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Material · Natural

Crude oil

A mixture, not a substance — and the feedstock behind almost every synthetic polymer, before it is anything to do with fuel.

Fuel

Crude oil is not a compound and has no formula. It is a mixture of thousands of hydrocarbons, varying enough between fields that grades are traded as separate commodities, and a refinery is built for the crude it expects to receive.

Most of a barrel becomes fuel. The part that matters here is the light fraction — naphtha — which is the feedstock for almost every synthetic polymer in use. Roughly a twentieth of world oil production ends up as plastic, which is small next to combustion and large next to everything else made from it.

Processing

Fractional distillation separates the mixture by boiling point: gases at the top of the column, then naphtha, kerosene, diesel, and residue at the bottom. Nothing is chemically changed at this stage — the fractions were already there.

The chemistry comes afterwards. Cracking breaks long molecules into short ones, reforming rearranges them, and it is cracking that produces the small reactive molecules polymers are built from. A refinery configured for fuel and one configured for petrochemicals make very different cuts from the same barrel.

Uses

As fuel, in a volume nothing else approaches. As the feedstock for polymers, solvents, detergents, synthetic fibres, fertiliser precursors, lubricants and bitumen. As asphalt, which is the bottom of the barrel used as a road.

The materials argument and the energy argument pull apart here and are constantly conflated. Ending combustion does not end petrochemical demand, and a polymer industry supplied from a fifth of current production would still need the molecules from somewhere.

History

Used from natural seeps for millennia — as bitumen for waterproofing and mortar in Mesopotamia long before anyone drilled for it. The industry begins in the 1850s and 1860s with kerosene for lamps, which was the product that mattered; petrol was initially a waste stream with no market.

The petrochemical use is a twentieth-century afterthought that became the second reason the industry exists. Almost every polymer in common use postdates 1930, and none of them would have been economic without a cracking industry already built for fuel.

Environmental impact

The combustion argument is not a materials question and is not made here. What is a materials question: a polymer made from oil locks its carbon into a solid rather than releasing it, and releases it at end of life only if the object is burned.

The extraction impacts are local and real — produced water, flaring, spills, and the disturbance of drilling — and they attach to the barrel rather than to any one product made from it. Attributing them to plastic specifically requires deciding how to allocate a shared feedstock, and every method of doing so gives a different answer.

Medium confidence Weak evidence

How we know: checked recently · only one source, so there is nothing to cross-check it against · stated directly by the source.

How this connects

Where a connection has been confirmed by an outside reference, that reference is named beside it.

is a source for

  • Naphtha material · the fraction boiling between about 30 and 200 °C, separated by distillation rather than made
  • Asphalt concrete material · the bitumen binder is the residue at the bottom of the distillation column
  • Plastic material · overwhelmingly — roughly a twentieth of world oil production ends up as plastic, by way of naphtha and steam cracking
  • Rubber material · for the synthetics, which are most of it by tonnage
  • Battery graphite material · the synthetic route: petroleum needle coke, a refinery by-product, graphitised at 3,000 °C for weeks — better material, and several times the energy

contains

  • Carbon element · the bulk of it, in molecules from one carbon to fifty and more
  • Hydrogen element · roughly one to two per carbon depending on the fraction
  • Sulfur element · a fraction of a per cent to several per cent, and the difference between sweet and sour crude — it poisons catalysts and must be removed before the chemistry downstream

is used in

  • Construction industry · as bitumen for roofing and asphalt for roads — the bottom of the barrel, and a construction material by volume
  • Chemical manufacture industry · the feedstock, before it is a fuel, for almost every synthetic polymer

is an alternative to

  • PLA material · as the origin of a polymer's carbon — plant sugar rather than a geological reservoir, which is a genuine distinction and a narrower one than the marketing suggests

Sources

  • Material World
    Our own writing
  • Wikimedia Foundation · Creative Commons CC0 1.0 Universal (public domain dedication)

Questions this page answers

Where it comes from, and what it becomes

Follow Crude oil back to what it starts as, and forward into what it becomes. Each step is a documented one — a real route material takes, not a chain of inference.

Downstream — what it becomes

  • Crude oil → is a source for (the synthetic route: petroleum needle coke, a refinery by-product, graphitised at 3,000 °C for weeks — better material, and several times the energy) → Battery graphite → is used in (the anode of essentially every cell ever sold, and roughly twice the mass of the cathode it is paired with) → Lithium-ion cell → is used in (and portable computing came first by two decades) → Electronics manufacture → is associated with (and the supply chain it produced is the deepest and most concentrated in the world economy) → The semiconductor era complete chain
  • Crude oil → is a source for (the fraction boiling between about 30 and 200 °C, separated by distillation rather than made) → Naphtha → is an input to (the European and Asian cracker feed; North American crackers mostly run on ethane from natural gas instead, and make a different product slate as a result) → Steam cracking → produces (the principal product, and the largest-tonnage organic chemical made anywhere) → Ethylene → is a source for (via ethylbenzene: ethylene alkylates benzene, and the product is dehydrogenated) → Styrene → is an input to (into polystyrene, into ABS with acrylonitrile and butadiene, and into SBR with butadiene) → Polymerisation
  • Crude oil → is a source for (the bitumen binder is the residue at the bottom of the distillation column) → Asphalt concrete → is used as (as pavement rather than as structure: a surface that spreads a wheel load into the ground beneath it) → Structural engineering
  • Crude oil → is a source for (overwhelmingly — roughly a twentieth of world oil production ends up as plastic, by way of naphtha and steam cracking) → Plastic → is an input to (which is how most rigid plastic objects come to exist) → Injection moulding
  • Crude oil → is a source for (for the synthetics, which are most of it by tonnage) → Rubber → is an input to (the crosslinking that turns a sticky, temperature-sensitive gum into an engineering material) → Vulcanisation
  • Crude oil → is used in (as bitumen for roofing and asphalt for roads — the bottom of the barrel, and a construction material by volume) → Construction

These are the most distinct paths onward. Crude oil ends up in others besides.