Help promote Energy Explained with the outreach toolkit

Refining Crude Oil

What is a refinery?

Petroleum refineries convert crude oil and other liquids into many petroleum products that people use every day. Most refineries focus on producing transportation fuels. On average, U.S. refineries produce, from a 42-gallon barrel of crude oil, about 20 to 19 gallons of motor gasoline, 12 gallons of distillate fuel distillate fuel, most of which is sold as diesel fuel, and 4 gallons of jet fuel. More than a dozen other petroleum products are also produced in refineries. Petroleum refineries produce liquids the petrochemical industry uses to make a variety of chemicals and plastics.

A photo of the Pascagoula Refinery in Mississippi
A night photo of the Pascagoula Refinery, Mississippi

Source: Stock photography (copyrighted)

Refineries operate 24/7

A refinery runs 24 hours a day, 365 days a year and requires a large number of employees. A refinery can occupy as much land as several hundred football fields.

Last updated: May 5, 2017

How crude oil is refined into petroleum products

Petroleum refineries change crude oil into petroleum products that are used as fuels for transportation, heating, paving roads, and generating electricity. Petroleum products are also used as feedstocks for making chemicals.

Refining breaks crude oil down into its various components, which are then selectively reconfigured into new products. Petroleum refineries are complex and expensive industrial facilities. All refineries have three basic steps:

Diagram of a refinery process flow. Adapted from Chevron.

Note: LPG is liquid petroleum gas.
Source: Adapted from Chevron

Separation

Modern separation involves piping crude oil through hot furnaces. The resulting liquids and vapors are discharged into distillation units.

Inside the distillation units, the liquids and vapors separate into petroleum components called fractions according to their weight and boiling point. Heavy fractions are on the bottom and light fractions are on the top.

The lightest fractions, including gasoline and liquid petroleum gas (LPG), vaporize and rise to the top of the distillation tower, where they condense back to liquids.

Medium weight liquids, including kerosene and diesel oil distillates, stay in the middle of the distillation tower.

Heavier liquids, called gas oils, separate lower down in the distillation tower, while the heaviest fractions with the highest boiling points settle at the bottom of the tower.

Fluid catalytic cracking distillation unit
Richmond Refinery, Fluid Catalytic Cracking Distillation Column.

Source: Chevron (copyrighted).

Refining workers overlooking a refinery
Caltex, Star Petroleum Refinery, Refining workers overlook refinery

Source: Chevron (copyrighted).

Conversion

After distillation, heavy, lower-value distillation fractions can be processed further into lighter, higher-value products such as gasoline. This is where fractions from the distillation units are transformed into streams (intermediate components) that eventually become finished products.

The most widely used conversion method is called cracking because it uses heat and pressure to crack heavy hydrocarbon molecules into lighter ones. A cracking unit consists of one or more tall, thick-walled, rocket-shaped reactors and a network of furnaces, heat exchangers, and other vessels.

Cracking is not the only form of crude oil conversion. Other refinery processes rearrange molecules to add value rather than splitting molecules.

Alkylation, for example, makes gasoline components by combining some of the gaseous byproducts of cracking. The process, which essentially is cracking in reverse, takes place in a series of large, horizontal vessels and tall, skinny towers.

Reforming uses heat, moderate pressure, and catalysts to turn naphtha, a light, relatively low-value fraction, into high-octane gasoline components.

Treatment

The finishing touches occur during the final treatment. To make gasoline, refinery technicians carefully combine a variety of streams from the processing units. Octane level, vapor pressure ratings, and other special considerations determine the gasoline blend.

Storage

Both incoming crude oil and the outgoing final products need to be stored. These liquids are stored in large tanks on a tank farm near the refinery. Pipelines then carry the final products from the tank farm to other tanks across the country.

Last reviewed: December 15, 2015

Petroleum refineries process crude oil into many different petroleum products. The physical characteristics of crude oil determine how the refineries turn it into the highest value products.

Not all crude oil is the same

The physical characteristics of crude oil determine how refineries process it. In simple terms, crude oils are classified by density and sulfur content. Less dense (lighter) crude oils generally have a higher share of light hydrocarbons. Refineries can produce high-value products such as gasoline, diesel fuel, and jet fuel from light crude oil with simple distillation. When refineries use simple distillation on denser (heavier) crude oils, it produces low value products. Heavy crude oils require additional, more expensive processing to produce high-value products. Some crude oils also have a high sulfur content, which is an undesirable characteristic in both processing and product quality.

Refineries use more than just crude oil

In addition to crude oil, refineries and blending facilities add other oils and liquids during processing to produce the finished products that are sold to consumers. These other oils and liquids include liquids that condense in natural gas wells (called lease condensates); natural gas plant liquids from natural gas processing; liquefied gases from the refinery itself; and unfinished oils that are produced by partially refining crude oil, such as naphthas and lighter oils, kerosene and light gas oils, heavy gas oils, and residuum. Residuum is a residue from crude oil that remains after distilling off all but the heaviest components.

Refineries and blending facilities combine various gasoline blending components and fuel ethanol to produce the finished motor gasoline that is sold for use. They add biodiesel to petroleum diesel fuel to make biodiesel fuel.

Refining output is larger than input

The total volume of products refineries produce (output) is greater than the volume of crude oil that refineries process (input), because most of the products they make have a lower density than the crude oil they process. This increase in volume is called called processing gain. The average U.S. processing gain was about 6.7% in 2016. In 2016, U.S. refineries produced an average of 44.77 gallons of refined products for every 42-gallon barrel of crude oil they refined.

Gasoline accounts for the largest share of total petroleum products produced each year in U.S. refineries.

Bar chart showing U.S. refiner and blender net production of refined petroleum products, 2016. Finished motor gasoline 50%, distillate fuel oil 24%, kerosene-type jet fuel 8%, petroleum coke 5%, still gas 3%, hydrocarbon gas liquids 3%, residential fuel oil 2%, asphalt and road oil 2%, petrochemical feedstocks 1%, lubricants 1%, other products 1%
Click to enlarge »

Petroleum products produced from
one 42-gallon barrel of oil input
at U.S. refineries, 2016

Product Gallons
Finished motor gasoline 19.74
Distillate fuel oil 11.93
Kerosene-type jet fuel   4.12
Petroleum coke   2.27
Still gas   1.76
Hydrocarbon gas liquids   1.60
Residual fuel oil   1.05
Asphalt and road oil   0.80
Naptha for feedstocks   0.46
Lubricants   0.42
Other oils for feedstocks   0.25
Miscellaneous products   0.21
Special napthas   0.08
Kerosene   0.04
Finished aviation gasoline   0.04
Waxes <0.01
Total 44.77
Processing gain   2.81

Note: the sum of the individual products may not equal the total because of independent rounding.
Source: U.S. Energy Information Administration, Petroleum Supply Annual, September 2017

More data »

Last updated: September 28, 2017

Top 10 U.S. refineries* operable capacity

(As of January 1, 2017)


Rank

Corporation

Company

State

Site
Barrels per calendar day
1 Motiva Enterprises LLC Motiva Enterprises LLC Texas Port Arthur 603,000
2 ExxonMobil Corp. ExxonMobil Refining & Supply Co. Texas Baytown 560,500
3 Marathon Petroleum Corp. Marathon Petroleum Co. LLC Louisiana Garyville 543,000
4 ExxonMobil Corp. ExxonMobil Refining & Supply Co. Louisiana Baton Rouge 502,500
5 Marathon Petroleum Corp. Marathon Petroleum Corp. Texas Galveston Bay 459,000
6 PDV America Inc. Citgo Petroleum Corp. Louisiana Lake Charles 425,000
7 BP PLC BP Products North America Inc. Indiana Whiting 413,500
8 ExxonMobil Corp. ExxonMobil Refining & Supply Co. Texas Beaumont 362,300
9 Chevron Corp Chevron USA Mississippi Pascagoula 340,000
10 WRB Refining LP WRB Refining LP Illinois Wood River 336,000

*Only refineries with Atmospheric Crude Oil Distillation Capacity
Source: Refinery Capacity Report  


See full list of refineries

Last updated: June 22, 2017