Environmental benefits from reduced landfill and combustion use../ Creation of newjobs./ Interest of the community../ Revenues from sale of recyclable ../ Compliance with the environmental regulations.

High=4; Medium =3; Low = 2; Zero = 1;

3.5.5 Other routesThese include temporary storage, and disposal via waste contractors using combinationsof the above with other specialist techniques. These included physical, chemical andbiological treatment methods.

3.5.6 SummaryThe following matrix attempts to compare the disposal options discussed above. Thecomparison will be done, based on the criteria listed in section 3.5. The ratings to beused is as follow:

Table 3.8 Matrix for Comparison of disposal optionsDisposal Method

Selection Criteria Lan4fill Lan4farminll Incineration Compostiiu:Functional (oily sludges) 2 3 4 2Functional (MSW) I I I 4Economic 2 3 4 3Environmental Impact 4 3 2 2Risk Reduction I 2 4 3Comply with regulations 2 4 4 4Need Skill &Knowledge 4 4 4 2Community Interest I 2 3 4Labor (creation of jobs) 1 1 2 4

In balance, it seems that the best technology to treat effectively oily sludge isincineration, followed by landfarming. In the case of Municipal Solid Waste (MSW),composting can be regarded as the best option, due to the fact that landfilling andlandfarming wastes space and incineration wastes energy and others reasons explainedin section 3.5.4.


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42such as characteristics of weather, transportation options to arrive to the city ofShushufindi, local recyclers and interest of the Municipality of Shushufindi.

Figure 4.1 Location of Shushufindi Complex

4/

r

.~-,s "

COLOI\1UIA

o o

3! lit Remffias I 3

4

2 2

PERUs

Source: PetroEcuador, 2003.

Characteristics of the weather:Sucumbios is a city located at 600 meters above the sea level, which I S characterized byits humid and tropical climate and high precipitation as much as 6.000 mm yearly. Theaverage temperature is around 23C (GAS, 2003).

If landfarming and composting are going to be used, Petrolndustrial must take intoaccount the meteorological data because the performance of these technologies isinfluenced by the characteristics of the weather. For instance, the soil temperature mustbe between 10 - 40 'T to landfaming (it is not a controllable variable); therefore,landfarming could be applied by the SIC.

Transportation OptionsTransportation options are another important issue to be discussed. The main road wasconstructed due to the "oil boom" in Sucumbios province some years ago. This main


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A'", ,+_Jroads start in Quito, crosses Pifo, Papallacta, Baeza and arrives to Nueva Loja. Thisroad links Lubamqui, E1 Dorado de Cascales and Shushufindi (Grupo'Sente, 2003). Bybus, traveling from Quito to Shushufindi takes around ten hours.

In Sucumbioss capital, Lago Agrio, there is an airport, which keeps contact withQuito's airport. By bus, it 1 S the only way to travel from Shushufindi to Lago Agrio andit ta ke s a ro un d three hours (Grupo 'Sen te , 2003).

Figure 4.2 shows the location of the road, which links Shushufindi to the other cities, aswell as the location of the airport.

Therefore, the transportation of recycling materials from Shushufindi to main cities ofEcuador, such as Quito, is possible. Trucks could be used and airplanes could be tooexpensive. Itwill allow the development of recycling programs.

I II iI II - - - - - - - - - - - - - - - - - - - - - - - - - ~ - - - - - - - - - - - - - - - - ~ - - - - - - l i I

IIIm Limoncocha I__. . ...._ .. . ..._. ...._.._._.__ ....._ ...._ .... .. .. ._.. . ...

Source: GrupoSente, 2003.

Figure 4.2 Transportation Options

Province's Capital Road CitiesII[ J j J Ethnic Group Cayambe-Coca Cuyabeno

Local Recvclers and Enterprises of IncinerationThere are no local recyclers in Shushufindi; all these enterprises are located in Quito(Luis Martinez, personal comm., April 14,2003).


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44Additionally, it is important to highlight that INCINEROX, an enterprise withexperience in Incineration, is operating in Shushufindi (Manuel Rivera, personalcomm., June 13,2003).

Therefore, PetroIndustrial must evaluate the possibility to sell its recycling materials toan enterprise located in Quito or other enterprises in Shushufindi, such asPetroProducci6n and PetroComercial, which can collect all recycling materials and sellthem to an enterprise in Quito.

Interest of the Municipality of ShushufindiThe Municipality of Shushufindi has an Environmental Department, which is trying towork together with oil enterprises, such as SIC; in issues related to the environmentalprotection. However, the Municipality of Shushufindi does not have suitableregulations, which allow having a control over the oil industries. According to ManuelRivera, a technician of the Munipality of Shushufindi, the oil industries only obey theEnvironmental Regulations, and they always wait for the Energy Ministry's slow andoften delayed actions.

Addittionaly, Shushufindi is an agricultural city and its main product is the oil palm.Therefore, a compo sting program between Municipality and Petrolndustrial should besatisfactory for the reason explained in Chapter Three. The compost product (humus)could be sold to local farmers in Shushufindi.

4.3 Shushufindi Industrial Complex (SIC)The Shushufindi Complex is made up by the Amazonas Refinery and the ShushufindiGas Plant, which will be described as follow:

4.3.1 The Amazonas RefineryThis project was conceived in 1997 with the purpose of giving a solution to the internaldemand growth of fuels as well as to satisfy the increasing number of internationalpetroleum companies, which were contracted for the exploration and exploitationactivities developed in the Amazonian region.


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45In 1985, the construction of the refinery began with a design capacity of 10000 barrelsper day (BPD). In May 1995, this capacity was doubled to 20000 BPD to process acrude oil of 30.7 API (PetroEcuador, 2003). Currently, the refinery processes a crudeoil of around 29 API (PetroEcuador, 2002).

This refinery has two primary distillation units, which are denominated as Amazonas 1and Amazonas 2 (each of them processing 10000 BPD). Table 4.1 shows some of thecharacteristics of these distillation units. The products obtained are: LPG, naphtha,kerosene, jet fuel, diesel 2 and atmospheric residuum (the latter is returned toPetroComercial through a secondary pipeline from Shushufindi-Lago-Agrio)(PetroEcuador, 2003).

Table 4.1- Characteristics of the distillation unitsPlant Construction Constructor Design DesignerDate Capacity (BPD)

Amazonas 1 1985 Kobe Steel- 10000 FisherNisho IwaiAmazonas 2 1995 Kellogg Bufete 10000 Kellogg-Bufete

Source: PetroEcuador, 2002.

Description of the Wastewater Treatment PlantA. Amazonas 1 RefineryThe wastewater streams, which feed this plant, include:

Storm wastewater containing oil coming from the process area:The storm water from the process area as well as the oil spills are collected bylateral channels to be sent to a storm wastewater pond. This pond relies on askimmer, which collect the oil phase of this stream, then is pumped to theentrance of the Corrugate Plates Interchange Separators (CP1).

Wastewater comingfrom the process area:The oil wastewater coming from the process area is transferred continually to theCPI separators.


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46~ Wastewater coming from the utility plant:

It is made up by the following wastewater streams: the water resulting from theretro-washing of the sand filter and the water resulting from the retro-washing ofthe activated carbon and draining of boilers. These streams are transferredintermittently to the wastewater treatment plant.

~ Wastewater coming from the drainage of tanks and some equipment:These streams are transferred intermittently to the CPI separators.

Wastewater comingfrom the laboratory:This wastewater stream (generated by the washing of materials) is transferredintermittently to the wastewater treatment plant.

The wastewater treatment plant is made up of two CPI separators, a homogenizationtank, a dissolved air flotation tank (DAP) and a pond for treatment of activated sludges.These sludges are collected in two open ponds with geo-membrane (or liner). The mainequipments of the wastewater treatment plant are listed in Table 4.2.

Table 4.2 - Equipments of the Wastewater Treatment Plant - Amazonas 1Equipment Shushu_findi Code Desien CapacityCPI Separators Y-U401 AlB 10 m3/h cluCompensation Chamber Y-U402-04T 3.66x 1.5mDxHFeed Pumps Y-U402 - 04 PAlPB 22. 7 m31hRetention Tank Y-U402-05T 610x 915 mmDx T-TAir Dissolve Flotation Tank Y-402 2.3 x 2.35 mDxHAeration Pond Y-U403-01Z 4.5 x4.5x1.5 mLxLxHAerators Y-U403A1BClarification Pond Y-U403-02Z 4 x 4 m L x L - base of 60Re-circulation Pumps Y-U403-02 PAlPB IOm31hSludge Pumps Y-U402-05P 0.5 m31hSludge Pond Y-U402-01Z 4m3Oil Pond Y-U401-0IZ 1 m3Oil Pumps Y -U401-01 PAlPB 50 It. /minChemical Doses Pumps -- -Source: PetroEcuador, 2002.A description of the process as well as each of the equipments is described as follow:

CPI Separators Y-U401 AlB:


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47There are two CPTseparators Y-U401 AlB, which have a capacity of 10 rn3/heach of them. One CPI separator is always in service, the other stays on stand-by. The oil storm wastewater, process wastewater and wastewater of drainage oftanks are sent to the CPI separators. The conditions of the wastewater streamswhich enter to the separators is as follows (PetroEcuador, 2002m):

Feed ConditionsOil free 150ppmpH 6-7TemperatureFlow

67C10m3/h maximum

Here, the oil, water and sludge phases are separated. The oil is collected in anopen pond, to then be sent to the slop tank. The wastewater is sent to theCompensation Chamber in order to be cleaned more. The sludges are settled inthe bottoms of the CPl separators, which are retired periodically and sent to asludge pond (Y-U402-05P)by gravity.

Compensation Chamber Y-U402-004T:Here the water still contains some particles of oil and grease. The function ofthis compensation chamber is to provide a continual flow to the feed pumps,which feed to the Retention Tank. In this tank some chemicals are added (acoagulant, alumina sulphate and sodium carbonate to adjust the pH). Thischamber has a mixer.

Feed Pumps Y-U402 - 04PAlPB:These pumps transfer the wastewater from the compensation chamber to theretention tank.

Retention Tank Y-U402-05T:The wastewater coming from the compensation chamber is sent to this tank. Inaddition, pressurized air is injected to this tank. This tank provides enough timein order to get a goodmix of air in water.


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48@ Dissolved Air Flotation Y-U402:

In this tank the solids (flocculants which have captured oil and grease) areseparated from the water by using the process of flotation of dissolved air. Thechemical added at this point is the flocculant, which is a polyelectrolyte. The rateof dose is adjusted according to the conditions.

Aeration Pond Y-U403-0IZ: The function of aeration is to provide a pond inwhich the wastewater could be treated with oxidant bacteria in the presence ofdissolved oxygen (DO.)

Aerators Y-U403 AlB:The mixing and absorption of oxygen is made by using surface aerators, and theamount of dissolved oxygen can be adjusted by raising or diminishing the gradeof immersion of the aerators.

Clarification Pond Y-U403-02z:The aerator effluent is sent by gravity to the end clarification pond. Thewastewater enters the clarification pond through an internal diffuser in which thebiomass is settled to the bottom. The clarified water overflows through thelateral channel of the clarification pond. The biomass is settled in the bottom tothen be pumped to the entrance of the aeration pond to assure the presence ofbacteria, which could oxidize the incoming effluent.

Recirculation Pumps Y-U403-02 PAlPB:The two pumps operate in the manner of service/stand-by and are shutdownmanually. These pumps re-circulate the sludge from the clarification pond to theinlet of the aeration pond. When the BOD (Biochemical Oxygen Dissolve) ofthe wastewater is reduced, biomass is produced, which must be periodicallyremoved.

Sludge Pond:This pond is used to store the sludges, which have been removed periodicallyfrom the bottom of the clarification pond. This sludgepond relies on a mixer.


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49 Sludge Pumps Y-U402-05P:

These pumps transfer the sludge from the sludge pond to two open dumps thatcontain a geo-membrane.

Oil Pond Y-U401-01Z:This oil pond is used to store the oil before being sent to the oil tank.

Storm wastewater pond:The clarified water is sent to this pond, along with the storm wastewater comingfrom the process area and the oil spills. As was mentioned previously, the oil phaseof the storm wastewater is separated. The clean water is then sent to the river, andmust have the following characteristics:

Table 4.3 - Characteristics of the waterParame t er RangepH 5.5 - 8.5

Oil Less than 5ppmBOD Less than 40 ppmSS Less than 50 ppm

Ten1perature ro~) 20-30Ammonium Max 0.1 ppn1Phenols Max. 1.0 ppmQOQ Max Z tl ppm02 dissolve Max 30 ppn1

Source: PetroEcuador, May 2000.

ANNEX 1 illustrates the wastewater treatment plant of Amazonas 1.

B. Amazonas 2 RefineryThe Amazonas 2 wastewater treatment plant is similar to Amazonas 1, with some minordifferences. That being said, the quality of the wastewater to be sent to the river has thesame characteristics as Amazonas 1, as shown in Table 4.3. Amazonas 2 also has twoopen ponds with geo-membrane for collection of oily sludges.


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50Additionally, the oil spills produced in all area of the complex are sent to the oilseparators - API separators, which are not connected to the wastewater treatment plant(petroEcuador, May 2000).

4.3.2 Shushufindi Gas PlantShushufindi is the main field of oil production in Ecuador, where in addition to oil,associated natural gas is also produced. The Shushufindi gas plant was constructed totake advantage of this resource, in order to get LPG and natural gasoline. The designcapacity is 25 MMSFC of associated natural gas; it has the capacity to produce 500metric Tonnes per day (Tonne/day) of LPG and 2800 BPD of natural gasoline. Itsoper

Documents

2003 Solid Waste Management Plan (SWMP) for Shushufindi Industrial Complex