Refineries are a major source of atmospheric emissions, which typically include CO, SO2, NOX, particulates, and volatile organic compounds (VOCs). There has been an increasing level of attention toward the emissions of VOCs related to their environmental impact as well as their potential to cause adverse effects on human health and the discomfort associated with their unpleasant odor. In general, an emission factor (EF) represents a model for a first order estimate of emissions, which correlates the quantity of pollutant released into the atmosphere with a so-called “activity index” related to the release of that pollutant. Based on the study of the scientific and technical literature regarding the Italian and European refining scenarios, an attempt was made to verify the existence of a correlation between the size of a refinery and the related total VOC emissions. Once this correlation was evaluated, it was possible to develop an emission factor for VOC emissions considering the plant capacity as the related activity index. After collecting and analyzing data concerning operative capacity and total VOCs emitted from 15 refineries in 2018, the resulting emission factor turned out to be equal to 188 ± 166 g per ton of crude oil processed. This value is in agreement with the range of 50–1000 g/ton reported in the European Best Available Techniques Reference Document for the Refining of Mineral Oil and Gas.

The hazardous air pollutants (HAPs) group is composed of 187 chemicals that are known to be potentially carcinogenic and dangerous for human health. Due to their toxicological impact, HAPs are an increasingly studied class of compounds. Of the different HAPs sources, refineries are one of the major sources. In order to obtain a preliminary assessment of the impact of a refinery in terms of emissions, a useful instrument is the determination of the emission factor (EF). For this reason, this work, focusing on the USA refining scenario, aims to provide evidence for a generic trend in refinery emissions to evaluate a correlation between the plant size and the amount of its emissions, in particular the HAPs emissions. Based on the analysis of the data collected from the U.S. Environmental Protection Agency (US EPA), a general trend in the emissions from refinery plants was established, showing a positive correlation between the HAPs emissions and the refinery size, represented by a value of the Pearson correlation coefficient r close to 1. Once this correlation was highlighted, a purpose of this work became the estimation of an organic HAPs emission factor (EF): from a whole refining plant, the EF of the total organic HAPs is equal to 10 g emitted for each ton of crude oil processed. Moreover, it was also possible to undertake the same evaluation for two specific HAP molecules: benzene and formaldehyde. The benzene and formaldehyde EFs are equal to, respectively, 0.8 g and 0.2 g for each ton of processed crude oil. This work provides a simple rule of thumb for the estimation of hazardous substances emitted from petroleum refineries in their mean operating conditions.