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Pollution Prevention
Learn about Flint Hills Resources' pollution prevention efforts and how you too can make a difference.


Source Data
Source Data information for air emissions. This file is in Microsoft Excel Comma Separated Values format.


Data Source and Quality
Learn where we get the data for the graphs and how we ascertain the data's quality.

Air Emissions

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Point/Counterpoint Significant reductions in air emissions were made as part of the emission reduction initiative. Air emissions decreased from over 12,000 tons per year to approximately 5000 tons in 2004.

Air emissions from the refinery come from three types of sources:
  • Combustion of fuels
  • Fugitive emissions
  • Process emissions

Fuel combustion emissions are primarily nitrogen oxides (NOx), sulfur dioxide(SO2), carbon monoxide(CO) and minor amounts of particulate matter and volatile organic compounds (VOCs), as well as carbon dioxide. These emissions come from the top of tall heater and boiler stacks (150 to 250 feet tall), at high temperatures (300 to 700 °F), and high velocities (15 to 30 feet per second), rising hundreds of feet into the air where they begin to disperse.

Fugitive emissions come from vapor leaks from tank seals, valves, flanges, pump and compressor seals and from moving, loading and storing petroleum coke. Most of the leaks from the processing equipment are VOCs while the petroleum coke fugitive emissions are primarily particulate matter. These emissions are generally at ambient temperature and occur close to the ground.

Process emissions come from just 7 of the regulated stacks in the refinery: the Fluid Catalytic Cracking Unit (FCCU), the 3 sulfur recovery plants, two reformers and the flare system.

The 1st bar chart entitled "Historic emissions - releases to air" shows that over the past decade, total air emissions of criteria pollutants from the refinery have decreased by 70%. Since 1997, FHR has done the following to reduce emissions:

  • Reduced flaring by 95% over the last six years using improved operations procedures
  • Installed better gaskets and sleeves on floating roof tanks
  • Installed additional tank roofs on gasoline tanks
  • Reduced VOC emissions from fugitive leaks (from valves and pump seals)
  • Improved emission controls put on the Fluid Catalytic Cracking (FCC) unit
  • Installed cooling tower drift eliminators
  • Shut down the sulfuric acid plant
  • Installed lox NOx burners on several heaters
  • Verified that valves and pumps that carry heavy liquids (e.g. diesel fuel) leak at a lower rate than previous estimates
  • Verified that drains with new controls (seals/covers) leak at a lower rate than previous estimates
Figure 1
Figure 2
Data Source
Data obtained from FHR's Annual MN Emission Inventory.

Point-Counterpoint
Flint Hills Resources
MCEA
As mentioned previously, significant reductions in air emissions were made as part of the emission reduction initiative. Emissions of volatile organic compounds (VOCs), nitrogen oxides (NOX) and sulfur dioxide (SO2) saw some of the biggest reductions.

The decrease in VOC emissions from fugitive leaks also translates into an overall reduction in benzene and similar compounds. Toxic metals emitted from the refinery in the form of fine particulate also decreased due to the addition of emission controls on the FCC unit.

The reductions in air emissions that were included in FHR's 1999 announcement of a 50% reduction in 5 years have been incorporated into the 2000 New Source Review agreement with EPA and MPCA. Under that agreement, FHR will reduce emissions from heaters and boilers by installing state-of-the-art burner technology, reduce emissions from fugitive leaks and sewers, and have, at the end of 7 years, one of the cleanest refineries in the United States.<
Benzene
While benzene emissions have been reduced over 60%, FHR’s Pine Bend refinery is still the largest emitter of benzene in Minnesota according to EPA’s annual Toxics Release Inventory (TRI) data. Benzene is a known carcinogen and is also recognized as toxic to developmental and reproductive systems. We encourage FHR to continue to reduce its benzene emissions.

Mercury
We are pleased that mercury emissions have reduced from 35 pounds noted in FHR’s health risk assessment (HRA) to 9.3 pounds in 2004. The HRA identified mercury as a significant potential health risk for children, due to the consumption of mercury contaminated fish and the ingestion of mercury contaminated soil. Mercury is a pollutant that builds up, and persists, in the environment. See www.pca.state.mn.us/air/mercury.html. Yet little is known about mercury emissions from refineries. Flint Hills Resources is a participant in Minnesota’s Mercury Reduction Initiative and through this program MCEA believes it is essential that Flint Hills Resources collect data on its mercury releases and find out how to reduce its contribution. FHR has committed to conduct a refinery mercury mass balance which includes examining mercury inputs and emissions. MCEA believes it is essential that FHR find out how to further reduce its mercury emissions. Information on the Mercury Reduction Initiative can be found at: www.pca.state.mn.us/publications/report/lrp-mercury2005.pdf

Carbon Dioxide
Burning fossil fuel creates emissions of carbon dioxide, also known as a “greenhouse gas” that contribute to global warming. As of Feb. 16, 2005, 141 countries have signed onto the Kyoto Protocol and are taking action to reduce greenhouse gases. Some of the actions include establishing emissions caps, taxes and trading systems. Although the US government is not a signatory to this agreement, some companies are addressing the issue of global warming. For example, BP has set up aninternal emission trading system and pledged a no net CO2 emissions increase from 2001 levels by the year 2012; and, ExxonMobil has invested in research to develop technologies to lower greenhouse gas emissions on a world wide scale. (See climate change pages on the following websites: www.bp.com, www2.exxonmobil.com, www.swissre.com and www.ge.ecoimagination.com ) MCEA believes tracking CO2 emissions from FHR Pine Bend is important, as is exploring ways to offset future carbon emissions from the refinery.

Dioxin
Dioxin is not only emitted as a result of burning municipal and industrial garbage, it is also emitted from other manufacturing processes, including oil refining. Dioxin is a toxic chemical. There is no safe level of dioxin emissions, even concentrations in the parts per trillion can cause adverse effects on people and animals. For more information, see). Pine Bend refinery reported emissions of dioxin and furans are approximately 0.02 grams per year. For answers to frequently asked questions about dioxin, go to: www.astdr.cdc.gov/tfacts104.html

©2000 Flint Hills Resources and Minnesota Center for Environmental Advocacy