How an Oil Refinery Works

(construction-physics.com)

95 points | by chmaynard 1 hour ago

5 comments

  • t_tsonev 35 minutes ago
    The article is quick to point out the huge role of oil in the modern energy mix. It also fails to note that most of the energy ends up us waste heat. The so called "Primary energy fallacy". Other than that, it's a great read.
  • shhsshs 12 minutes ago
    As someone with no real-world petrochemistry experience, but much gaming experience, I was very surprised how familiar the crude oil processing diagram looks. Factorio and GregTech are two prime examples of fairly realistic oil processing lines (probably as accurate as any game would reasonably try to be).
  • jmyeet 1 hour ago
    This is a really good overview of oil refining. I'll add a few things.

    1. The light and heavy distinction is covered by a measure called API gravity [1]. The higher the API gravity, the lighter the crude;

    2. Refiners mix different crude types depending on what kind of refined products they want to produce;

    3. Heavy crude tends to be less valuable although it's essential for some applications. Lighter crude produces generally more valuable products like gasoline, diesel and avgas. But heavy crude goes into construction (eg roads) and fuel for ships (ie bunkers));

    4. Most refineries in the US are very old and are very polluting. They don't need to be this way. A new refiner would produce vastly less pollution but they're almost impossible to get permission to build now. One exception is the Southern Rock refinery currently being built in Oklahoma [2], which will be powered by largely renewable energy and produce a lot less emissions than an equivalent older refinery with the same capacity;

    5. There are different blends of gasoline that the US produces. The biggest is so-called summer and winter blends. What's the differene? Additives are added to summer blends (in particular) to increase the boiling point so less of the gasoline is in gas form because that produces more smog;

    6. California uses their own blends so in 2021-2022 when CA gas went to $8+, it wasn't just "gouging". It doesn't really work that way. CA requires a particular blend that only CA refineries produce so it's simple supply and demand as no new capacity gets added to CA refineries and demand goes up with population growth.

    The reason for the CA blend goes back to the 80s and 90s when smog was a much bigger problem. Better vehicle emissions standards since then as well as improvements in the blends the rest of the country uses have largely made the CA blend obsolete so CA is really paying $1+/gallon more for literally no reason; and

    7. California doesn't build pipelines so is entirely dependent on seaborne oil imports (~75%) despite the US being a net energy exporter. Last I checked, ~20% of that foreign oil comes through the Strait (from Iraq, mostly) so, interestingly, CA is more vulnerable to the Strait of Hormuz closure than the rest of the country.

    I guess I'll add a disclaimer: I'm very much pro-renewables, particular solar. I think solar is the future. But we currently live in a world that has huge demand for oil and no alternatives for many of those uses (eg diesel, plastics, construction, industrial, avgas) so we should at least be smart about how we go forward.

    [1]: https://en.wikipedia.org/wiki/API_gravity

    [2]: https://www.oklahoman.com/story/news/2023/05/24/5-6-billion-...

    • criddell 30 minutes ago
      Looking at the chart in the article I was kind of surprised at how small wind and solar are globally and that coal is still ~25%.
    • vel0city 25 minutes ago
      > they're almost impossible to get permission to build now

      While I do agree there's a ton of regulatory hurdle to cross to build a new refinery, lots of interviews with oil executives have stated the economics of building a new refinery aren't always great. The reasons why they aren't building isn't necessarily because the regulatory hurdles are too high, its that they don't think they'll end up making any money building them. The future demand of many refined products are uncertain, adding a lot of new capacity is quite a capital risk.

      I'd love to see a lot of our ancient refineries shut down and replaced with far more modern designs, but the oil industry isn't going to do it because it probably won't be profitable.

      It will be interesting to see the economics of these few new refineries coming online actually play out in the coming years.

    • alephnerd 1 hour ago
      > Most refineries in the US are very old and are very polluting

      India's Reliance is also investing $300B [0] in a Texas megarefinery [1] in specifically for cleaner and more efficient shale refining.

      This is deeply technical and complex but low margins work (semiconductor fabrication falls in the same boat) which saw this industry leave for abroad in the 2000s and 2010s when other states like China and India subsidized their refinery industries to build domestic capacity for a number of petroleum byproducts with industrial applications.

      This is the same strategy Japan, South Korea, and Taiwan used in the 1960s-90s as well.

      [0] - https://www.bloomberg.com/opinion/articles/2026-03-17/ambani...

      [1] - https://www.bloomberg.com/news/articles/2026-03-11/reliance-...

  • arlobish 33 minutes ago
    Cool to see how when people talk about “transitioning off oil” it's more than replacing gasoline in cars. It's replacing this entire global machine.
  • tmellon2 4 minutes ago
    Oil is cooked. BYD is filing 52 patents every single day and has a 700 km in 9 minutes vehicle available TODAY ! Charging by Solar is going to be the norm. Watch : https://www.youtube.com/watch?v=vgCYYrhL-kE