Fractional Distillation of Crude Oil: KS3 Chemistry Guide

Crude oil is a complex mixture of hydrocarbons formed from the remains of ancient marine organisms over millions of years. Fractional distillation separates this mixture by heating it in a fractionating column and collecting the different components — called fractions — where they condense at their own boiling points.

What are hydrocarbons and where does crude oil come from?

Before we look inside a fractionating column, picture what we are starting with. Millions of years ago, vast quantities of microscopic marine organisms — plankton and algae — lived and died in ancient seas. Their remains sank to the seafloor and were buried under layers of sediment. Over geological time — roughly 300 to 400 million years — the combined heat and pressure deep underground converted these organic remains into the liquid we call crude oil (also known as petroleum). It is a fossil fuel, meaning it stores chemical energy that originally came from the Sun via photosynthesis.

Crude oil is a mixture of hydrocarbons: molecules built from only hydrogen and carbon atoms. The simplest hydrocarbon family is the alkanes, with the general formula CnH₂n₊₂. The shortest members are familiar fuels: methane (CH₄, one carbon atom), ethane (C₂H₆), propane (C₃H₈), and so on up to large molecules such as octane (C₈H₁₈, a component of petrol) and far beyond.

The critical point — and the key to understanding why distillation works — is that chain length determines boiling point. Shorter hydrocarbon chains have weaker intermolecular forces between them, so they require less energy to vaporise and boil at lower temperatures. They are also more volatile and more flammable. Longer chains have stronger forces, higher boiling points, and are more viscous. Crude oil is a jumble of all these different chain lengths, and fractional distillation is the process of sorting them out.

How does a fractionating column work?

Here is something to picture before we go through the steps: a tall metal tower, hottest at the bottom and coolest at the top, with horizontal collection trays at different heights. Now build the particle model in your mind — thousands of different hydrocarbon molecules, all vaporised and rising together, each one looking for the temperature at which it will condense back to a liquid.

Crude oil is heated at the base of the fractionating column to approximately 350–400 °C. The heat vaporises most of the oil; the very longest-chain molecules (bitumen) do not vaporise and drain away at the base.

The hot vapour mixture rises up the column. The column is engineered to be hottest at the bottom and progressively cooler towards the top.

As each vapour rises and cools, it reaches the level where the temperature matches its boiling point. At that point, it condenses from vapour to liquid.

Short-chain hydrocarbons have low boiling points and remain as gas or vapour for longer, condensing near the top of the column — or exiting as a gas at the very top.

Long-chain hydrocarbons have high boiling points and condense near the bottom, where the temperature is still relatively high.

Each fraction drips onto a horizontal collection tray at its condensation level and is piped away.

The essential principle is that this is a physical separation by boiling point — not a chemical change. The hydrocarbon molecules themselves are unchanged; they are simply sorted by the temperature at which they change state.

What are the main fractions and their properties?

Before examining the table, make a prediction: as you move from the bottom of the column to the top, do you expect the fractions to become more or less viscous? More or less flammable?

Fraction | Approximate boiling point range | Carbon chain length | Main uses | Key properties
Refinery gas | Below 40 °C (exits as gas) | C₁–C₄ | LPG, camping gas, cooking | Very volatile, flammable gas
Petrol (gasoline) | 40–100 °C | C₄–C₁₂ | Fuel for cars | Volatile, flammable liquid
Naphtha | 100–150 °C | C₈–C₁₂ | Making chemicals, plastics | Volatile liquid
Kerosene (jet fuel) | 150–250 °C | C₁₀–C₁₆ | Aircraft fuel, heating | Less volatile
Diesel | 220–350 °C | C₁₄–C₂₀ | Lorries, buses, cars | Less volatile, more viscous
Fuel oil | 300–370 °C | C₂₀–C₅₀ | Ships, power stations | Viscous, high energy density
Bitumen | Above 400 °C (not volatile) | C₅₀+ | Road surfaces, roofing | Very viscous, black, solid/semi-solid

Notice how the uses reflect the properties: the most volatile fractions (gases and petrol) are ideal for engines that need a readily ignitable fuel; the least volatile (fuel oil, bitumen) are suited to applications where a thick, persistent material is needed.

How do properties change along the column?

The particle model gives us a powerful way to explain all of the trends we observe, without needing to memorise them as separate facts. Picture the hydrocarbon molecules as chains of atoms — and the longer the chain, the more points of contact between neighbouring molecules.

Moving from the bottom of the column (longest chains, highest boiling points) to the top (shortest chains, lowest boiling points):

Boiling point decreases — shorter chains mean weaker intermolecular (van der Waals) forces; less energy is needed to separate the molecules from each other.

Viscosity decreases — shorter-chain molecules slide past each other more easily; the fraction pours freely rather than sluggishly. Petrol is runny; bitumen is almost solid at room temperature.

Flammability increases — more volatile fractions ignite more readily; refinery gases and petrol burn easily, whereas bitumen will not ignite at all under normal conditions.

Colour gets lighter — bitumen is a thick black liquid; petrol is almost colourless.

Once you have the particle model established in your mind, these trends follow naturally: every property difference between the fractions is a consequence of chain length, and chain length determines the strength of the intermolecular forces.

What is cracking and why is it needed?

Here is a supply-and-demand problem at the heart of the petroleum industry. Crude oil contains far more long-chain hydrocarbons (fuel oil, bitumen) than the market needs, and far less petrol and diesel than the market demands. Simply distilling crude oil produces too much of the wrong fractions.

The solution is cracking — a chemical process that breaks long-chain alkane molecules into shorter, more useful ones using heat (and sometimes a catalyst).

Worked example: Decane (C₁₀H₂₂) is a long-chain alkane from the kerosene fraction. Under cracking conditions it breaks down as follows:

C₁₀H₂₂ → C₈H₁₈ + C₂H₄

Octane (C₈H₁₈) is a useful petrol component. Ethene (C₂H₄) is an alkene — a hydrocarbon with a carbon–carbon double bond — and is a vital feedstock for making plastics (such as poly(ethene), commonly called polythene).

Two types of cracking are used industrially:

Thermal cracking uses very high temperatures (~500 °C) and high pressure to break carbon–carbon bonds without a catalyst.

Catalytic cracking uses a lower temperature with a zeolite catalyst, which is more energy-efficient and produces a higher proportion of branched alkanes (better for car engines).

Unlike distillation, cracking is a chemical change: new substances with different molecular formulae are formed, and bonds within the molecules are broken and made.

What are the environmental impacts of crude oil use?

The fractional distillation of crude oil KS3 curriculum rightly situates this chemistry within its environmental context. The combustion of hydrocarbon fuels drives our transport system, heats our homes, and powers industry — but it comes with significant environmental costs.

Carbon dioxide (CO₂) is produced when any hydrocarbon burns completely in oxygen. As a greenhouse gas, CO₂ traps heat in the atmosphere, driving climate change. The burning of fossil fuels since the Industrial Revolution has raised atmospheric CO₂ from approximately 280 ppm to over 420 ppm today.

Incomplete combustion occurs when there is insufficient oxygen. This produces carbon monoxide (CO), a colourless, odourless toxic gas, and soot (fine carbon particles) that cause respiratory disease and reduce air quality.

Nitrogen oxides (NOₓ) form when fuels burn at high temperatures inside engines, where nitrogen and oxygen in the air react. These gases contribute to acid rain and photochemical smog.

Oil spills — whether from tanker accidents or pipeline leaks — coat seabirds and marine mammals, contaminate coastlines, and devastate marine ecosystems.

Finally, crude oil is non-renewable: the geological processes that created it take hundreds of millions of years. Once we burn it, the energy stored over geological time is released in seconds. The world's recoverable oil reserves are finite, and alternative energy sources will be essential as they are exhausted.

Frequently asked questions

What is the difference between fractional distillation and simple distillation?

Simple distillation separates a dissolved solid from a liquid (e.g. salt from saltwater) or two liquids with very different boiling points. Fractional distillation is used when the mixture contains many components with similar but distinct boiling points — as in crude oil. The fractionating column provides a temperature gradient, so each component condenses at a different level and is collected separately. Without the temperature gradient of a fractionating column, you would collect all liquids together rather than as distinct fractions.

Why does petrol have a lower boiling point than bitumen?

Both petrol and bitumen are hydrocarbons, but petrol molecules contain only 4–12 carbon atoms, while bitumen molecules contain 50 or more. The longer the carbon chain, the more points of contact between molecules, and the stronger the intermolecular (van der Waals) forces holding them together. More energy (higher temperature) is needed to overcome those forces and turn the substance from liquid to gas. So bitumen — with its very long chains — only boils at over 400 °C, while petrol boils at 40–100 °C.

Is fractional distillation a chemical or physical process?

Fractional distillation is a physical process. The hydrocarbon molecules are not changed chemically — no new substances are formed, no bonds broken or made. The fractions are simply sorted by their boiling points, then condensed and collected separately. The chemical composition of each fraction remains identical to its composition in crude oil. This contrasts with cracking, which is a chemical process that breaks long-chain molecules into shorter ones.

Why are fossil fuels described as non-renewable?

Fossil fuels are non-renewable because they took hundreds of millions of years to form from ancient organisms under heat and pressure. Once burned, the carbon locked underground for geological timescales is released as CO₂ in seconds — consumed far faster than new reserves could form. Once the oil, coal, and gas deposits are gone, they cannot be replaced within any human timescale.

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