Rapid PFAS Testing Restores Operations at a Washington Oil Refinery

Following an incidental release at an oil refinery in Washington state, the site recovered a mixed oil and water stream tied to crude oil and aqueous film-forming foam (AFFF) response conditions. The refinery needed a clear treatment path that would stand up to scrutiny while keeping internal attention on core operating priorities.

The refinery brought in Onterris to design, install and manage a turnkey treatment system on site. The team focused on practical execution: build a treatment plan that fits refinery conditions, maintain predictable day-to-day performance and produce results that operators can use to make return-to-work decisions.

Two realities shaped the approach from day one.

First, time and storage pressure. Rented fractionation tanks add cost and create ongoing operational drag, so treatment needed to draw down volumes quickly and consistently.

Second, discharge confidence under strict PFAS limits. Washington and many other states have lowered discharge limits, and this project required treated water to meet non-detect levels using EPA Method 1633 for more than 40 PFAS compounds. The refinery needed performance at very low detection thresholds, backed by independent laboratory data.

Onterris also aligned the plan to refinery workflows. The team kept requirements clear, defined operating roles early and built an approach the site could run without distraction or repeated resets.

Onterris mobilized quickly through a rapid response program. The teams aligned on scope and approach on a Thursday afternoon, and Onterris arrived on site the following Monday.

Onterris deployed a treatment train using rapid response assets, including granular activated carbon (GAC), SORBIX™ PURE ion exchange (IEX) resin and SORBIX AvPURE. Onterris commissioned and deployed the full system within 10 days by drawing on equipment kept on standby for urgent, full-scale treatment needs.

Onterris set the operating flow rate at 35 gallons per minute (gpm) to move treated volume quickly while maintaining performance toward non-detect results. Onterris also staffed on-site operators to keep the system running steadily, maintain consistent performance and reduce day-to-day burden on refinery personnel as the facility moved back toward normal throughput.

In parallel, before startup, the Onterris research and development laboratory tested site water to identify potential roadblocks that could surface at full scale. That early work helped the field team commission with fewer surprises and clearer operating expectations.

A third-party laboratory conducted PFAS testing using EPA Method 1633. Results showed the deployed treatment approach reliably achieved non-detect PFAS levels across the compound list.

For refinery operators, the value extended beyond a compliant sample. Onterris converted a recovery stream into a controlled, verifiable process that ran on site under real operating conditions. With confirmed results in hand, the refinery met water quality compliance requirements and resumed normal operations.

Response and recovery work rarely happens under ideal conditions. Requirements can tighten quickly, storage pressure rises and decisions need defensible data. This project shows what supports progress in that environment: rapid mobilization, treatment designed for low detection thresholds, on-site operators who keep performance steady and early lab work that reduces uncertainty before full-scale operation.

For refineries navigating PFAS-driven discharge limits, the takeaway is practical. With the right treatment train and on-site execution, teams can reach non-detect performance on timelines that protect both compliance and uptime.