Kerosene: Production, Uses, and Future of a Key Petroleum Product

Introduction

Kerosene is a clear, colorless petroleum distillate that serves as a primary fuel for jet engines, residential heating, and industrial solvents. Its boiling range—302 °F to 527 °F (150 °C to 275 °C)—makes it ideal for high‑performance applications.

Background

While kerosene can be derived from coal, oil shale, and even wood, modern production relies almost exclusively on refined crude oil. Before electric lighting, kerosene lamps illuminated homes worldwide and represented one of the first large‑scale chemical separations in the petroleum industry.

History

• 1853 – Abraham Gesner isolates the inflammable liquid from asphalt; the term “kerosene” comes from the Greek word for wax.
• 1859 – The first commercial oil refinery in the U.S. begins producing kerosene.
• Early 20th century – Kerosene dominates as a lighting fuel until the rise of gasoline and electric power.
• Late 1990s – U.S. annual production exceeds 1 billion gallons (3.8 billion liters).

Raw Materials

Petroleum originates from the fossilized remains of ancient organisms trapped in sedimentary basins. Through diagenesis and catagenesis—complex biochemical and thermal processes—these deposits transform into crude oil rich in hydrocarbons.

Manufacturing Process

Crude Oil Recovery

1. Drilling techniques (cable‑tool, rotary, offshore) bring the oil to the surface.
2. Water flooding and surfactant injection recover up to 50 % of the oil that natural gas pressure cannot displace.
3. Extracted crude is stored and transported to refineries.

Separation (Distillation)

Crude is heated in a distillation column. Lighter fractions rise, heavier ones settle. Kerosene is collected from the 302 °F–482 °F (150 °C–250 °C) band.

• Atmospheric columns up to 116 ft (35 m) tall enable efficient separation.
• Vacuum columns (≈75 mm Hg) handle heavier fractions.
• Refluxing further purifies the kerosene by repeated condensation.

Purification

Advanced chemical treatments remove aromatics and other contaminants:

• Udex (glycol) extraction – popular in the U.S. during the 1970s.
• Sulfolane process – uses a polar solvent for high‑temperature stability.
• Lurgi Arosolvan – N‑methyl‑2‑pyrrolidinone with water or glycol.
• Dimethyl sulfoxide (DMSO) process – selective at low temperatures.
• Union Carbide, Formex, and Redox – each offers unique advantages for specific end‑uses.

Final Processing

After purification, kerosene is stored in dedicated tanks and transported by tanker trucks or railcars to distribution centers. It is packaged for commercial sale in metal containers, ensuring safe handling of this flammable liquid.

Quality Control

Recycling unconverted hydrocarbons and repeating distillation or extraction steps optimizes yield and purity. Continuous monitoring against ASTM D4867 and API Standard 5L guarantees product consistency.

By‑products and Waste

Residual fractions can become lubricating oils, asphalt, or specialty chemicals. Extracted aromatics such as paraffins find use in paints and coatings. All specifications are governed by ASTM and the American Petroleum Institute (API).

The Future

Innovation focuses on higher‑grade kerosene for military aviation (e.g., JP‑8), low‑misting formulations to reduce explosion risk, and additives that prevent diesel gelling in cold climates. ExxonMobil’s ammonia‑based adsorption technique now yields >90 % pure normal paraffin from kerosene, illustrating the potential for cleaner, more efficient processes.

Learn More

Books

Kirk Othmer Encyclopedia of Chemical Technology, Vol. 18. John Wiley & Sons, 1996.

Periodicals

Kovski, Alan. “New Kerosene Laws Get off to Bumpy Start.” The Oil Daily 48 (1998).

“Paraffins, Normal.” Hydrocarbon Processing 80 (2001): 116.