Largest Refineries in the US: An In-Depth Examination of America’s Oil Titans

As of January 1, 2024, the largest refineries in the US are predominantly situated along the Gulf Coast, underscoring the region’s pivotal role in the nation’s oil sector. These colossal facilities process millions of barrels of crude oil daily, making them essential to the country’s energy landscape. Analyzing their operational scale not only reveals their economic significance but also sheds light on the considerable risks faced by workers.

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At Armstrong Lee & Baker LLP, we acknowledge the vital contributions of refinery employees in Houston and throughout the Gulf Coast. We are aware of the hazardous conditions they often encounter. In this blog, we will delve into some of the largest refineries, examining their critical importance and the potential dangers that workers may face.

Marathon Petroleum Refinery in Galveston Bay, Texas

It is located in Texas City near Houston and is the largest refinery in the United States, with a capacity of 631,000 barrels per day. This massive facility, originally constructed in 1931, has continually expanded to meet growing energy demands. Most recently, Marathon Petroleum Corp. began preparing in July 2024 to restart multiple units at the Galveston Bay refinery after undergoing planned maintenance and upgrades. According to Hydrocarbon Processing, this restart is expected to enhance the refinery’s operational capacity and improve overall efficiency.

Worker Safety Concerns at Galveston Bay

The vast size and complexity of the Galveston Bay refinery make it one of the most important facilities in the U.S. but also one of the most dangerous. Refining over 630,000 barrels of crude oil daily, the facility requires thousands of workers to maintain its operations. NS Energy Business highlights that the industrial plant is responsible for producing a wide variety of petroleum products, including gasoline, diesel, and jet fuel, as well as operating large, high-risk units such as fluid catalytic crackers and coking units, which are critical to refining but pose significant dangers due to their high pressure and extreme heat.

Exposure to chemical spills, equipment malfunctions, and explosions are daily risks for workers. The sheer scale of the facility and the inherent dangers of handling volatile hydrocarbons make accidents more likely, which is why safety protocols and proper legal representation are critical in the event of an injury.

Port Arthur Refinery

The Port Arthur Refinery, owned by Saudi Aramco through its subsidiary Motiva Enterprises, is the third-largest refinery in the U.S., processing approximately 630,000 barrels of crude oil per day. This refinery plays a critical role in the energy landscape and stands out for its sustainability initiatives.

Sustainability and Innovation

As part of its long-term commitment to reducing environmental impacts, Port Arthur Refinery is involved in the creation of a sustainable refining platform. According to TotalEnergies, the project has two primary goals: building a world-class ethane-based steam cracker and integrating advanced technologies like hydrogen cogeneration. These innovations aim to reduce greenhouse gas emissions while improving the refinery’s overall efficiency, aligning with global trends toward greener energy.

Worker Hazards at Port Arthur Refinery

Despite the technological and environmental advancements, working at this location still presents significant dangers for employees. Handling hydrogen, volatile chemicals, and high-pressure systems within such a massive operation presents a continuous risk to worker safety. While sustainability efforts may reduce environmental harm, the complex nature of these operations can result in severe workplace accidents if safety protocols are not rigorously enforced.

Port Arthur II Integrated Hydrogen Cogeneration Facility

One of the key technological advancements is the Port Arthur II Integrated Hydrogen Cogeneration Facility, which further boosts efficiency by producing hydrogen while generating both steam and electricity. This project is a testament to the refinery’s efforts to adopt sustainable practices without compromising production. As Power Magazine explains, the cogeneration facility leverages by-products from the refinery to create cleaner energy, reducing emissions and overall energy costs.

Introducing such advanced technologies also means workers are tasked with managing even more challenging systems, increasing their exposure to hazardous materials like hydrogen and requiring greater vigilance in safety protocols.

Garyville Refinery

The Garyville Refinery, located in Louisiana, is the fourth-largest refinery in the United States, with a daily processing capacity of 564,000 barrels of crude oil. Owned by Marathon Petroleum, this facility plays a pivotal role in producing high-value petroleum products such as gasoline, diesel, jet fuel, and asphalt, serving both domestic and international markets. Its strategic location along the Mississippi River provides convenient access to fundamental transportation routes, making it one of the most efficient refineries in the country.

Built in 1976, it has undergone several expansions and technological upgrades to keep pace with growing energy demands. According to Marathon Petroleum’s fact sheet, the refinery uses advanced hydrocracking and catalytic reforming processes, which enhance fuel production efficiency while minimizing waste and reducing emissions. The facility also incorporates vapor recovery units and flue gas scrubbers to limit the release of harmful pollutants into the atmosphere. These control systems help it comply with stringent regulations, reinforcing its commitment to sustainable operations.

Worker Safety at Garyville

While the Garyville Refinery is an industry leader in both production and environmental responsibility, it is also a site where significant risks exist for workers. Handling flammable materials, operating heavy machinery, and working in high-temperature environments present constant dangers to employees. Even with state-of-the-art safety protocols in place, accidents such as chemical exposure, fires, and equipment malfunctions are ever-present risks.

The company has implemented rigorous safety procedures to mitigate these risks, including continuous operations monitoring and emergency response plans. However, despite these efforts, the refinery’s complex operations still require workers to be on constant alert, and accidents can still occur. Injured individuals need to be aware of their rights and the legal protections available to them in the event of a workplace accident.

Garyville’s Economic and Environmental Impact

The Garyville Refinery is a cornerstone of the local and regional economy, employing more than 900 full-time workers and hundreds of contractors. It contributes to the surrounding community by providing high-paying jobs and supporting local businesses that supply services and goods essential to refinery operations. In addition, the refinery’s infrastructure investments, including road and utility upgrades, benefit the broader economy of Louisiana.

Why Are So Many Large Refineries in Texas?

Texas is home to four of the five largest refineries in the United States, with Louisiana’s Garyville Refinery rounding out the top five. The Gulf Coast’s dominance in the oil refining industry is far from coincidental. The region’s natural resources, geographic location, and well-established infrastructure all contribute to making the state a hub for these operations. 

Here’s why the state is such a critical location for these massive facilities:

• Abundant natural oil reserves: It sits atop some of the richest oil fields in the country, including the Permian Basin and Eagle Ford Shale. These fields produce millions of barrels of crude oil daily, providing a steady and local supply of feedstock for refineries.
• Proximity to offshore drilling: In addition to its onshore reserves, Texas has direct access to offshore oil fields in the Gulf of Mexico. Offshore drilling is a significant contributor to the state’s oil production, and the refineries benefit from the proximity to these major sources of crude oil.
• Strategic Gulf Coast location: The industrial plants are located along the Gulf Coast, giving them easy access to ports and shipping routes. This allows for the efficient transport of crude oil to the refineries and the rapid distribution of refined products (gasoline, diesel, jet fuel) to both domestic and international markets.
• Established infrastructure: It has a vast and well-developed oil and gas infrastructure, including pipelines, storage facilities, and refineries. This infrastructure has been built up over decades, making Texas an ideal location for large-scale refining operations.
• Skilled workforce: The state is home to a large, experienced workforce in the oil and gas sector, and it has a long history in oil production, which means refineries have access to skilled labor, industry expertise, and established safety practices.

Legal Support for Refinery Workers

Despite the advantages of having refineries concentrated in Texas, these facilities’ sheer size and complexity mean that incidents are inevitable. Workers face numerous threats every day, including:

• Toxic chemical exposure: Refineries process crude oil using various chemicals, many of which are highly poisonous. Workers are at risk of exposure to dangerous substances such as benzene, which can cause long-term health effects, including cancer.
• Equipment failures and explosions: The facilities rely on heavy machinery, high-pressure systems, and flammable materials, all of which can cause devastating accidents if they malfunction. Fires, explosions, and equipment breakdowns are common risks.
• Physical injuries: Working around large, complicated equipment in high-pressure environments can result in severe physical injuries, from burns to broken bones or even fatalities.

If you’ve been injured in a refinery accident, it’s crucial to seek legal help from an attorney who understands the intricacies of refinery operations and Texas labor laws. Experienced legal representation ensures your rights are protected and helps you obtain compensation for medical expenses, lost wages, and other damages related to your injury.

How We Can Help You: Contact Armstrong Lee & Baker LLP

If you or a loved one has been injured in a refinery accident, Armstrong Lee & Baker LLP is here to help. Our experienced attorneys specialize in representing injured refinery workers, guaranteeing that you receive the compensation you deserve. Our team will review your case, explain your legal options, and fight for your rights every step of the way. Let us be your advocate in seeking justice and securing the compensation you’re entitled to after an incident. Contact us today for a free case review.