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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

A Life Cycle Analysis of Refinery Fuel Products Air Emissions Using Refinery Emissions Inventory Data

With the transportation sector being a major source of air pollutant emissions, this study seeks to evaluate criteria pollutant emissions associated with the use of petroleum fuels in vehicles using the GREET® (Greenhouse gases, Regulated Emissions, and Energy use in Transportation) well-to-wheel model. The life cycle of petroleum fuels includes the major stages of crude recovery, crude transportation, crude refining, fuel distribution and fuel combustion (vehicle operation). This study focuses on quantifying refinery emissions, in terms of both refinery throughput and various refinery fuel products, by matching a refinery emissions inventory dataset with refinery operation information, at various levels (national, regional, facility, and process unit). The refinery emissions in terms refinery throughput (per refinery crude input, in g/mmbtu crude) are developed at a regional level for various Petroleum Administration for Defense Districts (PADD), and also aggregated at the national level. To allocate refinery emissions to refinery products, a methodology is developed using a refinery operation optimization Linear Programming (LP) model for individual refineries. The results from individual refinery facilities are then aggregated to obtain statistical national average (capacity weighted) emissions for each product. Because refineries vary by complexity of operation, configuration, crude quality, and product slate, the derived emissions demonstrate large variation for each product and per unit of crude input. Relative to previous estimates used in the GREET model, the present research shows reductions in refinery (and life cycle) emissions for most criteria pollutants. The reduction is especially significant for sulfur dioxide (SOx) emissions.

Allocation↗
DOE OSTI2019

Criteria Air Pollutant and Greenhouse Gases Emissions from U.S. Refineries Allocated to Refinery Products

Using Greenhouse Gas Reporting Program data (GHGRP) and National Emissions Inventory data from 2014, we investigate U.S. refinery greenhouse gas (GHG) emissions (CO2, CH4, and N2O) and criteria air pollutant (CAP) emissions (VOC, CO, NOx, SO2, PM10, and PM2.5). The study derives (1) combustion emission factors (EFs) of refinery fuels (e.g., refinery catalyst coke and refinery combined gas), (2) U.S. refinery GHG emissions and CAP emissions per crude throughput at the national and regional levels, and (3) GHG and CAP emissions attributable to U.S. refinery products. The latter two emissions were further itemized by source: combustion emission, process emission, and facility-wide emission. We estimated U.S. refinery product GHG and CAP emissions via energy allocation at the refinery process unit level. The unit energy demand and unit flow information were adopted from the Petroleum Refinery Life Cycle Inventory Model (PRELIM version 1.1) by fitting individual U.S. refineries. This study fills an important information gap because it (1) evaluates refinery CAP emissions along with GHG emissions and (2) provides CAP and GHG emissions not only for refinery main products (gasoline, diesel, jet fuel, etc.) but also for refinery secondary products (asphalt, lubricant, wax, light olefins, etc.).

allocation↗
DOE OSTI2019

Expansion of the Petroleum Refinery Life Cycle Inventory Model (PRELIM) to Support Characterization of a Full Suite of Commonly Tracked Impact Potentials

This study updates the Petroleum Refinery Life Cycle Inventory Model (PRELIM) to provide a more complete gate-to-gate life cycle inventory and to allow for the calculation of a full suite of impact potentials commonly used in life cycle assessment (LCA) studies. We updated the model to add criteria air pollutants, hazardous air pollutants, releases to water, releases to land, and managed wastes reflecting 2014 reported releases and waste management practices using data from the U.S. Environmental Protection Agency Greenhouse Gas Reporting Program, National Emissions Inventory, Discharge Monitoring Reports, and Toxic Release Inventory together with process unit capacities and fuel consumption data from the U.S. Energy Information Administration (U.S. EIA). The expanded version of PRELIM offers users a reliable, transparent, and streamlined tool for estimating the effect of changes in petroleum refineries on LCIA results in the context of policy analysis.

Source record↗
DOE OSTI2020

Quantitative Determination of Biomass-derived Renewable Carbon in Fuels from Coprocessing of Bio-oils in Refinery Using a Stable Carbon Isotopic Approach

Increasing renewable carbon incorporation into conventional fuels through coprocessing with vacuum gas oil (VGO, a petroleum refining feedstock) is a critical step in biofuels development, scaling-up, adoption and associated GHG reduction. Optimization of the co-processing parameters maximizes incorporation of the renewable carbon in the fuel products. Quantitative determination of the renewable carbon content in the co-processed products provides direct evaluation of the parameters. The co-processing bio-oil with VGO through hydrocracking (HC) or fluid catalytic cracking (FCC) system resulted in carbon isotopic fractionation that prevented the direct use of the isotope mixing model for quantifying the renewable carbon. Here, we report an algorithm of using a stable carbon isotope approach to quantify the renewable carbon content in co-processing biofuel products through high-precision ?13C analysis. A controlled experiment carried out by blending a fossil diesel (-29.013‰) with a bio-diesel (-30.099‰) at various blending levels up to 98.0/2.0 wt% is presented and has demonstrated the applicability of this approach. The carbon isotope fractionation factors for the bio-oil co-processing were obtained by using a 14C-derived isotope-mixing model. The ?13C method was tested by co-processing 13C-labeled bio-crude and natural woody biomass-derived fast pyrolysis (FP) and catalytic fast pyrolysis (CFP) bio-oils with VGO. The results were verified by 14C accelerator mass spectrometry (AMS) method (ASTM-D6866) and compared with the yield mass balance (YMB) method. Strong agreement between d13C and 14C AMS methods demonstrated the applicability of the ?13C method to quantify renewable carbon content in co-processing fuel products and guide the co-processing optimization

Li, Zhenghua↗
DOE OSTI2024

Prospects of hydrogen cogeneration and carbon dioxide utilization in electrochemical refineries for ethylene production via oxidative coupling of methane: A techno-economic assessment

Ethylene is recognized as one of the most significant chemicals globally. The projected ethylene production for 2023 stands at 227.6 million tonnes, with expectations of continued demand growth. The primary use of ethylene, accounting for over 76%, lies in the production of plastics such as polyethylene, polyvinyl chloride, and polystyrene. Despite the enduring carbon retention potential of plastics themselves, traditional ethylene feedstock production from fossil resources contributes substantially to greenhouse gas emissions, ranging from 0.29 to 2.29 kg CO2 /kg Ethylene depending on various factors like feedstock and process design. Various decarbonization strategies, including the utilization of hydrogen as a primary heat source, have been proposed to reduce the carbon footprint of ethylene production, but their efficacy remains limited, offering at best a 0–30% reduction in on-site CO 2 emissions.

09 BIOMASS FUELS↗
DOE OSTI2016

Well-to-Wheels Greenhouse Gas Emission Analysis of High-Octane Fuels with Ethanol Blending: Phase II Analysis with Refinery Investment Options

Higher-octane gasoline can enable increases in an internal combustion engine’s energy efficiency and a vehicle’s fuel economy by allowing an increase in the engine compression ratio and/or by enabling downspeeding and downsizing. Producing high-octane fuel (HOF) with the current level of ethanol blending (E10) could increase the energy and greenhouse gas (GHG) emissions intensity of the fuel product from refinery operations. Alternatively, increasing the ethanol blending level in final gasoline products could be a promising solution to HOF production because of the high octane rating and potentially low blended Reid vapor pressure (RVP) of ethanol at 25% and higher of the ethanol blending level by volume. In our previous HOF well-to-wheels (WTW) report (the so-called phase I report of the HOF WTW analysis), we conducted WTW analysis of HOF with different ethanol blending levels (i.e., E10, E25, and E40) and a range of vehicle efficiency gains with detailed petroleum refinery linear programming (LP) modeling by Jacobs Consultancy and showed that the overall WTW GHG emission changes associated with HOFVs were dominated by the positive impact associated with vehicle efficiency gains and ethanol blending levels, while the refining operations to produce gasoline blendstock for oxygenate blending (BOB) for various HOF blend levels had a much smaller impact on WTW GHG emissions (Han et al. 2015). The scope of the previous phase I study, however, was limited to evaluating PADDs 2 and 3 operation changes with various HOF market share scenarios and ethanol blending levels. Also, the study used three typical configuration models of refineries (cracking, light coking, and heavy coking) in each PADD, which may not be representative of the aggregate response of all refineries in each PADD to various ethanol blending levels and HOF market scenarios. Lastly, the phase I study assumed no new refinery expansion in the existing refineries, which limited E10 HOF production to the volume achievable by the cracking refinery configuration. To be able to satisfy large market demands of E10 HOF, that study arbitrarily relaxed the RVP requirements by replacing reformulated gasoline (RFG) RVP requirement of 7 psi in summer with conventional gasoline (CG) RVP requirement of 9 psi in summer. To examine the response by all refineries in major refinery regions, this phase II of the HOF WTW analysis employed regionally aggregated refinery models for the following six regions: PADDs 1, 2, 3, 4, and 5 excluding California (CA) and CA separately. Using aggregate refinery models, this phase II study examined the impacts of ethanol blending and HOF market shares on the refinery operations in these six regions. Also, this study included refinery expansion to produce a pre-determined HOF volume with 10% ethanol blending. In particular, this study examined several refinery expansion options using refinery configuration models to investigate a practical refinery response to the increase in E10 HOF market demand.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Comparative techno-economic and environmental analysis of using nuclear energy and fossil energy with carbon sequestration in U.S. Gulf Coast petroleum refineries

U.S. Gulf Coast refineries have processing capacity of approximately 9.4 million barrels of crude oil per day—about 50% of U.S. national capacity—while consuming natural gas, electricity, and hydrogen, resulting in approximately 100 million metric tonnes (MMT) of onsite CO₂ emissions in 2022. This study evaluates two alternative refinery energy supply pathways: nuclear energy (NE) and fossil energy-derived hydrogen with carbon capture and sequestration (FE-CCS; autothermal reforming), intermittent renewable sources are not considered as they cannot reliably meet continuous industrial heat and hydrogen demands. Using publicly available data for refineries, we conducted a bottom-up, facility-level assessment to estimate energy use by type, well-to-gate refinery emissions, and associated costs of integration. Compared to current refinery operations using natural gas energy supply and conventional hydrogen production (steam methane reforming without sequestration), NE and FE-CCS could produce, respectively, average emissions reductions of 37% and 42%, total abatement costs of $\$$52–$\$$221 and $\$$211–$\$$612/MT CO₂, and additional costs of about $\$$0.2–$\$$6 and $\$$3–$\$$11 per barrel of crude, respectively. Our analysis indicates that 25 out of 27 refineries have lower total additional cost ($\$$/bbl.) for the NE scenario than the FE-CCS scenario, making a strong case for NE integration with petroleum refineries. This work's main contribution is a detailed bottom-up refinery-level analysis method that can be utilized by the worldwide refining industry and stakeholders as they assess different technological options, along with their costs and environmental impacts for a specific refinery operation.

Carbon capture and sequestration↗
DOE OSTI2016

Mild Biomass Liquefaction Process for Economic Production of Stabilized Refinery-Ready Bio-oil

Southern Research (SR) in cooperation with U.S. Department of Energy (DOE), Bioenergy Technology Office (BETO), investigated a biomass liquefaction process for economic production of stabilized refinery-ready bio-oil. The project was awarded by DOE under a Funding Opportunity Announcement (DE-FOA-0000686) for Bio-oil Stabilization and Commoditization that intended to evaluate the feasibility of using bio-oil as a potential feedstock in an existing petroleum refinery. SR investigated Topic Area 1 of the FOA at Technology Readiness Level 2-3 to develop thermochemical liquefaction technologies for producing a bio-oil feedstock from high-impact biomass that can be utilized within a petroleum refinery. Bio-oil obtained from fast pyrolysis of biomass is a green intermediate that can be further upgraded into a biofuel for blending in a petroleum refinery using a hydro-deoxygenation (HDO) route. Co-processing pyrolysis bio-oil in a petroleum refinery is an attractive approach to leverage the refinery’s existing capital. However, the petroleum industry is reluctant to accept pyrolysis bio-oil because of a lack of a standard definition for an acceptable bio-oil feedstock in existing refinery processes. Also per BETO’s multiyear program plan, fast pyrolysis-based bio-fuel is presently not cost competitive with petroleum-based transportation fuels. SR aims to develop and demonstrate a cost-effective low-severity thermal liquefaction and hydrodeoxygenation (HDO) process to convert woody biomass to stabilized bio-oils that can be directly blended with hydrotreater input streams in a petroleum refinery for production of gasoline and/or diesel range hydrocarbons. The specific project objectives are to demonstrate the processes at laboratory scale, characterize the bio-oil product and develop a plan in partnership with a refinery company to move the technology towards commercialization.

09 BIOMASS FUELS↗
DOE OSTI2024

Technical and Economic Assessment and Gap Analysis of Advanced Nuclear Reactor Integration with a Reference Oil Refinery

Efforts to identify the most-economic methods to decarbonize several sectors of the U.S. economy are underway. Industrial processes such as crude-oil refining rely heavily on energy-dense and easily stored and transported fossil fuels for powering their operations. Refineries use large amounts of energy, primarily derived from fossil sources to separate crude-oil components, break down heavier hydrocarbons into lighter compounds, remove impurities, reform hydrocarbon molecules, and generate steam and electricity for pumps and compressors and other various auxiliary systems. Crude-oil refining operations such as distillation, cracking, desulfurization, reforming, utilities systems and some offsite facilities collectively account for most of the energy consumption. Other operations such as hydrocracking or hydrotreating also require hydrogen for developing hydrogenation reactions which involve substantial heating to keep the reactors at high-temperature and pressure levels. All heat and energy demands are typically provided by natural gas (NG), oil, or other fuels, which makes refinery industry one of the most-difficult sectors to decarbonize. Nuclear power is a viable and energy-dense source of clean electricity, heat, and hydrogen to provide the large, sustainable energy supply that the refining industry demands. The U.S. Department of Energy’s (DOE’s) Integrated Energy Systems (IES) program is working to perform research and development, design, economic siting, and risk analysis. This state-of-the-art work will enable the first on-site demonstrations and commercial deployments of advanced small modular nuclear reactors (SMNRs) integrated with industries such as chemical production, refining, iron and steel making, and more. IES seeks to demonstrate the ability of advanced nuclear reactors to meet the heat and power demands of these industries while reducing carbon emissions in a sustainable and cost-competitive way. The primary objective of this research effort is to analyze industrial-scale SMNR integration intended to decarbonize refining facilities. The foreseen outcome is the provision of reliable, cost-competitive, and sustainable clean energy, alongside a reduction of carbon emissions. Specifically, the focus of this work lies on meeting the reference facilities’ heat and electricity demands with nuclear power while also supplying clean hydrogen via integrated high-temperature steam electrolysis (HTSE). This report presents a comprehensive technical and economic assessment of the integration of advanced nuclear reactors into a reference refinery, leveraging financial incentives from the Inflation Reduction Act (IRA). The evaluation aims to explore the potential economic benefits and challenges associated with incorporating advanced nuclear reactors into refinery operations, particularly in terms of energy efficiency, economic implications and environmental impact. By examining both the technical feasibility and economic viability, this analysis seeks to identify existing gaps and propose solutions for successful nuclear integration implementation. The findings are intended to provide valuable insights for stakeholders considering the adoption of advanced nuclear reactors in the refining sector. A refinery reference-plant was developed, using an open-source refinery model, Petroleum Refinery Lifecycle Inventory Model (PRELIM) and expert assessment, as a base case for comparison with various nuclear integration options. The capacity of 100 kbd/day (KBD) of heavy crude-oil feed was selected to represent a general coking-type refinery with deep conversion capabilities (incorporating heavy-oil upgrading with FCC, coking, and associated hydrotreating process units), using a heavy crude-oil feed, which represents about 70% of U.S. refineries configurations. A summary of all cases considered in this study is shown in Table 1.

13 HYDRO ENERGY↗
DOE OSTI2020

Air Pollutant Emissions and Regulatory Implications of Co-Processing Raw Bio-Oil in U.S. Petroleum Refineries

Pyrolysis oil, often referred as bio-oil or biocrude, has attracted considerable attention because it has higher energy density and carbon content compared to the raw biomass. Using pyrolysis oil derived from low cost and underutilized biomass to produce renewable hydrocarbon fuels provides a viable link between the agriculture/forestry and (petro-) chemical industry. Co-processing bio-oil with vacuum gas oil (VGO) in petroleum refinery is appealing due to the relatively low capital requirement to retrofit refinery and the compatibility of fuel products with existing infrastructure. In order to implement co-processing, a petroleum refinery would need to consider several process modifications and therefore could be subject to varying levels of air permitting requirements based on bio-oil co-processing ratio, co-processing capacity in existing units, the amount of regulated pollutants expected to be emitted, among other factors. This analysis considers co-processing 5% (by weight) of raw bio-oil with VGO in the fluidized catalytic cracking (FCC) unit(s) in a petroleum refinery. We estimate the potential increase in emissions of regulated air pollutants resulting from the modifications required to implement bio-oil co-processing and evaluate the regulatory and permitting implications for three FCC size categories in the U.S. refineries, which could co-processes raw bio-oil to produce partially renewable transportation fuels. We also assess technically feasible emission control options petroleum refineries could adopt to avoid being subject to major source permitting requirements if the estimated increase in regulated air pollutant emission exceeds the applicable threshold for major modifications. Insights from our analysis can help overcome challenges and risks associated with timely obtaining air permits required to implement bio-oil co-processing in existing refineries. Our analysis also provides needed information for decision makers (e.g., local air quality agencies) to understand the potential air quality implications for retrofitting refineries to co-process bio-oil, particularly in areas with high concentration of petroleum refineries.

09 BIOMASS FUELS↗
DOE OSTI2025

Refinery Integration Analysis: Pathways, Challenges, and Opportunities

Integrating biomass-derived intermediates into traditional petroleum refineries presents unique challenges and opportunities, requiring innovative analysis approaches that account for biofuel producers and refiners. Consequently, teams within the National Renewable Energy Laboratory (NREL) have developed a comprehensive refinery integration analysis framework that combines experimental data, detailed techno-economic analyses of bio-conversion pathways, and economic projections within refinery linear programming (LP) optimization models. These models enable the identification of promising bio-integration strategies tailored to specific refinery configurations, economic conditions, and production goals. They also capture upstream and downstream impacts, highlighting critical bottlenecks and research opportunities for increasing the share of biogenic feedstocks in traditional refining operations. Refinery models are also packaged into a broader bio-economy optimization framework which enables biofuel supply chain optimization with standalone biofuel production and refinery co-processing/repurposing options. This presentation discusses promising refinery bio-integration strategies along with key challenges and opportunities identified using NREL's refinery and bio-economy optimization frameworks.

09 BIOMASS FUELS↗
DOE OSTI2023

An Analysis of the Potential and Cost of the U.S. Refinery Sector Decarbonization

In 2019, U.S. petroleum refineries emitted 196 million metric tons (MT) of CO 2 , while the well-to-gate and the full life cycle CO 2 emissions were significantly higher, reaching 419 and 2843 million MT of CO 2 , respectively. This analysis examines decarbonization opportunities for U.S. refineries and the cost to achieve both refinery level and complete life-cycle CO 2 emission reductions. Here, we used 2019 life-cycle CO 2 emissions from U.S. refineries as a baseline and identified three categories of decarbonization opportunity: (1) switching refinery energy inputs from fossil to renewable sources (e.g., switch hydrogen source); (2) carbon capture and storage of CO 2 from various refining units; and (3) changing the feedstock from petroleum crude to biocrude using various blending levels. While all three options can reduce CO 2 emissions from refineries, only the third can reduce emissions throughout the life cycle of refinery products, including the combustion of fuels (e.g., gasoline and diesel) during end use applications. A decarbonization approach that combines strategies 1, 2, and 3 can achieve negative life-cycle CO 2 emissions, with an average CO 2 avoidance cost of $\$113$ - $\$477$/MT CO 2 , or $\$54$ - $\$227$/bbl of processed crude; these costs are driven primarily by the high cost of biocrude feedstock.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2018

Air Pollutant Emissions and Regulatory Implications of a Biorefinery Co-Processing Bio-Oil in a Petroleum Refinery: Preprint

Pyrolysis oil, often referred to as bio-oil when derived from biomass through a fast pyrolysis process, has attracted considerable attention because of the high carbonaceous matter and high heating value compared to the original biomass. Pyrolysis oil provides a viable link between the agriculture/forestry and (petro-) chemical industry. Utilizing existing fossil fuel infrastructure by introducing bio-oil in petroleum refineries to produce renewable hydrocarbon fuels (i.e., repurposing existing assets) is appealing due to its relatively low capital requirement. Our analysis examined the air pollutant emissions for a biorefinery utilizing an ex situ catalytic fast pyrolysis process to produce raw bio-oil, with a design capacity of 2,000 dry metric tons of biomass per day. Such a biorefinery is capable of providing sufficient bio-oil to a 4,200 barrels per day capacity of fluidized catalytic cracking unit if the bio-oil is co-processed at 5% (by volume) feed rate. This research is focused on understanding the potential air pollutant regulatory and permitting implications for a refinery co-processing 5% bio-oil with 95% vacuum gas oil in a fluidized catalytic cracking unit for two scenarios: the first case assumes that an ex situ biorefinery is collocated with a petroleum refinery, and the second one assumes that a petroleum refinery will receive bio-oil from a stand-alone biorefinery. We estimated the potential-to-emit values for 4 biorefinery and FCC sizes and assessed technically feasible emission control options that could help to avoid being subject to prevention of significant deterioration requirements due to petroleum refinery modifications to co-process bio-oil. This research fills gaps and overcomes barriers related to air permitting requirements for co-processing bio-oil in existing refineries for various stakeholders. The insights gained from this analysis can facilitate decision making and help expedite permitting processes for petroleum refineries, which seek opportunities to produce lower carbon fuels in their existing infrastructure.

09 BIOMASS FUELS↗