Top 28 Largest Refineries in the U.S. as of Jan 1, 2011 -- EIA

by Aaron and David Rachovich

U.S. Refineries* Operable Capacity 

Rank  Jan 1, 2011	Corporation	Company	State	Site	Barrels per Calendar Day (b/cd)
1.	Exxon Mobil	ExxonMobil Refining & Supply	Texas	Baytown	560,640
2.	Exxon Mobil	ExxonMobil Refining & Supply	Louisiana	Baton Rouge	502,000
3.	Hovensa LLC (50% Hess, 50% PDVSA)	Hovensa LLC	Virgin Islands (territory of the U.S.)	Kingshill	500,000
4.	Marathon Oil	Marathon Petroleum	Louisiana	Garyville	464,000
5.	PDV America Inc	Citgo Petroleum	Louisiana	Lake Charles	427,800
6.	BP PLC	BP Products North America	Texas	Texas City	406,570
7.	BP PLC	BP Products North America	Indiana	Whiting	405,000
8.	WRB Refining LLC (50% ConocoPhillips, 50% Cenovus)	WRB Refining	Illinois	Wood River	362,000
9.	Exxon Mobil	ExxonMobil Refining & Supply	Texas	Beaumont	344,500
10.	Sunoco Inc	Sunoco Inc (R&M)	Pennsylvania	Philadelphia	335,000
11.	Chevron	Chevron USA Inc	Mississippi	Pascagoula	330,000
12.	Deer Park Refining LTD Ptnrshp (50% Royal Dutch/Shell, 50% Pemex)	Deer Park Refining	Texas	Deer Park	327,000
13.	Valero Energy	Premcor Refining Group	Texas	Port Arthur	292,000
14.	Koch Industries	Flint Hills Resources	Texas	Corpus Christi	290,078
15.	Motiva Enterprises LLC (50% Royal Dutch/Shell, 50% Saudi Aramco)	Motiva Enterprises LLC	Texas	Port Arthur	285,000
16.	Access Industries	Houston Refining LP	Texas	Houston	280,390
17.	Chevron	Chevron USA Inc	California	El Segundo	273,000
18.	Koch Industries	Flint Hills Resources	Minnesota	Saint Paul	262,000
19.	BP PLC	BP West Coast Products	California	Los Angeles	253,000
20.	ConocoPhillips	ConocoPhillips Co	Louisiana	Belle Chasse	247,000
21.	ConocoPhillips	ConocoPhillips Co	Texas	Sweeny	247,000
22.	Chevron	Chevron USA Inc	California	Richmond	245,271
23.	ConocoPhillips	ConocoPhillips Co	Louisiana	Westlake	239,400
24.	Exxon Mobil	ExxonMobil Refining & Supply	Illinois	Joliet	238,600
25.	ConocoPhillips	ConocoPhillips Co	New Jersey	Linden	238,000
26.	Motiva Enterprises LLC (50% Royal Dutch/Shell, 50% Saudi Aramco)	Motiva Enterprises LLC	Louisiana	Convent	235,000
27.	Motiva Enterprises LLC (50% Royal Dutch/Shell, 50% Saudi Aramco)	Motiva Enterprises LLC	Louisiana	Norco	233,500
28.	Total SA	Total Petrochemicals Inc	Texas	Port Arthur	232,000

*Only refineries with atmospheric crude oil distillation capacity.

Source: U.S. Energy Information Administration/EIA, Ranking of U.S. Refineries, Updated/Reviewed June 2011.

(ExxonMobil's Baytown Refinery is the largest oil refinery in the United States. Also, the Baytown area which is home to several of ExxonMobil's integrated sites---including the Baytown Refinery, Baytown Chemical Plant, Baytown Olefins Plant, Mont Belvieu Plastics Plant, Americas Area Engineering Office and Baytown Technology & Engineering Complex---is the largest petroleum & petrochemical complex in the United States. Texas is home to 26 refineries, with a total capacity of 4.72 million barrels per day. Louisiana is home to 19 refineries, with a total capacity of 3.22 million barrels per day. And California is home to 20 refineries, with a total capacity of 1.96 million barrels per day. Nearly half---49%---of U.S. refinery distillation capacity is located in the Gulf Coast region, i.e., PAD district 3 comprising Alabama, Arkansas, Louisiana, Mississippi, New Mexico and Texas. January 2011 U.S. refining capacity of 17.7 million barrels per day, excluding the Virgin Islands, reached the highest level recorded since 1982---please see EIA, Today in Energy, Jun 29, 2011, here. Also, please see "Top 20 Largest Refining Companies/Refiners in the U.S. as of Jan 1, 2011;" "World's Top 25 Largest Refining Companies, Jan 1, 2011 -- OGJ;" "Top 10 Largest Refining Companies in Asia, the USA and Western Europe -- OGJ;" and "World's Top 21 Largest Oil Refineries -- OGJ." Update 1:  Royal Dutch Shell Plc and Saudi Aramco became co-owners of the largest U.S. refinery on Thursday when a new crude distillation unit at their joint-venture Motiva Enterprises Port Arthur, Texas, plant [ranked 15th as of Jan 1, 2011, above -- D.R.] received oil for the first time, said Shell's Chief Financial Officer. The 325,000 barrel-per-day (bpd) atmospheric crude distillation unit that started processing on Thursday combines with existing crude units to give Motiva's Port Arthur, Texas, refinery a total crude oil refining capacity of 600,000 bpd, said Shell Chief Financial Officer Simon Henry during the company's first quarter earnings call. […] With the startup of the new Port Arthur crude unit, Exxon Mobil Corp's 560,640 bpd Baytown, Texas, refinery becomes the nation's second-largest refinery---please see "Motiva Port Arthur refinery becomes U.S. largest - Shell," Reuters, Apr 26, 2012. Update 2: But by far the biggest refining story in North America in 2012 centered on the massive expansion at Motiva Enterprise LLC's Port Arthur, Tex., refinery. The 325,000 bpd, $10 billion expansion, largest at a US refinery in nearly 40 years and designed for feedstock flexibility, was dedicated on May 31, raising capacity to 600,000 bpd and making it the largest US refinery. On June 9, 2012, however, the new crude distillation unit sprung leaks traced to massive corrosion; a fire ensued and the expansion was shut down. Motiva has since traced the problem to faulty design. The unit will not restart before the end of first-quarter 2013, if then---please see Warren R. True and Leena Koottungal, "Asia, Middle East lead modest recovery in global refining," OGJ, Dec 3, 2012 -- D.R.)

Top 20 Largest Refining Companies/Refiners in the U.S. as of Jan 1, 2011

by David Rachovich

Refiners' Total Operable Atmospheric Crude Oil Distillation Capacity 

Rank  Jan 1, 2011	Company	No. of Refineries	Barrels per Calendar Day (b/cd)*
1.	ConocoPhillips (USA)**	13	2,041,000
2.	ExxonMobil (USA)***	7	1,951,490
3.	Valero Energy Corp. (USA)	12	1,682,300
4.	BP (UK)^	6	1,368,050
5.	Marathon Oil Corp. (USA)	6	1,142,000
6.	Chevron Corp. (USA)	6	1,027,271
7.	Royal Dutch/Shell (NL/UK)+	8	976,650
8.	PDVSA (Venezuela)#	4	854,050
9.	Koch Industries Inc. (Flint Hills Resources; USA)	3	771,578
10.	Sunoco Inc. (USA)	3	673,000
11.	Tesoro (USA)	7	657,300
12.	Saudi Aramco (Saudi Arabia)$	3	376,750
13.	PBF Energy (USA)	2	342,200
14.	Holly Corp. (USA)	4	285,350
15.	Access Industries (USA)	1	280,390
16.	Cenovus Energy (Canada)>	2	254,000
17.	Total (France)	1	232,000
18.	Alon (Israel)	4	231,500
19.	Western Refining Inc. (USA)	4	226,200
20.	Frontier Oil Corp. (USA)	2	185,000
U.S. Total^^		141"	17,736,370

*Includes partial interests in refineries not wholly owned by the company.  

**Including its 50% stake in the Wood River, Illinois, refinery and 50% stake in the Borger, Texas, refinery. WRB Refining LLC operates as a 50/50 joint venture between ConocoPhillips and Cenovus Energy (Calgary).

***Including its 50% stake in the Chalmette, Louisiana, refinery.

^Including its 50% stake in the BP-Husky, Toledo, Ohio, refinery.

+Including Shell's stakes in Motiva (i.e., its 50% stake in the Port Arthur, Texas, refinery; its 50% stake in the Convent, Louisiana, refinery; and its 50% stake in the Norco, Louisiana, refinery), and its 50% stake in the Deer Park, Texas, refinery.  

#Including its 50% stake in the Chalmette, Louisiana, refinery. Also, Citgo, a wholly-owned subsidiary of PDVSA, operates three refineries – Lakes Charles, Louisiana; Lemont, Illinois; and Corpus Christi, Texas.

$Consists of 50% stake in Motiva. Motiva is a 50/50 joint venture between Shell and Saudi Aramco.

>Consists of 50% stake in WRB Refining LLC (a 50/50 joint venture between ConocoPhillips and Cenovus), i.e., 50% stake in the Wood River, Illinois, refinery and 50% stake in the Borger, Texas, refinery.

^^Including other refineries but excluding Hovensa's 500,000 barrels-per-day refinery on the Caribbean island of St. Croix in the United States Virgin Islands. Hovensa is a joint venture between subsidiaries of Hess Corporation and Petróleos de Venezuela, S.A. (PDVSA).

"Only refineries with atmospheric crude oil distillation capacity.

Notes: PBF Energy Company LLC on Tuesday, March 1, 2011, announced that its subsidiary, Toledo Refining Company LLC, has completed its purchase of the Toledo Refinery in Ohio from Sunoco, Inc. Separately, Western Refining  indefinitely suspended refining operations at the Bloomfield, New Mexico, refinery in November 2009.  Atmospheric crude oil distillation -- The refining process of separating crude oil components at atmospheric pressure by heating to temperatures of about 600 degrees to 750 degrees Fahrenheit (depending on the nature of the crude oil and desired products) and subsequent condensing of the fractions by cooling.

Source: Based on data from the U.S. Energy Information Administration/EIA, Refinery Capacity Report, Release date: Jun 24, 2011, Table 5, here.

(ConocoPhillips is the largest refiner in the United States, with crude oil distillation capacity of 2 million barrels per day as of Jan 1, 2011, followed by ExxonMobil and Valero. Also, please see my post "Top 10 Largest Refining Companies in Asia, the USA and Western Europe -- OGJ," and Aaron and David Rachovich, "Top 28 Largest Refineries in the U.S. as of Jan 1, 2011 -- EIA." Update: As of late 2012, the top 5 largest refiners/refining companies in the United States have been Valero/12 refineries with 2,096,500 b/cd of crude capacity, Phillips 66, ExxonMobil, BP and Marathon---please see Warren R. True and Leena Koottungal, "Asia, Middle East Lead Modest Recovery in Global Refining," OGJ, Dec 3, 2012, Table 2 in my post "World's Top 25 Largest Refiners, Jan 1, 2013 -- OGJ," Notes. For the USA, Valero has moved into the top spot for company-wide capacity, pushing Phillips 66 to No. 2 -- D.R.)