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Comparative Life Cycle Assesment of Traditional and Emerging Oily Sludge Treatment Approaches
Comparative Life Cycle Assesment of Traditional and Emerging Oily Sludge Treatment Approaches
Guangji Hu, Haibo Feng, Pengwei He, Jianbing Li, Kasun Hewage, Rehan Sadiq
PII: S0959-6526(19)34464-6
DOI: https://doi.org/10.1016/j.jclepro.2019.119594
Reference: JCLP 119594
Please cite this article as: Hu G, Feng H, He P, Li J, Hewage K, Sadiq R, Comparative life-cycle
assessment of traditional and emerging oily sludge treatment approaches, Journal of Cleaner Production
(2020), doi: https://doi.org/10.1016/j.jclepro.2019.119594.
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approaches
Guangji Hu1, Haibo Feng1, Pengwei He1,2, Jianbing Li3*, Kasun Hewage1, Rehan Sadiq1**
1
School of Engineering, University of British Columbia, Okanagan, 3333 University Way,
Kelowna, BC V1V 1V7, Canada
2
School of Business, Central South University, Changsha, Hunan, 410083, PR China
3
Environmental Engineering Program, University of Northern British Columbia, 3333
University Way, Prince George, BC V2N 4Z9, Canada
*Corresponding Author:
Dr. Jianbing Li, Professor, P. Eng.
Environmental Engineering Program
University of Northern British Columbia
3333 University Way, Prince George
British Columbia, Canada V2N 4Z9
Tel: 1-(250) 960-6397
Email: Jianbing.Li@unbc.ca
**Corresponding Author:
Dr. Rehan Sadiq, Professor, P. Eng.
School of Engineering
University of British Columbia, Okanagan
3333 University Way, Kelowna
British Columbia, Canada V1V 1V7
Tel: 1-(250) 807-9013
E-mail: rehan.sadiq@ubc.ca
1
Abstract
This study presents a comparative life cycle assessment (LCA) of traditional and emerging
treatment approaches for hazardous refinery oily sludge handling. Two traditional oily sludge
disposal approaches, including incineration and landfilling, and two emerging energy recovery
approaches, including solvent extraction and pyrolysis, were investigated. Life cycle inventories
listing all energy and material flows were established for the two emerging treatment approaches,
and the life cycle environmental impacts were assessed by following the International
Organization for Standardization (ISO) 14040 procedure. The TRACI 2.1 method and Ecoinvent
3 database were used in the LCA. The results show that the two emerging energy recovery
approaches only account for < 10% of the total impacts posed by the traditional alternatives.
Traditional oily sludge treatment approaches are generally associated with relatively high global
warming potential, ecotoxicity, and adverse human health effects. Solvent extraction has the
lowest total effect on the environment, and the main adverse effects are related to ecotoxicity and
fossil fuel depletion. In solvent extraction treatment, vacuum distillation and combustion of
recovered oil account for the main impacts. In pyrolysis treatment, processes such as drying,
pyrolysis, and combustion of pyrolysis products are the main contributors to the total impact.
The energy recovery processes used in the two emerging approaches can significantly offset the
total adverse impacts. The two energy recovery approaches have great potential to be used for
Keywords
Life cycle assessment (LCA); oily sludge; incineration; landfilling; solvent extraction; pyrolysis
2
1. Introduction
have been consumed and wastes have been generated (Cossu and William, 2015; He et al.,
2018). As an effective solution to the adverse impacts from natural resources depletion and waste
disposal, urban mining involves reclaiming compounds and elements from any kind of
receiving anthropogenic emissions (Lederer et al., 2014). Urban mining has also been
successfully applied to extract useful resources from municipal wastes (e.g., sewage sludge) and
industrial wastes (e.g., spent adsorbents and catalysts) (Cossu and William, 2015).
Oily sludge is an industrial waste generated from various petrochemical production processes
such as crude oil exploration, transportation, storage, and refining (Roldán et al., 2012). It is
estimated that a medium-sized refinery (refining capacity: 12,000 to 15,000 m3/d) generates
30,000 tons of oily sludge annually. The sludge generation quantity has been increasing because
of the ascending energy demand worldwide (Hu et al., 2013; EPA, 1991). Oily sludge generally
exists as a complex mixture of various petroleum hydrocarbons (PHCs, or oil), water, metals,
and solid particles (Hu et al., 2013). It has been classified as a hazardous waste in both developed
and developing countries due to the presence of harmful substances such as carcinogenic
polycyclic aromatic hydrocarbons and toxic heavy metals (Naik et al., 2011). Owing to its large
generation quantity and toxic nature, the effective management of oily sludge has become a
Over the past decade, significant efforts have been made in developing innovative oily
increasing public concerns over the adverse environmental impacts posed by traditional oily
3
sludge disposal approaches (Chirwa et al., 2013; Hu et al., 2015). Traditional oily sludge
disposal approaches, such as incineration, landfarming, and landfilling, are associated with
several limitations such as high treatment cost and environmental risks. For example,
incineration requires the use of auxiliary fossil fuels to maintain the desired combustion
temperature and generates undesirable fugitive gaseous emissions and hazardous ash residues
(Gong et al., 2018; Liu et al., 2009); landfarming and landfilling represent important pathways
for the release of contaminants such as leachate and landfill gas to the environment (Cao and
Pawlowski, 2012).
Oily sludge can be a potential energy source considering its large production quantity and
high PHCs content (e.g., 30-50%) (da Silva et al., 2012). Energy recovery has been receiving
extensive research interests in recent years because this approach can not only recover valuable
resource but also mitigate the adverse environmental impacts by reducing the disposal volume of
oily sludge and contents of harmful PHCs. In the past decade, innovative technologies such as
enhanced oil recovery and their combinations have been developed for oily sludge treatment (Hu
et al., 2013; da Silva et al., 2012). These developed technologies are associated with different
Prior to the adoption of innovative technologies and smart oily sludge waste management
strategies, the long-term impacts of related activities on public health, economy, and the
environment must be estimated. The selection of appropriate waste treatment strategies is of vital
importance and complexity that not only requires performance data but also assessment within
4
assessment framework is essential for selecting, building, or offering products and processes that
balance the environment, economic costs, and human health (Guinée et al., 2011).
Among various sustainability assessment frameworks and tools, life cycle assessment (LCA)
environmental burdens of a product or process from its origin to the final disposal. In LCA, the
inputs and outputs to a system, including energy, materials, products, wastes, and pollutants, are
identified and quantified (Gentil et al., 2010). LCA has been widely used to evaluate the
environmental impacts of various waste (e.g., sewage sludge, municipal waste, and wastewater)
management practices (Mills et al., 2014; Reza et al., 2013; Vlasopoulos et al., 2006). For
example, Li and Feng (2018) investigated the life cycle impacts of an integrated anaerobic
digestion and pyrolysis approach for sewage sludge treatment, and the results showed that the
integrated approach had better environmental performance than the individual treatments.
Abuşoğlu et al. (2017) compared the life cycle impacts from digested sewage sludge incineration
using a fluidized bed combustor and a cement kiln, and they found that using the fluidized bed
combustor generated lower environmental impacts than using the cement kiln. The majority of
LCA studies on waste management practices have focused on the environmental loads from
scenarios, while others focused on assessing the influence of system boundaries and scale
Although the LCA methodology has been widely used in evaluating the environmental
strategies, limited attention has been paid to the life cycle environmental impacts of different oily
sludge treatment practices. Specifically, a significant knowledge gap exists regarding the
5
difference in environmental load or energy consumption between traditional and emerging oily
sludge treatment approaches. The environmental benefits of using emerging technologies are
debatable depending on many aspects, including energy recovery performance, resource and
management inputs, and impact outputs. As these influential aspects differ significantly from one
scenario to another, the environmental impacts associated with different treatment approaches
can also be highly variable, resulting in high uncertainties in adopting new oily sludge treatment
technologies.
As the first attempt to fill this knowledge gap, this study holistically quantified and compared
the life cycle environmental impacts of four different oily sludge treatment approaches, including
two emerging energy recovery approaches (i.e., solvent extraction and pyrolysis) and two
traditional alternatives (i.e., incineration and landfilling). The assessment began with oily sludge
generation from a petrochemical refinery through different treatments and ended with the final
the processes involved in the two emerging treatment approaches were analyzed. The results
would provide the critical oil and gas sector with useful information in selecting suitable
2.1. Incineration
with excess air and auxiliary fuels. Since oily sludge contains a relatively high water content, a
dewatering treatment is often required before incineration, while auxiliary fuels such as coal are
often used to increase the heat generated from the incineration process. The combustion
6
temperature is often > 1000 °C for complete decomposition of complex PHCs. Fluidized bed
incinerator is commonly used for oily sludge incineration owing to low pollutant emission and
high combustion efficiency compared to rotary kilns (Liu et al., 2009; Abuşoğlu et al., 2017).
Under optimum conditions, a combustion efficiency as high as 95% can be achieved by oily
sludge incineration (Bhattacharyya and Shekdar, 2002). However, the hazardous ash residues
and gaseous emissions need to be treated and properly handled for safe disposal (Gong et al.,
2018).
2.2. Landfilling
Land disposal is the ultimate destination for most hazardous wastes, although it is not an
involves the mixing of oily sludge with soil, and then the mixture is placed in a secure landfill
for natural attenuation. This technology isolates sludge wastes from air and water through the use
of thick layers of impermeable clay and synthetic materials. A leachate collection system
consists of a network of perforated pipes above the bottom liners is also used to prevent
groundwater contamination (Mishra et al., 2017). Biological activity usually accounts for most of
the degradation of PHCs, although this degradation process is considerably slow (e.g., > 12
months in cold regions). A groundwater monitoring system that includes a series of deep wells
drilled in and around the landfilling site is also required. The wells allow a routine program of
sampling and testing to detect any leaks or groundwater contamination (Mishra et al., 2017).
In solvent extraction, oily sludge is mixed with suitable organic solvents at desirable ratios
to ensure that solvents can extract most PHCs in oily sludge. Water and solid impurities are not
miscible with the solvents, which can be separated by gravitational force or centrifugation (Hu et
7
al., 2013). Mechanical agitation is often used to facilitate the extraction process. The solvent/oil
mixture is then sent for vacuum distillation to separate oil from the solvent. The recovered oil
can be used for energy recovery and solvents can be reused for repeating the extraction cycle.
The separated water and solids need to be properly handled for safe disposal. Methyl ethyl
ketone (MEK) has been reported to be a suitable organic solvent for extracting oil from oily
sludge due to the relatively low cost and toxicity. MEK can extract approximately 33-39 w.t.%
of oil from oily sludge through mechanically assisted extractions (Hu et al., 2016; Zubaidy and
Abouelnasr, 2010), while the recovered oil has good quality in terms of the total PHCs and water
content compared to fresh crude feedstock. Hu et al. (2016) reported an optimum solvent-to-
sludge mixing ratio of 3:1 for energy recovery from oily sludge. In a closed extraction system,
roughly 95 w.t.% of the solvent can be recovered (Hu et al., 2016; Zubaidy and Abouelnasr,
2010).
2.4. Pyrolysis
Pyrolysis is the thermal-chemical conversion process that turns organic materials in oily
sludge into pyrolysis oil, gaseous products, and solid char in an oxygen-free environment. Since
pyrolysis is an endothermic process, the products from this process have a higher total heating
value than the original oily sludge. About 33 w.t.% of pyrolysis oil, 14 w.t.% of solid char, and
53 w.t.% of gaseous products can be produced from oily sludge pyrolysis between the
temperature range of 450-500 °C (Hu et al., 2017; Qin et al., 2015). The resultant pyrolysis oil
has a similar physical property and element composition to heavy fuel oil. The gaseous products
generally include 50 w.t.% of CO2, 6 w.t.% of CO, 18 w.t.% of H2O, and 25 w.t.% of non-
condensable hydrocarbon gases such as methane, ethane, and hydrogen sulfide (Chang et al.,
2000). Non-condensable hydrocarbon gases and CO are combustible for energy recovery.
8
Pyrolysis oil and combustible gaseous products can be used as energy sources, while the solid
char can be used for soil conditioning (Chen et al., 2014). Unlike incineration, pyrolysis of oily
sludge generates lower emissions of NOX and SOX (Qin et al., 2015). However, this approach
requires the dewatering of oily sludge before the thermal-chemical conversion treatment.
3. Methodology
In this study, the ISO 14040 standard was followed to conduct the LCAs of different oily
sludge treatment approaches. The goal and scope definition, life cycle inventory (LCI), life cycle
impact assessment (LCIA) method, and result interpretation are presented in the following
The goal of LCA was to assess the environmental performances of two emerging energy
recovery approaches for oily sludge treatment (i.e. solvent extraction and pyrolysis) and to
compare with those of two traditional oily sludge treatment approaches. The quantified life cycle
environmental impacts can provide practitioners with a holistic view of the environmental
performances of different oily sludge treatment systems, enabling them to identify suitable
treatment approaches that have low environmental impacts throughout their life cycle as well as
the limitations of each approach in different processing stages for potential improvement.
In this study, the functional unit was defined as treatment and/or disposal of 1000 kg of oily
sludge. The composition of oily sludge was determined based on the analysis of samples taken at
the American Petroleum Institute (API) oil-water separator of a refinery in Western Canada. The
9
oily sludge sample roughly consists of 50% of water, 30% of oil, and 20% of solids and has a
density of 0.97 kg/L (Hu et al., 2016; 2017). The oily sludge was assumed to be treated through
the four aforementioned approaches. The material and energy flows of each approach were used
as input data for the LCIA, and the quantified environmental impacts were the outputs from the
assessments. All input and output data were adapted to the functional unit.
The second step of LCA was to define the system boundaries of each approach as shown in
Fig. 1. The system boundaries included all the processes taking place from the beginning of oily
sludge treatment in the proposed treatment facilities to the final landfill of treatment residuals. In
most LCA studies on waste management practices, the environmental impacts of treatment
infrastructure were not considered due to their large throughput and long service life (Li and
Feng, 2018; Ramachandran et al., 2017; Sebastião et al., 2016). In this study, the environmental
approaches. Thus, the impacts of treatment infrastructure were considered negligible and not
included. Also, the time period of LCA was not considered because the goal of this study is to
quantify the total impacts from treatments of one ton of oily sludge using different approaches
rather than to estimate the total life cycle impacts within a time range.
==========================
==========================
10
3.2. Life cycle inventory
Data required as inputs for each approach were mainly obtained from experimental
investigations and literature reviews. In addition, inventory data for the chemicals, heat, and
electricity requirements in different treatment approaches were collected from the Ecoinvent 3.3-
unit process database in SimaProTM 8.3.0.0. The inventories established for the four oily sludge
treatment approaches was presented in the following sections, and the detailed material flows of
the two emerging oily sludge treatment approaches can also be found in the supplementary file.
3.2.1 Incineration
The inventory data of oily sludge incineration was obtained from the Ecoinvent 3.3
database. Since the refinery sludge mentioned in the database has a higher water content (88.8%)
than that of the oily sludge (50%) investigated in this study, the input mass of refinery sludge
needs to be modified. The element composition of the dried refinery sludge in the database is
calculated as 13% of hydrogen, 84% of carbon, and 3% of oxygen, sulfur, phosphorus, and
nitrogen; while the dried API water-oil separator oily sludge in this study contains 17.6% of
hydrogen, 78% of carbon, and 3.4% of other elements (Hu et al., 2017). The percentages of
PHCs, which mainly consist of hydrogen and carbon, in the two types of oily sludge can be
considered similar. Assuming the chemical compositions of the two types of oily sludge are
Mos × (1−Wos )
Mrs = (1)
(1 −Wrs )
where Mrs and Wrs are the mass and water content of the refinery sludge input in the Ecoinvent
database, respectively, and Mos and Wos are the mass and water content of the oily sludge
11
investigated in this study, respectively. It was calculated that the PHC content of one functional
unit (i.e., 1000 kg) of oily sludge investigated in this study is equivalent to that of 4465 kg of
refinery sludge recorded in the Ecoinvent database. The water content of oily sludge is reduced
to 10% before incineration using a sludge paddle dryer. The material and energy consumptions
of the sludge paddle dryer are provided in Section 3.2.4. Since the refinery sludge has a higher
water content than the oily sludge, the impacts from the removal of excessive amount of water
(3465 kg) in the refinery sludge were subtracted from the calculated impacts from incineration of
4465 kg of the refinery sludge, and the resultant values were presented as the impacts of
incineration process.
The lower heating value (LHV) of refinery sludge described in the Ecoinvent database is
2.45 MJ/kg. The energy recovery process involves converting the heat energy produced from
incineration of 500 kg of dried oily sludge to electricity to counteract the electricity consumption
in the incineration process. The incineration plant is equipped with air and waste emission
treatment units such as the wet flue gas scrubber and low-dust selective catalytic reduction
(SCR) DeNOx facility. Thus, the impacts of treatment of air emissions are included in the total
impacts of the incineration process. After incineration, about 10 w.t.% of the original oily sludge
is left as ash residuals, which need to be disposed of in a secure landfill (HKEPD, 2018).
3.2.2 Landfilling
The inventory data of oily sludge landfilling was also obtained from the Ecoinvent 3.3
database. The environmental data of treating 1000 kg of oily sludge under “waste treatment”
category in the Ecoinvent database was chosen. The landfill described in the Ecoinvent database
includes base seal, landfill gas and leachate collection system, and treatment of leachate in a
12
municipal wastewater treatment plant. The main environmental impacts of landfilling are related
As shown in Fig. 1, solvent extraction begins with mixing oily sludge with a suitable
organic solvent in an extraction tank (i.e., the extraction process). MEK is selected as the
extraction solvent. The extraction tank is equipped with a paddle agitator with a power of 2.2 kW
to facilitate the mixing of oil and solvent, and its capacity is chosen as 5000 L (BLS, 2018). Oily
sludge and MEK is mixed at a mass ratio of 1:3, and the extraction time is set at 0.5 hours per
batch to ensure that the oil is completely miscible with the solvent (Hu et al., 2016).
After mixing, the extraction mixture is transferred to a sludge decanter centrifuge (41 kW)
with a capacity of 8000 L/h for liquid-solid separation (Fuyi, 2018). Solids can be removed from
the extraction mixture by centrifugation, and about 90% of the liquid consisting of water, oil, and
solvent can be recovered. The liquid loss (10%) is mainly water due to the fact that water has a
higher density than the solvent/oil mixture. The liquid with a higher density is accumulated at the
bottom of the centrifuge, and thus it is prone to be removed along with the solid. The separated
solids (200 kg) contain 2% of PHCs, which are mainly asphaltenes that are not miscible with
MEK (Hu et al., 2016). Thus, the solid residuals containing asphaltenes need to be disposed of in
a secure landfill. The inventory data of landfilling of asphaltenes waste in the Ecoinvent database
The recovered liquid is transferred to a continuous flow water-oil centrifuge (3 kW) for
further water-oil/solvent mixture separation. The liquid flow rate into the water-oil centrifuge is
3000 kg/h (Zonelink, 2018). The separated water (500 kg) is treated in a WWTP, and the
standard inventory data of industrial wastewater treatment in the Ecoinvent database was used as
13
a reference. The separation of liquid and solids and the separation of water and oil-solvent
mixture are collectively called the water-oil separation process, and the transportation and
disposal of the solid residuals and wastewater are collectively called the waste disposal process.
The mixture of oil and solvent (3300 kg) separated from the liquid is sent to a vacuum
distillation unit (30 kW with a working capacity of 300 L/h) for the separation of oil and solvent
(Vbolt, 2018). Since the distillation unit is a closed system, as high as 93% of MEK can be
recovered (Vbolt, 2018). The recovered solvent can be reused in the next extraction cycle.
Therefore, the environmental impact of replenishing the MEK loss (7%) was considered in the
assessment. The remaining liquid in the distillation unit is recovered oil. Roughly 300 kg of
recovered oil can be generated from the extraction treatment of 1000 kg of oily sludge. The
recovered oil mainly consists of 47% of PHCs with a carbon chain length between C10-C16
(similar to diesel), 50% of PHCs with a carbon chain length between C16-C34 (similar to heavy
fuel oil), and 3% of asphaltene impurities (Hu et al., 2016). Since the chemical composition of
the recovered oil is similar to the mixture of diesel and heavy fuel oil, the inventory data for
combustion of diesel and heavy fuel oil were used to calculate the impact of recovered oil
combustion. The LHV of the recovered oil is 40.26 MJ/kg (Hu et al., 2016).
The heat generated from the combustion of recovered oil is used for generating electricity.
According to the estimation by the US Department of Energy, the efficiency of a large fuel
generator that converts fuel into electricity lies between 45-50% (Edwards et al., 2011). In this
study, the lower efficiency (i.e., 45%) was chosen to convert the total heating value from the
combustion of recovered oil into grid electricity. The impacts of generating the same amount of
grid electricity using natural gas were calculated as the offsets to the total impacts of oily sludge
14
treatment. All the materials, energy, and waste involved in the solvent extraction approach are
summarized in Table 1.
==========================
==========================
3.2.4 Pyrolysis
As shown in Fig. 1, pyrolysis treatment starts with the drying process. A sludge paddle dryer
with a treatment capacity of 1.85 m3/h and working power of 11 kW is used to dewater the oily
sludge (Dingli, 2018). The water content in oily sludge is reduced to 10%. The sludge paddle
dryer uses steam (130 °C) as the heating medium to reduce the loss of volatile PHCs, which is
suitable for drying heat-sensitive materials. About 1.2 kg of steam is required to dry 1 kg of oily
sludge (Dingli, 2018). The inventory data of steam generation using natural gas is collected from
the Ecoinvent database. After the drying process, roughly 556 kg of dried oily sludge remains
After dewatering, the dried oily sludge is pyrolyzed at 500 °C to produce pyrolysis oil (py-
oil) and pyrolysis gas (py-gas). Solid residuals are generated as the by-products of this treatment
approach. The pyrolysis process is conducted in a pyrolysis reactor (60 kW, 30 ton/day)
combined with a py-gas combustion unit (Jinpeng, 2018). About 100 m3 of natural gas and 200
kg of heavy fuel oil are required to generate heat to reach the desired pyrolysis temperature
(Jinpeng, 2018). The py-gas produced during the pyrolysis process is combusted in the py-gas
combustion unit to maintain the temperature of the pyrolysis reactor. About 228 kg of py-gas
15
(roughly 1/2 of the dried oily sludge weight) and 185 kg of py-oil (1/3 of the dried oily sludge
weight) can be produced from the pyrolysis of 556 kg of dried oil sludge (Hu et al., 2017).
The impacts of py-gas combustion were calculated based on the pyrolysis gas combustion
data from the Ecoinvent database. The obtained py-oil has an LHV of 45.65 MJ/kg, which can be
combusted for energy recovery (Hu et al., 2017). The inventory data of heavy fuel oil
combustion from the Ecoinvent database was used to simulate that of combustion of py-oil due
to their similar chemical compositions and physical properties (Hu et al., 2017). The impact
offsets by energy recovery process were calculated following the same method used for solvent
extraction approach. The solid by-products from the pyrolysis process can be used as a soil
conditioner, and thus the environmental impact was considered negligible (Chen et al., 2014).
All the materials, energy, and waste involved in the oily sludge pyrolysis treatment are listed in
Table 2.
==========================
==========================
3.2.5 Transportation
A hazardous waste treatment facility in Western Canada was selected to landfill the solid
wastes generated from the four treatment approaches. The distance from the refinery to the
landfill is approximately 530 km, and long-haul transport trucks were selected for waste
transport. The environmental impacts of truck transportation were considered in the LCAs, and
16
In terms of the incineration treatment, the incineration facility was assumed to be built
beside the petroleum refinery. Therefore, only the environmental impacts posed by the
transportation of ash residuals (100 kg) to the landfill was considered. In the landfilling treatment
approach, untreated oily sludge is directly transported to the landfill. In the solvent extraction
approach, 200 kg of solid residuals and 500 kg of wastewater generated from the treatment of
1000 kg of oily sludge require proper disposal. The solid residuals are delivered to the landfill by
trucks powered by diesel engines, and the environmental impacts of truck transportation are
included in the life cycle. Wastewater is transported through pipelines to a WWTP for safe
disposal, and the wastewater treatment data in the Ecoinvent database was used to calculate the
SimaPro 8.3.0.0TM was used together with the TRACI impact assessment method to
calculate the following impacts: ozone depletion potential (ODP), global warming potential
potential (EP), carcinogenic effects (CAR), non-carcinogenic effects (NCAR), respiratory effects
(RE), ecotoxicity (ECT), and fossil fuel depletion (FFD). In order to calculate the total
environmental impacts of each approach and compare the overall performance of the four
treatment approaches, normalization factors were applied to each impact category. The
ISi
Ni = (2)
NFi
where Ni is the normalized impact score for impact category i, ISi is the impact score of a
process/approach earned on impact category i, and NFi is the normalization factor (impact capita-
17
1
year -1). As shown in Table 3, the normalization factors for North America LCA studies were
used to calculate the overall performance of each treatment approach (Ryberg et al., 2014). The
total life cycle environmental impact was determined by aggregating the normalized impact
scores.
==========================
==========================
The life cycle environmental impacts generated from the four oily sludge treatment
approaches are presented in ten categories. The impact scores for different impact categories
were converted to logarithm values for results presentation as the scores are determined at
different magnitudes. A lower logarithm value indicates a lower impact, on a ten-fold scale. The
heat generated from the energy recovery process is used to generate electricity, and this can
offset the environmental impacts posed by generating the same amount of electricity using
natural gas. Thus, the impact scores for energy recovery were calculated in negative values. The
absolute values of impact scores for energy recovery were used in the logarithm conversion, and
a higher value indicates a higher impact offset. The normalized total impacts of the four
treatment approaches were compared, and the key processes and substances contributing most
4.1. Incineration
The life cycle environmental impacts of oily sludge incineration are shown in Fig. 2. As can
be seen, the corresponding impact comprises three parts: the impact from oily sludge
18
incineration, the impact from solid residuals transportation and disposal, and the impact offset
from energy recovery. Particularly, the incineration process accounts for almost all of the
impacts in different categories. For example, 12.0 ton of CO2-eq, 49.0 kg of SO2-eq, and 32.0 kg
of N-eq emissions are released into the atmosphere from the incineration of 1000 kg of oil
sludge, and only 5 kg of CO2-eq, 0.03 kg of SO2-eq, and 0.03 kg of N-eq emissions are generated
from the transportation and disposal of ash residuals. It has been reported that the main gas
emissions from oily sludge incineration include CO2, SO2, and NOx (Liu et al., 2009). In this
study, about 90% of the GWP impact is contributed by CO2 from the incineration process, while
NOx and ethene emissions account for 96% and 3% of the SM impact from the incineration
process, respectively. NOX emissions are also responsible for 14% of the impact in terms of AP,
whereas SO2 is the dominant contributor (82%) to this impact category. The amount of SO2 and
NOx emissions can be reduced by the wet flue gas scrubber and the low-dust SCR DeNOx
facility, respectively. The relatively high emission of CO2-eq and fugitive emission of SO2-eq
result in high impact scores for categories such as GWP and AP. On the other hand, oily sludge
incineration generates heat for producing electricity, which offsets the total adverse
environmental impacts. About 1366 kWh of grid electricity can be generated using the recovered
heat energy from the incineration of 1 ton of oily sludge. However, the impact offsets by energy
recovery are much less than the total adverse impacts of the incineration process. Among the
three main processes, transportation and disposal of incineration by-products to the disposal
The oily sludge incineration approach has significant impacts on several impact categories,
such as GWP, ECT, FFD, and SM. This is because auxiliary fossil fuels are required for the
19
complete combustion of oily sludge. The FFD impact is mainly due to the consumption of crude
oil (66%), coal (18%), and natural gas (16%) during the incineration. The combustion of
auxiliary fossil fuels and organic-rich sludge at high temperatures could generate a relatively
large amount of GHG, SO2, and NOx emissions, resulting in high impact scores in these
emission-related impact categories (Abuşoğlu et al., 2017). The emissions of PM2.5 (47%) and
SO2 (41%) are the dominant contributors to the RE effect. Potential water contamination by the
metals from the incineration process such as zinc, nickel, and vanadium are responsible for the
high ECT impact. However, the incineration approach is associated with relatively low ODP,
CAR, and NCAR impacts since most of the toxic emissions will be treated before releasing into
the environment. The ODP, CAR, and NCAR effects are mainly due to emissions of
bromofluoromethane to air (> 95%), chromium (VI) to water (90%), and various metals (e.g.,
==========================
==========================
4.2. Landfilling
The life cycle environmental impacts resulting from the landfilling approach are shown in
Fig. 3. The impacts of landfilling treatment approach can be divided into two parts: the impacts
from the transportation of oily sludge from the refinery to the landfill and the impacts from the
landfilling process. In this treatment approach, the landfilling process is associated with the most
significant impacts in terms of GWP and ECT. Roughly 648 kg of CO2-eq emissions are released
20
from the landfilling process, which accounts for 93% of the total GWP impact. The GWP impact
is mainly due to methane (77%) and CO2 (23%) emissions. It has been reported that fugitive
gaseous products (e.g., CO2, CH4) released from aerobic and anaerobic biodegradation of PHCs
in oily sludge are the main contributors to the GWP effect (Hejazi et al., 2003). More critically,
about 4.02 × 104 CTUe of ECT are released to the environment from the landfilling process,
accounting for 99% of the total ECT impact. The ECT impact could be a result of the potential
soil and groundwater contamination by the leachate containing toxic polycyclic aromatic
hydrocarbons and heavy metals (Karamalidis and Voudrias, 2007). In this study, the ECT impact
is mainly due to the potential water contamination by heavy metals such as zinc (79%), copper
The impacts on FFD, ODP, and SM are mainly due to the transportation of oily sludge from
the refinery to the landfill. The FFD and ODP impacts result from the consumption of fossil fuel
in form of crude oil (> 85%) and emission of bromotrifluoromethane (92%), respectively. Diesel
is used by transportation trucks as the fuel, and the combustion of diesel could generate a high
amount of undesirable NOX emissions, which are contaminants responsible for SM (Gilbert et
al., 2018). It is found that the NOX emission accounts for all the SM impact from the
transportation process in the landfilling treatment approach. Hence, the transportation method is
an important contributor to the total impact of the landfilling approach when the distance
between the refinery and landfill is long. Since the landfilling does not contain any energy
==========================
21
==========================
approach are shown in Fig. 4. In this approach, the extraction, water-oil separation, vacuum
distillation, recovered oil combustion, and waste disposal processes generate adverse impacts on
the environment. The extraction process is associated with the lowest impact in each impact
category. Significant adverse impacts are generated from the vacuum distillation, recovered oil
combustion, and waste disposal processes. Moreover, a large portion of adverse impacts can be
The extraction process only generates < 1% of the total impact for all impact categories
since the extraction tank is the only equipment that requires energy input and generates impacts
on the environment. The water-oil separation process also has a low contribution to the total
impact, although the impact scores are much higher than those of the extraction process. In
contrast, the vacuum distillation process has a significant contribution to the total life cycle
impacts. For example, 3.3 × 10-5 kg CFC-11 eq of ODP is generated from this process,
accounting for nearly 90% of the total impact score value. The ODP impact is primarily due to
dichloroethane (4%), and various chloromethanes (4%). This process also generates 0.23 kg
PM2.5- eq of RE, which accounts for more than 70% of the total value. The RE effect is mainly a
result of emissions of PM2.5 (66%), SO2 (25%), and particles (Ø > 2.5 µm) (7%). Additionally,
about 68% of EP impact is generated from the vacuum distillation process, which is equivalent to
0.81 kg of N eq emissions. Phosphate (55%), COD (20%), and BOD5 (20%) are the main
22
substances responsible for the EP impact. The environmental impact from the vacuum
distillation process is mainly due to the relatively high electricity consumption and MEK solvent
loss, and replenishing the loss of MEK has a much higher adverse impact than the electricity
consumption.
The process of recovered oil combustion also generates high impacts in terms of GWP (79%
of the total GWP impact), SM (80%), AP (78%), CAR (57%), NCAR (73%), ECT (56%), and
FFD (64%). The GWP (i.e., 1140 kg of CO2 eq) and SM (i.e., 220 kg of kg O3 eq) impacts are
predominantly because of CO2 (97%) and NOX (99%) emissions from the combustion of
recovered oil, respectively. NOX also accounts for 42% of the AP impact, following sulfur
monoxide (47%). The toxic effects such as CAR, NCAR, and ECT from the combustion of
recovered oil are mainly due to potential water resource contaminations by heavy metals such as
barium, chromium, and nickel (Corbin et al., 2018). The FFD impact is a result of the
consumption of crude oil and natural gas resources, which accounts for 95% and 5% of the
It should be noted that the waste disposal process comprises the transportation and disposal
of unrecoverable solids and wastewater. The impact of waste transportation is much higher than
that of waste disposal. For example, about 2.48 × 10-6 kg CFC-11 eq of ODP and 9.76 kg CO2 eq
of GWP emissions are generated from the transportation, which are higher than those of solid
residual (ODP: 7.23 × 10-7 kg CFC-11 eq; GWP: 3.18 kg CO2 eq) and wastewater (ODP: 2.16 ×
10-8 kg CFC-11 eq; GWP: 0.27 kg CO2 eq) treatments. Significant impact offsets can be
generated from the energy recovery process. For example, about 85% and 96% of adverse
impacts in ODP and EP can be eliminated by the energy recovery process, and roughly 40-50%
of human health toxic effects (i.e., CAR and NCAR) can be offset. Particularly, the adverse
23
impact in RE category can be completely eliminated. For instance, roughly 0.33 kg PM2.5-eq of
RE are generated in total and 0.43 kg PM2.5-eq of RE can be eliminated by the energy recovery,
resulting in a negative impact score for RE. The energy recovery process can also mitigate
approximately 14% of adverse impacts in terms of GWP, SM, and AP, but the offsets are much
lower than the adverse impacts posed by the combustion of recovered oil, which account for
nearly 80% of the total impacts. Approximately 1150 kWh of grid electricity can be generated
==========================
==========================
4.4. Pyrolysis
The impacts of the pyrolysis treatment approach are illustrated in Fig. 5. As can be seen,
GWP, ECT, FFD, and SM are the main impact categories of concern for this approach. The
pyrolysis process and combustion of pyrolysis products are the two main processes identified
with significant impacts. The impacts from the pyrolysis process and the combustion process are
approximately equivalent. For instance, 1.05- and 1.19-ton CO2 eq of GWP are generated from
the pyrolysis process and the combustion process, respectively, and 2440 and 2480 CTUe of
ECT are generated from the pyrolysis process and the combustion process, respectively. The
high impact of the pyrolysis process in GWP category is linked to CO2 (1018 kg, 95% of the
CO2 eq) and methane (32 kg, 5% of the CO2 eq) emissions as a result of using external fossil
energy (i.e., heavy fuel oil and natural gas) for maintaining the temperature of the pyrolysis
24
reactor. Similar percentages of CO2 and methane emissions are generated from the combustion
of pyrolysis products. The relatively high ECT impact from both the pyrolysis and py-oil
combustion processes is due to the potential water contamination by metals such as barium
(73%), chromium (16%), and zinc (5%). These metals are generated from the combustion of
heavy fuel oil as a recent study found that the soot from the combustion of heavy fuel oil
contains several toxic heavy metals, such as vanadium, nickel, and barium (Corbin et al., 2018).
The oily sludge drying process also generates significant impacts in terms of GWP, ECT,
FFD, and SM because of considerable external energy inputs. Particularly, the drying process
generates the highest impact in terms of ODP (1.33 × 10-5 kg CFC-11 eq, 95% of the total ODP
impacts) and EP (0.24 kg N eq, 42% of the total EP impacts) among all the processes involved in
are the main substances responsible for the ODP impact from the drying process. The high EP
impact from the drying process is mainly due to water contamination of phosphate (90%), NOX
(5%), and nitrate (3%). It is estimated that the energy consumption of the drying process is
roughly 1/5 of the energy required for pyrolyzing 1000 kg of oily sludge. More importantly, the
recovered energy could considerably offset the adverse impacts of the entire pyrolysis approach.
The adverse ODP and EP effects can be completely eliminated by the energy recovery process.
About 24-53% of human health toxic effects, in terms of CAR, NCAR, and RE, and 4-6% of
adverse environmental impacts, in terms of GWP, SM, and AP, can be mitigated by energy
recovery. The energy recovery process can generate 1015 kWh of grid electricity using the heat
==========================
25
PLEASE INSERT FIG. 5 HERE
==========================
Different categories of life cycle environmental impacts of the four oily sludge treatment
approaches are compared. As Fig. 6. shows, three environmental impact categories including
ECT, GWP, and FFD are the main concerns regarding oily sludge treatment. Generally, oily
sludge treatment has relatively insignificant impacts on the environment in terms of ODP, SM,
AP, EP, CAR, NCAR, and RE. In fact, solvent extraction and pyrolysis treatment approaches
could contribute offsets to impact categories such as RE, EP, and ODP, achieving negative
impact scores for these categories. The two traditional oily sludge treatment approaches,
incineration and landfilling, are associated with much higher ECT effects than the two emerging
treatment approaches. For example, the ECT impacts generated by solvent extraction and
approach, respectively. This indicates that the two emerging oily sludge treatment approaches
could have much lower adverse effects on environmental media such as groundwater and soils.
The incineration treatment approach has the highest impact on GWP due to the combustion
of PHCs in oily sludge and the use of auxiliary fossil fuels. In comparison, landfilling has a
much lower impact on global warming, suggesting that the GHG emissions from biodegradation
of 1000 kg of oily sludge are significantly lower than those generated by incineration. Moreover,
the three treatment approaches with an energy recovery process are associated with different
levels of FFD potential. Pyrolysis approach has the highest FFD because it is an endothermal
process that requires a considerable amount of energy input to carry out the pyrolysis process.
26
==========================
==========================
The normalized life cycle environmental impacts of different oily sludge treatment
approaches are presented in Fig. 7. As can be seen, solvent extraction and pyrolysis have total
normalized score values of 34.4 and 47.3 impacts per person per year, respectively, which are
much lower than those of incineration (701 impacts per person per year) and landfilling (586
impacts per person per year). Solvent extraction approach shows the lowest total normalized
generated by oily sludge incineration. Thus, from an environmental perspective, the emerging
energy recovery treatments are more desirable than the traditional approaches. The total
pyrolysis approach.
It is found that the main adverse effect of the emerging oily recovery approaches is related
to ECT, which consists of nearly 80% of the total impact per person per year. Also, over 80%
and 90% of the total life cycle impacts from the incineration and landfilling approaches,
respectively, are related to the ECT impact. The high ECT impact of oily sludge treatments
might be due to the toxic nature of the waste. After normalization, it can be found that
incineration and landfilling approaches have significant life cycle NCAR toxic effects on human
health. The potential human toxic effects might be due to relatively large amounts of toxic
substances that are released to the environment through fugitive gaseous emission (i.e., SO and
27
NOX) from the incineration process and potential groundwater and soil contamination by the
leachate (i.e., heavy metals) during the landfilling process. Moreover, the incineration approach
shows a significant CAR effect on human health as a result of potential water and air
contamination by carcinogenic heavy metals such as chromium VI and arsenic from direct oily
sludge incineration.
==========================
==========================
Based on the LCIA results, it can be concluded that the emerging energy recovery
approaches are more desirable for oily sludge treatment owing to their much lower life cycle
environmental impacts. However, several assumptions were made to perform the LCAs, which
could result in uncertainties in the assessment outcomes. The inputs of the life cycle inventory
for the two emerging energy recovery approaches were collected from experimental data. Hence,
applications. Different methodologies have also been developed to estimate the life cycle
impacts of scaling-up systems based on experimental data, which provide great references to
estimate the effects of scaling-up of oily sludge treatment systems (Piccinno et al., 2016; 2018;
Also, the properties of the refinery sludge investigated in the two traditional approaches
were considered the same as those of the oily sludge investigated in the two emerging
approaches due to lack of experimental data on the two traditional approaches. This assumption
28
could result in uncertainties in the quantified impacts. More accurate results may be obtained
when better information of the two traditional approaches becomes available. Moreover, the two
emerging treatment approaches might have different treatment performances on oily sludge with
different physical properties and chemical compositions. In fact, oily sludges from different
sources are often associated with different properties and/or compositions. The variation of
treatment performance could also lead to uncertainties in the LCIA results, and these
uncertainties are difficult to quantify due to data constraints. However, the results in this study
could provide preliminary information for decision making in selecting low-impact hazardous
oily sludge waste treatment technologies, and the developed method can be used as a reference to
5. Conclusion
The life cycle environmental impacts of traditional and emerging oily sludge treatment
approaches were assessed. The life cycle environmental impacts were assessed by following the
standardized ISO 14040 procedure. The results show that the two emerging approaches,
including solvent extraction and pyrolysis, have much lower life cycle environmental impacts
than the traditional alternatives such as incineration and landfilling. Traditional oily sludge
treatment approaches are generally associated with relatively high GWP, ECT, and adverse
human health effects. Solvent extraction has the lowest adverse effect on the environment, which
is only equivalent to 5% of the total normalized impact of incineration approach. The adverse
effects of solvent extraction were found to be related to ECT and FFD. In the solvent extraction
treatment approach, the vacuum distillation process and combustion of recovered oil account for
the main impacts. In pyrolysis treatment, the drying, pyrolysis, and combustion of py-oil and py-
29
gas are the main contributors to the total impact. The energy recovery process in both emerging
approaches can reclaim heat energy for generating electricity and offset the total adverse
impacts. The emerging approaches are promising for low-impact refinery oily sludge treatment.
The results add new knowledge to urban mining regarding the recycling of hazardous industrial
wastes and provide useful information facilitating the oil and gas industry in transiting towards
Acknowledgment
This study was supported by the Natural Sciences and Engineering Research Council of
Canada (NSERC), the Multi-Partner Oil Spill Research Initiative (MPRI) of Fisheries and
Oceans Canada, and the China Scholarship Council (Sponsorship number: 201706370234). The
authors would also like to thank the editor and anonymous reviewers for their help in improving
30
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Tables
Table 1 Life cycle inventory of oily sludge treatment through solvent extraction approach.
4
Log value of impact score
0
ODP GWP SM AP EP CAR NCAR RE ECT FFD
-2
-4
-6
0
ODP GWP SM AP EP CAR NCAR RE ECT FFD
-2
-4
-6
Fig. -8
3. Life cycle environmental impacts of landfilling treatment of 1000 kg of oily sludge.
4
Extraction Water-oil separation Vacuum distillation Recovered oil combustion Energy recovery Waste disposal Total
3
2
Log value of impact score
1
0
-1 ODP GWP SM AP EP CAR NCAR RE ECT FFD
-2
-3
-4
-5
-6
-7
-8
Fig. 4. Life cycle environmental impacts of solvent extraction treatment of 1000 kg of oily
sludge (* represents an impact offset).
4 Drying Pyrolysis Py-oil and gas Energy recovery Total
combustion
Log value of impact score
0
ODP GWP SM AP EP CAR NCAR RE ECT FFD
-2
-4
-6
-8
Fig. 5. Life cycle environmental impacts of pyrolysis treatment of 1000 kg of oily sludge (*
represents an impact offset).
Fig. 6. LCIA results of four oily sludge treatment approaches.
Fig. 7. Total normalized life cycle impacts of four oily sludge treatment approaches.