Hazardous Waste Disposal for Oil Refineries

Comprehensive Hazardous Waste Management Services for Petroleum Refining Operations Nationwide

Oil refineries and petroleum processing facilities generate diverse hazardous waste from refining operations, maintenance activities, environmental control systems, and process units. From spent catalysts and treatment sludges to contaminated materials and equipment waste, proper disposal is required for regulatory compliance and environmental protection. Hazardous Waste Disposal provides expert waste management services tailored to the petroleum refining industry.

Call (800) 582-4833 for oil refinery waste disposal services or email info@hazardouswastedisposal.com

Understanding Oil Refinery Hazardous Waste

Petroleum refineries are among the most complex industrial operations, producing numerous hazardous waste streams from crude oil processing, product manufacturing, and facility operations. Proper waste management is critical for regulatory compliance, environmental protection, and operational efficiency.

Why Refinery Waste Management Matters:

• EPA RCRA regulations for refineries

• Clean Water Act compliance

• Clean Air Act requirements

• State environmental regulations

• OSHA safety requirements

• CERCLA liability concerns

• Consent decrees and permits

• Public scrutiny and community relations

• Environmental justice concerns

• Potential for significant penalties

• Refinery-specific listing (K-listed wastes)

Common Refinery Waste Streams:

• Spent process catalysts

• API separator sludge

• Dissolved air flotation (DAF) float

• Slop oil emulsion solids

• Heat exchanger bundle cleaning sludge

• Tank bottoms and sludges

• Spent caustic solutions

• Spent acids (sulfuric, hydrofluoric)

• Wastewater treatment sludges

• Spent adsorbents and molecular sieves

• Contaminated soil and materials

• Turnaround and maintenance waste

• Laboratory waste

• PCB materials (older equipment)

Types of Refinery Operations We Serve

Conventional Crude Oil Refineries

Integrated refining operations:

• Atmospheric distillation

• Vacuum distillation

• Catalytic cracking (FCC)

• Hydrocracking

• Catalytic reforming

• Alkylation

• Isomerization

• Hydrotreating

Waste characteristics:

• Full range of K-listed wastes

• High volumes

• Complex waste mixtures

• Process-specific wastes

• Equipment maintenance waste

Specialty Refineries

Focused operations:

• Asphalt refineries

• Lubricating oil refineries

• Petrochemical feedstock production

• Re-refining operations

Waste generated:

• Process-specific residues

• Equipment cleaning waste

• Product off-spec materials

• Maintenance waste

Small Independent Refineries

Regional facilities:

• <75,000 barrel/day capacity

• Limited processing units

• Simpler operations

Waste characteristics:

• Lower volumes than major refineries

• May be SQG vs. LQG

• Basic refining waste streams

• Equipment and maintenance waste

K-Listed Refinery Waste Streams

Primary K-Listed Wastes from Refineries

EPA has specific waste codes for petroleum refining:

K048 - Dissolved air flotation (DAF) float:

• From petroleum refining operations

• Oil and grease with process contaminants

• Benzene constituent of concern

• Large volume waste stream

K049 - Slop oil emulsion solids:

• From petroleum refining wastewater treatment

• Oil, water, and solids mixture

• Benzene and other VOCs

• Recovery may be possible

K050 - Heat exchanger bundle cleaning sludge:

• From petroleum refining operations

• Hydrocarbons with metals and scale

• Chromium constituent of concern

• Generated during turnarounds

K051 - API separator sludge:

• From petroleum refining wastewater treatment

• Three-phase separator bottom sludge

• Oil, water, and solids

• Benzene and chromium concerns

• Very common refinery waste

K052 - Tank bottoms (leaded gasoline):

• From storage of leaded gasoline

• Mostly obsolete (leaded gas phased out)

• Lead constituent of concern

• Historical waste at older facilities

These K-codes make refinery waste automatically hazardous regardless of characteristics

Treatment, Recovery, and Derived-From Rule

Important K-waste concepts:

Derived-From Rule:

• Waste derived from treating K-listed waste remains hazardous

• Applies to treatment residues

• Affects disposal options

Mixture Rule:

• K-listed waste mixed with other waste remains K-listed

• Important for segregation

Treatment Standards:

• Land Disposal Restrictions (LDR) apply

• Must meet treatment standards before landfilling

• Often requires stabilization or treatment

• Increases disposal costs

Common Refinery Waste Materials

Spent Process Catalysts

Catalytic unit wastes:

Fluid Catalytic Cracking (FCC) Catalyst:

• Spent zeolite catalyst

• Contains metals (nickel, vanadium) from crude oil

• Coke deposits

• High volume waste

• May have recovery value (metals)

Hydrocracking Catalyst:

• Spent metal-containing catalyst

• Cobalt, molybdenum, nickel

• Often has significant metal recovery value

• Specialized recycling available

Reforming Catalyst:

• Platinum and rhenium containing

• High precious metal value

• Almost always sent for metal recovery

• Not typically "disposed" but recycled

Hydrotreating Catalyst:

• Cobalt-molybdenum or nickel-molybdenum

• Metal recovery potential

• Common waste stream

Management:

• Metal recovery often economically favorable

• We coordinate catalyst recycling

• Disposal when recovery not viable

• Proper characterization required

API Separator Sludge (K051)

From oily water separation:

• Oil, water, and solids mixture

• First stage of refinery wastewater treatment

• Benzene and chromium listing constituents

• Requires stabilization before landfilling

Volume:

• Varies by refinery size and operations

• Can be hundreds to thousands of tons annually

• Continuous generation

Treatment options:

• Thermal treatment

• Stabilization and landfilling

• Some recovery of oil possible

• Land treatment (with permit)

DAF Float (K048)

Dissolved air flotation waste:

• From secondary wastewater treatment

• Lighter than API sludge

• Oil and grease concentrated

• Benzene constituent

Management:

• Similar to API sludge

• Often combined for disposal

• Requires treatment before landfill

• High moisture content

Slop Oil Emulsion Solids (K049)

From wastewater treatment:

• Emulsified oil and water with solids

• From slop oil systems

• Difficult to break emulsion

• Benzene listing constituent

Recovery potential:

• Some facilities recover oil

• Centrifugation or other separation

• Reduces disposal volume and cost

Heat Exchanger Bundle Cleaning Sludge (K050)

From maintenance activities:

• Generated during turnarounds

• Hydrocarbons with scale and deposits

• Chromium from corrosion

• Intermittent generation

Characteristics:

• Thick, viscous material

• Contains metals

• Process-dependent composition

Tank Bottoms and Sludges

Storage tank residues:

• Crude oil tank bottoms

• Product tank bottoms

• Water and sediment accumulation

• Requires periodic cleaning

Types:

• K052 (leaded gasoline - mostly historical)

• Characteristic waste (if not K-listed)

• Volume depends on tank size and contents

Management:

• Tank cleaning contractors

• Proper characterization

• May require stabilization

• Disposal or treatment

Spent Caustic

From treating operations:

• From crude desalting

• From treating sour gases

• From naphtha treating

• Sodium hydroxide or potassium hydroxide based

Characteristics:

• Extremely high pH (>13)

• Corrosive (D002)

• Contains sulfides, phenols, mercaptans

• Odorous

• Difficult to handle

Treatment:

• Neutralization required

• Oxidation of sulfides

• May be treatable on-site

• Or sent to specialized facilities

Spent Sulfuric Acid

From alkylation and other units:

• Sulfuric acid catalyst

• Contains hydrocarbons and organics

• Highly corrosive

• Large volumes in alkylation units

Management:

• Spent acid regeneration (at some facilities)

• Neutralization and treatment

• Specialized disposal facilities

• May have recovery value

Spent Hydrofluoric Acid

From HF alkylation units:

• Hydrofluoric acid catalyst

• Extremely hazardous

• Strict safety requirements

• Regeneration or disposal

Special considerations:

• Highly toxic

• Requires specialized handling

• Emergency response planning critical

• We coordinate specialized disposal

Wastewater Treatment Sludges

From biological treatment:

• Activated sludge from biotreatment

• May contain oil and refinery compounds

• Heavy metals possible

• Large volumes

Other treatment sludges:

• Chemical precipitation sludge

• Clarifier sludge

• Oil-water separator sludge

Characterization needed:

• May or may not be hazardous

• TCLP testing often required

• Depends on wastewater composition

Spent Adsorbents and Molecular Sieves

From treating and drying:

• Spent clay (from oil treating)

• Molecular sieves (from gas drying)

• Activated carbon (from vapor recovery)

• Desiccants

Characteristics:

• Adsorbed hydrocarbons

• May be ignitable

• Contains process contaminants

Contaminated Soil and Materials

From spills and operations:

• Petroleum-contaminated soil

• Oily materials

• Tank farm soil

• Process area contamination

• Excavation from remediation

Management:

• Characterization required

• Treatment options available

• Land treatment (with permit)

• Thermal treatment

• Landfilling

Turnaround and Maintenance Waste

From periodic shutdowns:

• Coke and scale from process units

• Equipment cleaning residues

• Pipe and vessel cleaning waste

• Catalyst changeouts

• Filter media

• Insulation materials

• Contaminated equipment

Characteristics:

• Large volumes during turnarounds

• Variety of waste types

• Planning required

• Timing critical

Oil Refinery Waste Regulations

EPA RCRA Regulations

Refineries are Large Quantity Generators:

• Generate >1,000 kg hazardous waste per month

• 90-day accumulation limit

• Full RCRA compliance required

• EPA ID number required

• Contingency plan and emergency procedures

• Personnel training mandatory

• Weekly inspections

• Annual reporting

K-Listed Wastes:

• K048, K049, K050, K051, K052

• Automatically hazardous

• Derived-from rule applies

• Mixture rule applies

• Land disposal restrictions

Characteristic Wastes:

• D001 Ignitable

• D002 Corrosive

• D004-D011 Toxic metals

Land Disposal Restrictions (LDR)

Treatment Standards:

• K-listed wastes must meet treatment standards

• Characteristic wastes too

• Stabilization often required

• Thermal treatment alternatives

• Increases disposal costs significantly

Documentation:

• LDR notification and certification

• Treatment standards must be met

• We ensure compliance

Clean Water Act

NPDES Permits:

• Wastewater discharge limits

• Oil and grease limits

• Benzene and other VOC limits

• Heavy metals limits

• pH requirements

• Biological oxygen demand (BOD) limits

Pretreatment:

• API separators

• Dissolved air flotation

• Biological treatment

• Generates K-listed wastes

Clean Air Act

Air Emissions:

• Benzene NESHAP

• VOC emissions

• Flaring regulations

• Leak detection and repair (LDAR)

Affects waste management:

• Closed systems required

• Vapor control

• Emissions from waste

CERCLA / Superfund

Liability concerns:

• Off-site disposal creates liability

• Choose disposal facilities carefully

• Potential for future cleanup costs

• We help minimize CERCLA risk

State Regulations

Vary by state:

• California very strict

• Texas large refining state

• Louisiana regulations

• State hazardous waste programs

• Additional requirements

• Permits and notifications

Consent Decrees

Many refineries operate under:

• EPA consent decrees

• State agreements

• Enhanced monitoring

• Specific compliance requirements

• Reporting obligations

Our Oil Refinery Waste Services

Regular Scheduled Pickup

Routine waste collection:

• Weekly or bi-weekly service

• Monthly service for some streams

• Turnaround support (intensive periods)

• Custom schedules

We collect:

• Laboratory waste

• Maintenance waste

• Contaminated materials

• Equipment cleaning waste

• Small quantity waste streams

Bulk Waste Management

Large volume services:

• Tanker trucks (2,000-6,000 gallons)

• Vacuum trucks

• Roll-off containers (20-40 yard)

• Specialized equipment

• High-capacity service

For waste streams:

• API separator sludge

• DAF float

• Tank bottoms

• Spent caustic

• Wastewater sludges

• Contaminated soil

Spent Catalyst Management

Complete catalyst services:

• Catalyst removal and packaging

• Metal recovery coordination

• Recycling when economically viable

• Proper disposal when necessary

• Documentation and certificates

Types handled:

• FCC catalyst

• Hydrocracking catalyst

• Reforming catalyst (precious metals)

• Hydrotreating catalyst

• All other refinery catalysts

Tank Cleaning Services

Tank bottom removal:

• Coordination with tank cleaning contractors

• Proper containerization

• Transportation

• Treatment and disposal

• Complete documentation

K-Listed Waste Disposal

Specialized handling:

• K048, K049, K050, K051 waste

• Proper treatment to meet LDR standards

• Approved disposal facilities

• Complete manifesting

• Compliance documentation

Spent Acid and Caustic Management

Corrosive waste handling:

• Spent sulfuric acid disposal

• Spent caustic disposal

• Neutralization coordination

• Specialized facilities

• Safety-focused handling

Turnaround Support

During plant shutdowns:

• Increased waste generation

• Multiple waste types

• Intensive scheduling

• Large equipment and staff

• Rapid response

• Complete waste removal

Planning services:

• Pre-turnaround planning

• Container staging

• Logistics coordination

• On-site support staff

Contaminated Soil Management

Soil remediation support:

• Soil characterization

• Excavation coordination

• Treatment options analysis

• Thermal treatment

• Land treatment coordination

• Landfill disposal

• Cost optimization

Laboratory Waste

Refinery laboratory disposal:

• Analytical waste

• Quality control samples

• Testing reagents

• Expired chemicals

• Lab pack services

Emergency Response

24/7 emergency services:

• Spills and releases

• Equipment failures

• Process upsets

• Tank leaks

• Fire damage cleanup

• Regulatory response

• Crisis management support

Waste Characterization

Complete testing:

• TCLP metals analysis

• Ignitability testing

• pH and corrosivity

• Benzene and VOC analysis

• Proper waste code determination

• LDR compliance testing

• Disposal pathway selection

Regulatory Consulting

We help refineries:

• Maintain RCRA compliance

• LDR documentation

• Waste minimization plans

• Generator certifications

• Record keeping systems

• Audit preparation

• Consent decree compliance

Oil Refinery Disposal Costs

Cost Factors:

• K-listed vs. characteristic waste

• Land disposal restrictions (treatment required)

• Volume and frequency

• Treatment requirements

• Transportation distance

• Specialized handling needs

• Market conditions

K-Listed Waste (K048, K049, K050, K051):

• Requires treatment before landfilling

• Most expensive refinery waste

• $200-$800 per ton typical

• Can exceed $1,000/ton for some waste

• Treatment adds significant cost

Spent Catalysts:

• May have positive value (metal recovery)

• Or disposal cost if no recovery

• FCC catalyst: Often $0-$200/ton

• Precious metal catalyst: CREDIT (payment to you)

• Hydrocracking catalyst: Often credit or low cost

Oily Waste (non-K-listed):

• Characteristic ignitable waste

• $100-$400 per ton

• Depends on oil content and contamination

Spent Acids/Caustics:

• $200-$600 per ton

• Depends on concentration and contaminants

• Neutralization costs if not done on-site

Contaminated Soil:

• $50-$300 per ton

• Depends on contamination level

• Treatment method affects cost

• Thermal treatment more expensive

Wastewater Treatment Sludge:

• $100-$400 per ton

• If hazardous

• Non-hazardous much less expensive

Maintenance Waste:

• Varies by type

• $150-$500 per drum typical

• Contaminated materials: $200-$600 per drum

Turnaround Waste:

• Project-based pricing

• Often $50,000-$500,000+ per turnaround

• Depends on unit size and waste quantity

Annual Refinery Waste Disposal:

• Small refinery: $200,000-$1,000,000/year

• Medium refinery: $1,000,000-$5,000,000/year

• Large refinery: $5,000,000-$20,000,000+/year

Note: Refinery waste disposal is a major operating expense. We work to optimize costs while maintaining compliance.

Call (800) 582-4833 for customized pricing for your refinery

Waste Minimization for Refineries

Source Reduction

Reduce waste generation:

• Process optimization

• Better crude selection

• Equipment upgrades

• Improved maintenance

• Leak reduction

• Spill prevention

Catalyst Management

Extend catalyst life:

• Proper operation

• Guard beds to protect catalysts

• Catalyst regeneration

• Optimal changeout timing

• Reduces replacement frequency

Waste Segregation

Keep streams separate:

• Segregate K-listed from non-K-listed

• Separate recyclable materials

• Don't contaminate non-hazardous streams

• Clean oils separate from contaminated

• Reduces overall disposal costs

Beneficial Reuse

Where possible:

• Use as fuel (with permits)

• Road oil (some materials)

• Asphalt manufacturing

• Other approved beneficial uses

• Reduces disposal quantity

On-Site Treatment

Treat waste at refinery:

• Caustic oxidation

• Neutralization

• Oil-water separation

• Biological treatment

• Reduces off-site disposal volume

Catalyst Metal Recovery

Maximize recovery:

• Send all catalysts to recovery

• Don't dispose of valuable materials

• Can generate revenue or offset costs

• Environmental benefit

Common Oil Refinery Scenarios

Medium Refinery - Regular Service

A 100,000 barrel/day refinery generates continuous API sludge, DAF float, maintenance waste, and laboratory waste. We provide weekly pickup of containerized waste and monthly bulk removal of K-listed sludges.

Monthly average: 200 tons K-listed waste, plus maintenance waste
Monthly cost: $80,000-$200,000

Refinery Turnaround

A 150,000 barrel/day refinery performs turnaround on FCC unit and related equipment. We provide comprehensive waste removal including spent catalyst, heat exchanger cleaning sludge, coke, scale, and maintenance waste over 6-week shutdown.

Total turnaround waste: 500-1,500 tons
Project cost: $250,000-$800,000

Catalyst Changeout

A refinery is changing out hydrocracking catalyst (300 tons). We coordinate catalyst removal, packaging, transportation to metal recovery facility, and processing. Cobalt and molybdenum recovery generates credit.

Catalyst quantity: 300 tons
Net cost: $0-$30,000 (or may receive payment after metal recovery)

Tank Farm Cleanup

A refinery is cleaning 10 large crude oil storage tanks, generating 800 tons of tank bottoms and sludge. We coordinate tank cleaning contractor, provide disposal of residues, and complete all documentation.

Total project: 800 tons
Project cost: $150,000-$400,000

Small Refinery Annual Service

A 30,000 barrel/day refinery generates limited waste - primarily maintenance materials, lab waste, and some process waste. We provide monthly pickup service.

Annual waste: ~100 tons
Annual cost: $150,000-$400,000

Why Oil Refineries Choose Us

Refinery Industry Expertise

Over 30 years serving petroleum refineries. We understand your processes, waste streams, and regulatory requirements.

K-Listed Waste Specialists

Complete understanding of refinery-specific K-codes, LDR requirements, and proper disposal pathways.

Large-Scale Capabilities

Equipment and capacity to handle refinery waste volumes. Bulk tankers, roll-offs, and specialized equipment.

Turnaround Support

Experienced in supporting major turnarounds with intensive waste removal during critical shutdowns.

Regulatory Compliance

Full RCRA, LDR, and DOT compliance. Complete manifesting and documentation for your records and audits.

Catalyst Recovery Coordination

Maximize value from spent catalysts through metal recovery programs. Turn waste into revenue.

Reliable Service

Dependable scheduled service and responsive emergency response. We understand refineries run 24/7.

Cost Optimization

We work to minimize disposal costs through proper segregation, beneficial reuse, and efficient logistics.

Safety Focus

Safety-oriented operations compatible with refinery requirements. We follow your site safety protocols.

Best Practices for Refinery Waste Management

Waste Characterization

• Proper initial characterization

• Regular testing programs

• Generator knowledge documentation

• TCLP and LDR testing as required

• Accurate waste code determination

Segregation

• Keep K-listed separate from other waste

• Separate recyclable catalysts

• Don't mix waste unnecessarily

• Maintain clean waste streams

• Reduces disposal costs

Accumulation Management

• Don't exceed 90-day limit

• Date all containers

• Weekly inspections

• Proper labeling

• Satellite accumulation procedures

Personnel Training

• Annual RCRA training for all involved staff

• Job-specific training

• Emergency procedures

• Waste handling and segregation

• DOT training for shippers

Record Keeping

• Maintain all manifests (3+ years)

• Exception reports

• Testing results

• Training records

• Inspection logs

• Annual reports

• LDR notifications and certifications

Emergency Preparedness

• Spill response procedures

• Emergency equipment

• Coordination with local responders

• Contingency plans

• Regular drills

Waste Minimization

• Document waste minimization efforts

• Certify on manifests

• Implement reduction programs

• Track progress

• Required for LQGs

Getting Started

Initial Assessment

We'll evaluate:

• Current waste streams and quantities

• K-listed vs. characteristic wastes

• Existing disposal practices

• Catalyst recovery opportunities

• Compliance status

• Cost reduction opportunities

Service Setup

We provide:

• Appropriate containers and equipment

• Proper labeling materials

• Manifesting procedures

• Service schedules

• Emergency contact information

• Training support materials

Ongoing Partnership

We work with your teams:

• Environmental department

• Operations personnel

• Maintenance department

• Laboratory staff

• Safety department

• Management

• Contractors during turnarounds

Get Started with Refinery Waste Services

Call (800) 582-4833 or email info@hazardouswastedisposal.com

What to have ready:

• Refinery name and location

• Barrel/day capacity

• Processing units present

• Types of waste generated

• Approximate monthly/annual quantities

• K-listed waste volumes

• Current disposal practices

• Turnaround schedule

• Any special concerns

We'll provide:

• Free consultation and assessment

• Customized service plan

• Competitive pricing

• Equipment recommendations

• Catalyst recovery evaluation

• Written proposal

• Service agreement

• Turnaround planning support

Services available:

• Regular scheduled pickup

• Bulk waste management

• Spent catalyst management

• Tank cleaning support

• K-listed waste disposal

• Spent acid and caustic management

• Turnaround support

• Contaminated soil management

• Laboratory waste disposal

• Emergency response

• Waste characterization

• Regulatory consulting

• Multi-unit service

• Annual contract pricing

Serving oil refineries nationwide, since 1992 - comprehensive waste management services that keep your refinery compliant and operating efficiently

Expert refinery waste management - we understand your complex operations and regulatory requirements