Development of Baseline Data and Analysis of Life Cycle Greenhouse Gas Emissions of Petroleum-Based Fuels November 26, 2008 DOE/NETL-2009/1346 Disclaimer This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference therein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed therein do not necessarily state or reflect those of the United States Government or any agency thereof. Development of Baseline Data and Analysis of Life Cycle Greenhouse Gas Emissions of Petroleum-Based Fuels DOE/NETL-2009/1346 November 26, 2008 NETL Contacts: Timothy J. Skone, P.E. Kristin Gerdes Office of Systems, Analyses and Planning National Energy Technology Laboratory www.netl.doe.gov This page intentionally left blank. Acknowledgements This work was funded by the U.S. Department of Energy’s National Energy Technology Laboratory (U.S. DOE-NETL). The NETL sponsor for this project was Dan Cicero, Office of Coal and Power R&D, Technology Manager for Hydrogen and Syngas Program. The NETL management team provided guidance and technical oversight for this study. Contract support was provided by Massood Ramezan and Barbara Bennett, Research and Development Solutions, LLC (RDS) under contract number DE-AC26-04NT 41817.403.01.12A. NETL would like to acknowledge and thank the contributions of Bill Harrison, U.S. Air Force Research Laboratory; Dr. James Hileman, Massachusetts Institute of Technology; and Dr. Joyce Cooper, University of Washington for their review comments that helped improve the quality of this report. NETL would also like to thank Aaron Levy and Ari Kahan from the U.S. Environmental Protection Agency, Office of Transportation and Air Quality for developing the national average vehicle emissions profile for the year 2005. This page intentionally left blank. Table of Contents List of Tables ................................................................................................................................ vi List of Figures............................................................................................................................... xi Acronyms and Abbreviations ................................................................................................... xiv Executive Summary.............................................................................................................. ES - 1 1.0 Introduction....................................................................................................................... 1 1.1 Background..................................................................................................................... 1 1.2 Purpose & Goal of the Study .......................................................................................... 2 1.3 Study Boundary and Modeling Approach ...................................................................... 2 1.3.1 Scope of the Environmental Life Cycle Analysis................................................... 2 1.3.2 Cut-off Criteria for the System Boundary .............................................................. 4 1.3.3 Exclusion of Data from the System Boundary ....................................................... 4 1.3.4 Data Reduction and Allocation Procedures ............................................................ 5 1.3.5 Geography, Technology and Time-frame Represented.......................................... 5 1.4 Life Cycle Stages ............................................................................................................ 5 2.0 LC Stage #1: Raw Material Acquisition ........................................................................ 8 2.1 Raw Material Acquisition for Domestic Petroleum Refineries ...................................... 8 2.1.1 Crude Oil Acquisition............................................................................................. 9 2.1.1.1 Crude Oil Extraction GHG Profiles.................................................................... 9 2.1.1.2 Canadian Crude Oil Mix Extraction GHG Profile............................................ 11 2.1.1.3 Crude Oil Mix Composite Extraction GHG Profiles........................................ 12 2.1.2 Natural Gas Liquids Extraction and Processing ................................................... 13 2.1.3 Unfinished Oils Extraction and Processing .......................................................... 14 2.1.4 LC Stage #1 Summary for Domestic Refineries................................................... 15 2.2 Raw Material Acquisition for Foreign Petroleum Refineries....................................... 15 2.2.2 Raw Material Extraction for Gasoline Imports..................................................... 22 2.2.3 Raw Material Extraction for Diesel Imports......................................................... 22 2.2.4 Raw Material Extraction for Jet Fuel Imports ...................................................... 22 2.3 Summary of Life Cycle Stage #1 GHG Emissions Profiles ......................................... 23 3.0 Life Cycle Stage #2: Raw Material Transport ............................................................ 24 3.1 Crude Oil Mix Transport .............................................................................................. 25 3.1.1 Crude Oil Mix Transport to Domestic Refineries................................................. 25 i 3.1.1.1 Crude Oil Transport within Exporting Country................................................ 25 3.1.1.2 Crude Oil Mix Ocean Transport to Domestic Ports.......................................... 25 3.1.1.3 Crude Oil Mix Domestic Transport .................................................................. 27 3.1.2 Crude Oil Mix Transport to Foreign Refineries ................................................... 30 3.2 Natural Gas Liquids Transport...................................................................................... 31 3.3 Unfinished Oils Transport............................................................................................. 31 3.4 Summary of Life Cycle Stage #2 GHG Emissions Profiles ......................................... 32 4.0 Life Cycle Stage #3: Liquid Fuels Production.............................................................. 33 4.1 General Description of a Petroleum Refinery............................................................... 34 4.2 Liquid Fuels Production at Domestic Petroleum Refineries......................................... 37 4.2.1 Reported Refinery Data ........................................................................................ 39 4.2.2 Refinery Energy Usage......................................................................................... 39 4.2.3 Fuels Acquisition.................................................................................................. 41 4.2.3.1 Purchased Electricity and Steam....................................................................... 41 4.2.3.2 Coal................................................................................................................... 42 4.2.3.3 Natural Gas....................................................................................................... 47 4.2.3.4 Refinery-Produced Fuels.................................................................................. 47 4.2.3.5 Refinery Fuels Acquisition Emissions Profile.................................................. 48 4.2.4 Refiner Fuels Combustion .................................................................................... 48 4.2.4.1 CO2 Emissions from Refinery Fuels Combustion ............................................ 48 4.2.4.2 Methane Emissions from Refinery Fuels Combustion ..................................... 48 4.2.4.3 N2O Emissions from Refinery Fuels Combustion............................................ 49 4.2.4.4 Refinery Fuels Combustion Emissions Profile................................................. 50 4.2.5 Hydrogen Production............................................................................................ 51 4.2.5.1 Hydrogen Production Via Steam Methane Reforming (SMR)......................... 52 4.2.5.2 Hydrogen Produced from Catalytic Reformer.................................................. 55 4.2.5.3 Summary of Hydrogen Pool ............................................................................. 56 4.2.6 Flaring Operations................................................................................................ 58 4.2.6.1 CO2 Emissions .................................................................................................. 58 4.2.6.2 Methane Emissions ........................................................................................... 58 4.2.6.3 N2O Emissions.................................................................................................. 60 4.2.7 Vented/Fugitive Emissions ..................................................................................