We seem to again and again come up to the topic of Refinery energy consumption. This doesn't include oil and syn oil production or transporation of the fuels and other products, but hopefully it will provide a baseline on energy consumed and what it is. The US government has compiled most of the statistics. http://www.energystar.gov/sites/default/files/tools/ENERGY_STAR_Guide_Petroleum_Refineries_20150330.pdf Page 22 has the breakdown by type of energy in a chart. This is is great we have 2010 figures.,Perhaps 18 Twh electricity produced, 62 Twh consumed (using that 29%), meaning 44 Twh of electricity purchased, which looks correct on the chart on page 23.
That sounds right. So for electricity, we're looking at ~.25kWh/gallon (refined gasoline/diesel/jet fuel/propane). Natural gas is ~234billion kWh, which is ~.4+kWh/gallon of natural gas assuming it was used in a CC nat gas plant to generation electricity. Coal maybe adds another ~.1kWh if it was used to generate electricity, so the national average is something like ~.75kWh/gallon for refining.
I found this more up to date figure from eia. It is about as you said U.S. Fuel Consumed at Refineries 2014 had 893.2 billion cubic feet, which is 262 billion kwh, if burned in the average natural gas power plant at 42% efficiency and 7% grid losses that comes to .102.3 billion kwh of electricity at the plug, more if you do it in a new ccgt versus average usage. Purchased electricity is 47.2 billion kwh coal is 16,000 short tons, if we use 2000 kwh per short ton that is 32 million kwh or a rounding error. This coal would not be burned in the US if not at the refinery. There are 130.5 billion pounds of purchased steam, I'm not sure if the energy to produce that could be converted to electricity, or how much it would provide. So really if the natural gas and electricity was used we get 149.5 billion kwh electricity at the plug. I'm not sure what to divide by to get kwh per gallon. Do you assign it all to gasoline? Or to gasoline and diesel? Or to all refined products (maybe not coke) leaving the refinery.
I'm assigning it to all fuels from refining, which as near as I can tell, is ~36 gallons. It's mostly gasoline (19+)... then diesel (9), jet-fuel (4), propane(2+), and misc fuels like kerosene, etc... (2+). There's ~3% lower refining efficiency when comparing gasoline to diesel/jet-fuel/propane, so I think we should bump up the energy inputs for gasoline by that amount and reduce the inputs for the other fuels by the same amount. All told, we use ~6.95 billion barrels of oil per year, so that's 250 billion gallons of fuel.
According to eia the US refineries processed 6.05 billion barrels of oil (not inclucding other energy imputs in 2014. We can break it down per barrel 7.8 kwh purchased electricity 43.3 kwh of natural gas that would produce (17.3 kwh of electricity at the plug if produced at average grid efficiency) 21.6 pounds of purchased steam 0.005 pounds of coal, I think we can ignroe that From the oil they use 0.6 gallons of coke 1.6 gallons of still gas and hydrocarbons other than coke These items represent most of the ghg and energy used at the refinery. If we ignore the steam which I don't know how to handle and use the electricity produced by natural gas we get 25.1 kwh of electricity. The crack of a barrel gives us 44.8 gallons of product, if we subtract the 2.2 gallons of product used at the refinery we get 42.6 gallons that can be sold. U.S. Refinery Yield 18.9 gallons of gasoline 12.5 gallons of diesel and other fuel oil 4 gallons of aviation fuel 1.1 gallons of residual fuel oil ----------------------------------------------- 36.6 gallons of fuel + 6 gallons of other stuff leaving the refinery (note most of the coke needs to be exported to foreign countries, and if they change their laws may need to be buried). Lets just consider the fuel and not other stuff, if all natural gas was put as electricity then 0.7 kwh of electricity or natural gas to make electricity for each gallon of fuel at US refineries. Note E10 only uses 0.9 of refined product plus 0.1 of ethanol. The ethanol probably needed much more electricity and natural gas than the gasoline portion.
