Energy

What’s Made from a Barrel of Oil?

Published

1 year ago

September 14, 2021

Niccolo Conte

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What Products Are Made from a Barrel of Oil?

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From the gasoline in our cars to the plastic in countless everyday items, crude oil is an essential raw material that shows up everywhere in our lives.

With around 18 million barrels of crude oil consumed every day just in America, this commodity powers transport, utilities, and is a vital ingredient in many of the things we use on a daily basis.

This graphic visualizes how much crude oil is refined into various finished products, using a barrel of oil to represent the proportional breakdown.

Barrel of Oil to Functional Fuel and More

Crude oil is primarily refined into various types of fuels to power transport and vital utilities. More than 85% of crude oil is refined into fuels like gasoline, diesel, and hydrocarbon gas liquids (HGLs) like propane and butane.

Along with being fuels for transportation, heating, and cooking, HGLs are used as feedstock for the production of chemicals, plastics, and synthetic rubber, and as additives for motor gasoline production.

Refined Crude Oil Product	Share of Crude Oil Refined
Gasoline	42.7%
Diesel	27.4%
Jet fuel	5.8%
Heavy fuel	5.0%
Asphalt	4.0%
Light fuel	3.0%
Hydrocarbon gas liquids	2.0%
Other	10.1%

Source: Canadian Association of Petroleum Producers

Crude oil not only powers our vehicles, but it also helps pave the roads we drive on. About 4% of refined crude oil becomes asphalt, which is used to make concrete and different kinds of sealing and insulation products.

Although transportation and utility fuels dominate a large proportion of refined products, essential everyday materials like wax and plastic are also dependent on crude oil. With about 10% of refined products used to make plastics, cosmetics, and textiles, a barrel of crude oil can produce a variety of unexpected everyday products.

Personal care products like cosmetics and shampoo are made using petroleum products, as are medical supplies like IV bags and pharmaceuticals. Modern life would look very different without crude oil.

The Process of Refining Crude Oil

You might have noticed that while a barrel of oil contains 42 gallons, it ends up producing 45 gallons of refined products. This is because the majority of refined products have a lower density than crude oil, resulting in an increase in volume that is called processing gain.

Along with this, there are other inputs aside from crude oil that are used in the refining process. While crude oil is the primary input, fuel ethanol, hydrocarbon gas liquids, and other blending liquids are also used.

U.S. Refiner and Blender Inputs	Share of Total
Crude oil	85.4%
Fuel ethanol	4.8%
Blending components	3.5%
Hydrocarbon gas liquids	3.0%
Other liquids	3.3%

Source: EIA

The process of refining a 30,000-barrel batch of crude oil typically takes between 12-24 hours, with refineries operating 24 hours a day, 365 days a year. Although the proportions of individual refined products can vary depending on market demand and other factors, the majority of crude oil will continue to become fuel for the world’s transport and utilities.

The Difficulty of Cutting Down on Crude Oil

From the burning of heavy fuels that tarnish icebergs found in Arctic waters to the mounds of plastic made with petrochemicals that end up in our rivers, each barrel of oil and its refined products impact our environment in many different ways.

But even as the world works to reduce its consumption of fossil fuels in order to reach climate goals, a world without crude oil seems unfathomable.

Skyrocketing sales of EVs still haven’t managed to curb petroleum consumption in places like Norway, California, and China, and the steady reopening of travel and the economy will only result in increased petroleum consumption.

Completely replacing the multi-faceted “black gold” that’s in a barrel of oil isn’t possible right now, but as electrification continues and we find alternatives to petrochemical materials, humanity might at least manage to reduce its dependence on burning fossil fuels.

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Energy

Green Steel: Decarbonising with Hydrogen-Fueled Production

How will high emission industries respond to climate change? We highlight industrial emissions and hydrogen’s role in green steel production.

Written By

Omri Wallach

Graphics & Design

Sabrina Fortin

Published September 28, 2022 • Updated September 28, 2022 •

This infographic highlights industrial emissions and hydrogen's role in green steel production.

Green Steel: Decarbonising with Hydrogen-Fueled Production

As the fight against climate change ramps up worldwide, the need for industries and economies to respond is immediate.

Of course, different sectors contribute different amounts of greenhouse gas (GHG) emissions, and face different paths to decarbonisation as a result. One massive player? Steel and iron manufacturing, where energy-related emissions account for roughly 6.1% of global emissions.

The following infographic by AFRY highlights the need for steel manufacturing to evolve and decarbonise, and how hydrogen can play a vital role in the “green” steel revolution.

The Modern Steel Production Landscape

Globally, crude steel production totalled 1,951 million tonnes (Mt) in 2021.

This production is spread all over the world, including India, Japan, and the U.S., with the vast majority (1,033 million tonnes) concentrated in China.

But despite being produced in many different places globally, only two main methods of steel production have been honed and utilised over time—electric arc furnace (EAF) and blast furnace basic oxygen furnace (BF-BOF) production.

Both methods traditionally use fossil fuels, and in 2019 contributed 3.6 Gt of carbon dioxide (CO₂) emissions:

Steel Production Method	Materials Utilised	CO2 Emissions (2019)
EAF	Scrap	0.5 Gt
BF-BOF	Scrap, iron ore, coke	3.1 Gt

That’s why one of the main ways the steel industry can decarbonise is through the replacement of fossil fuels.

Hydrogen’s Role in Green Steel Production

Of course, one of the biggest challenges facing the industry is how to decarbonise and produce “green” steel in an extremely competitive market.

As a globally-traded good with fine cost margins, steel production has been associated with major geopolitical issues, including trade disputes and tariffs. But because of climate change, there is also a sudden and massive demand for carbon-friendly production.

And that’s where hydrogen plays a key role. Steel traditionally made in a blast furnace uses coke—a high-carbon fuel made by heating coal without air—as a fuel source to heat iron ore pellets and liquify the pure iron component. This expels a lot of emissions in order to get the iron hot enough to melt (1,200 °C) and be mixed with scrap and made into steel.

The green steel method instead uses hydrogen to reduce the iron pellets into sponge iron, metallic iron that can then be processed to form steel. This process is also done at high temperature but below the melting point of iron (800 – 1,200 °C), saving energy costs.

And by introducing non-fossil fuels to create iron pellets and renewable electricity to turn the sponge iron and scrap into steel, fossil fuels can be removed from the process, significantly reducing emissions as a result.

The Future of Green Steel Production

Given the massive global demand for steel, the need for hydrogen and renewable energy required for green steel production is just as significant.

According to AFRY and the International Renewable Energy Agency, meeting global steel production in 2021 using the green steel method would require 97.6 million tonnes of hydrogen.

And for a truly carbon-free transition to green steel, the energy industry will also need to focus on green hydrogen production using electrolysis. Unlike methods which burn natural gas to release hydrogen, electrolysis entails the splitting of water (H₂O) into oxygen and hydrogen using renewable energy sources.

Full green steel production would therefore use green hydrogen, electrolysers running on renewables, and additional renewables for all parts of the supply chain:

Steel Production Source	Annual Steel Production	Green Hydrogen Required	Electrolyser Capacity Required	Total Renewables Capacity Required
Base Reference	1 Mt	50 kT	0.56 GW	0.7 GW
U.S.	85.8 Mt	4.3 Mt	48 GW	60 GW
Europe	103 Mt	5.2 Mt	58 GW	72 GW
China	1032.8 Mt	51.6 Mt	581 GW	726 GW
Global	1951 Mt	97.6 Mt	1,097 GW	1,371 GW

Currently, green hydrogen production costs are higher than traditional fossil fuel methods, and are dependent on the levelised costs of renewable energy sources. This means they vary by region, but also that they will reduce as production capacity and subsidies for renewables and green hydrogen increase.

And many major European steel manufacturers are already leading the way with pilot and large scale facilities for green steel production. Germany alone has at least seven projects in the works, including by ArcelorMittal and ThyssenKrupp, two of the world’s 10 largest steelmakers by revenue.

AFRY is a thought leadership firm that provides companies with advisory services and sustainable solutions, in their efforts to fight climate change and lead them towards a greater future.

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Here’s a snapshot of global energy production, and which countries have produced the most fossil fuels, nuclear, and renewable energy since 1980.

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Carmen Ang

Energy was already a hot topic before 2022, but soaring household energy bills and a cost of living crisis has brought it even more to the forefront.

Which countries are the biggest energy producers, and what types of energy are they churning out? This graphic by 911 Metallurgist gives a breakdown of global energy production, showing which countries have used the most fossil fuels, nuclear, and renewable energy since 1980.

All figures refer to the British thermal unit (BTU), equivalent to the heat required to heat one pound of water by one degree Fahrenheit.

Editor’s note: Click on any graphic to see a full-width version that is higher resolution

1. Fossil Fuels

View the full-size infographic

While the U.S. is a dominant player in both oil and natural gas production, China holds the top spot as the world’s largest fossil fuel producer, largely because of its significant production and consumption of coal.

Over the last decade, China has used more coal than the rest of the world, combined.

However, it’s worth noting that the country’s fossil fuel consumption and production have dipped in recent years, ever since the government launched a five-year plan back in 2014 to help reduce carbon emissions.

2. Nuclear Power

View the full-size infographic

The U.S. is the world’s largest producer of nuclear power by far, generating about double the amount of nuclear energy as France, the second-largest producer.

While nuclear power provides a carbon-free alternative to fossil fuels, the nuclear disaster in Fukushima caused many countries to move away from the energy source, which is why global use has dipped in recent years.

Despite the fact that many countries have recently pivoted away from nuclear energy, it still powers about 10% of the world’s electricity. It’s also possible that nuclear energy will play an expanded role in the energy mix going forward, since decarbonization has emerged as a top priority for nations around the world.

3. Renewable Energy

View the full-size infographic

Renewable energy sources (including wind, hydro, and solar) account for about 23% of electricity production worldwide. China leads the front on renewable production, while the U.S. comes in second place.

While renewable energy production has ramped up in recent years, more countries will need to ramp up their renewable energy production in order to reach net-zero targets by 2050.