CREATION OF UNIT PROCESS DATA FOR LIFE CYCLE ASSESSMENT OF STEAM METHANE REFORMING AND PETROLEUM REFINING PREPARED BY: Ben Young, Ben Morelli and Troy R. Hawkins Franklin Associates, A Division of Eastern Research Group (ERG) 110 Hartwell Avenue Lexington, Massachusetts PREPARED FOR: Amgad Elgowainy, Jeongwoo Han, Zifeng Lu, and Pingping Sun Argonne National Laboratory 9700 S. Cass Avenue, Building 362 Argonne, Illinois 60439 October 2017 This page is intentionally blank. TABLE OF CONTENTS 1. BACKGROUND ................................................................................................................................................ 5 2. STANDARDIZED DEFINITIONS .................................................................................................................. 5 3. DATASETS ........................................................................................................................................................ 8 3.1. CRITERIA AIR POLLUTANT EMISSIONS ........................................................................................... 9 3.2. GREENHOUSE GAS EMISSIONS ......................................................................................................... 10 3.3. SUBPROCESS ACTIVITY LEVELS...................................................................................................... 11 3.4. FUEL CONSUMPTION .......................................................................................................................... 15 3.5. PRODUCT OUTPUTS............................................................................................................................. 16 4. EMISSION FACTORS FOR REFINERY PRODUCTS .............................................................................. 23 4.1. ASSIGNING EMISSIONS TO REFINERY SUBPROCESS UNITS ..................................................... 23 4.2. ASSIGNING HEAT RELATED EMISSIONS TO REFINERY SUBPROCESS UNITS FROM UNIT THROUGHPUT ..................................................................................................................................................... 25 4.3. ALLOCATING REFINERY SUBPROCESS UNIT EMISSIONS TO FINAL PRODUCTS ................. 30 4.4. EMISSION FACTORS BY REFINERY PRODUCT .............................................................................. 33 4.5. VALIDATING FINAL PRODUCT EMISSION FACTORS .................................................................. 37 5. COMBUSTION-RELATED EMISSION FACTORS BY FUEL TYPE AT REFINERIES ..................... 47 5.1. CLASSIFYING COMBUSTION EMISSIONS BY FUEL TYPE ........................................................... 47 5.2. EMISSION FACTORS BY FUEL TYPE ................................................................................................ 51 5.3. VALIDATING COMBUSTION EMISSION FACTORS ....................................................................... 54 6. EMISSION FACTORS FOR HYDROGEN PRODUCTION AT SMR FACILITIES.............................. 60 7. REFERENCES ................................................................................................................................................. 62 APPENDIX A. SUPPORTING INFORMATION .................................................................................................. 65 ALLOCATION FACTOR VERIFICATION SUPPORTING INFORMATION ................................................... 95 1 FIGURES Figure 2-1. Process diagram of general petroleum refinery showing process options. .................................................. 6 Figure 4-1. Simplified example of calculating final product allocation factors via PRELIM subprocess output. ....... 31 Figure 4-2. Comparison of PRELIM and EIA estimates of vacuum distillation utilization per bbl of crude input, [ThroughputPRELIM–ThroughputEIA]/ThroughputEIA. .................................................................................................... 38 Figure 4-3. Comparison of PRELIM and EIA estimates of fluid catalytic cracker utilization per bbl of crude input, [ThroughputPRELIM–ThroughputEIA]/ThroughputEIA. .................................................................................................... 39 Figure 4-4. Comparison of PRELIM and EIA estimates of coking utilization per bbl of crude input, [ThroughputPRELIM–ThroughputEIA]/ThroughputEIA. .................................................................................................... 39 Figure 4-5. Comparison of PRELIM and EIA estimates of gas oil catalytic hydrocracking utilization per bbl of crude input, [ThroughputPRELIM–ThroughputEIA]/ThroughputEIA. .......................................................................................... 40 Figure 4-6. Comparison of PRELIM and EIA estimates of total hydrotreating utilization per bbl of crude input, [ThroughputPRELIM–ThroughputEIA]/ThroughputEIA. .................................................................................................... 40 Figure 4-7. Comparison of PRELIM and EIA estimates of catalytic reformer utilization per bbl of crude input, [ThroughputPRELIM–ThroughputEIA]/ThroughputEIA. .................................................................................................... 41 Figure 4-8. Comparison of PRELIM and EIA estimates of isomerization utilization per bbl of crude input, [ThroughputPRELIM–ThroughputEIA]/ThroughputEIA. .................................................................................................... 41 Figure 4-9. Comparison of PRELIM and EIA estimates of alkylation utilization per bbl of crude input, [ThroughputPRELIM–ThroughputEIA]/ThroughputEIA. .................................................................................................... 42 Figure 4-10. Histogram representing the percent difference in EIA reported and PRELIM estimated production of 14 products for each PADD. ............................................................................................................................................. 44 Figure 4-11. Comparison of refinery final product emission factors. Emissions factors for each pollutant are normalized to the maximum emissions factor for that pollutant.................................................................................. 45 Figure 5-1. Contributions of fuel type to combustion emissions at each PADD. ........................................................ 49 Figure 5-2. Comparing EIA fuel consumption at refineries to estimated fuel consumption calculated from GHGRP reported CO2 emissions. .............................................................................................................................................. 51 Figure 5-3. Comparison of combustion emission factors. ........................................................................................... 56 Figure 5-4. Distribution of Fluid Catalytic Cracker CO2 emissions compared to unit throughput. ............................ 58 Figure 5-5. Comparing catalyst coke consumption with Fluid Catalytic Cracker unit throughput at each PADD ...... 59 Figure 5-6. Distribution of CO2 emission factors at the Fluid Catalytic Cracker by PADD ....................................... 59 Figure 6-1. Comparison of emission factors for hydrogen production in 2014. .......................................................... 61 Figure 7-1. Comparison of combustion emission factors.. .......................................................................................... 94 Figure 7-2. Comparison of emission factors for hydrogen production in 2011. .......................................................... 97 2 TABLES Table 2-1. Refinery subprocess presence within datasets. ............................................................................................. 7 Table 2-2. Overview of flows used to develop life cycle inventory. ............................................................................. 8 Table 2-3. Overview of final products for life cycle inventory of refineries. ................................................................ 8 Table 3-1. Data sources for use in creating emission LCIs based on reported releases and emission/activity factors. 8 Table 3-2. Correspondence between NEI source categorization and process diagram unit ID numbers. .................... 10 Table 3-3. Fuel type categories for sources of combustion emissions under GHGRP Subpart C. .............................. 11 Table 3-4. Correspondence between GHGRP source categorization and process diagram unit ID numbers. ............. 11 Table 3-5. EIA unit capacity designations. Correspondence to refinery subprocess unit in parenthesis. .................... 12 Table 3-6. PADD level refinery unit throughput (in millions), 2014. ......................................................................... 14 Table 3-7. Fuel consumption at refineries, 2014. ........................................................................................................ 15 Table 3-8. Adjusted fuel consumption at refineries for NEI Emissions dataset by PADD, 2014. ............................... 15 Table 3-9. Correspondence between refinery products across EIA and PRELIM. ...................................................... 16 Table 3-10. Final product output at refineries by PADD (in thousands), 2014. .......................................................... 18 Table 3-11. Comparison of allocation options for final product output at refineries, 2014. ........................................ 18 Table 3-12. Comparison