U.S. Oil Refineries: Current Operations and Future Prospects
The United States remains one of the world’s largest refining hubs, with approximately 125 operational oil refineries as of 2024. These facilities are strategically concentrated along the Gulf Coast—primarily in Texas and Louisiana—due to the region’s proximity to offshore oil fields, major shipping routes, and crude oil import channels. Additional refinery clusters operate in California, the Midwest, and the Northeast, ensuring broad coverage for domestic fuel demand. California’s refineries, centered around Los Angeles and the San Francisco Bay Area, play a critical role in supplying the West Coast’s unique fuel standards and energy needs.
Major U.S. refinery operators include ExxonMobil, Chevron, Marathon Petroleum, Phillips 66, and Valero Energy, collectively processing millions of barrels of crude oil every day. Once refined, products move through an extensive distribution network of pipelines, trucks, and marine vessels to reach fuel terminals, gas stations, industrial facilities, and petrochemical manufacturers across the country.
What U.S. Refineries Produce
U.S. refinery output is essential to nearly every sector of the economy. On average:
45% becomes gasoline for passenger vehicles
30% becomes diesel for trucking, agriculture, and heavy machinery
20% becomes jet fuel, heating oil, and lubricants
5% becomes petrochemical feedstocks used to make plastics, chemicals, and synthetic materials
These refined products support transportation, manufacturing, agriculture, pharmaceuticals, and consumer goods—making refinery operations vital to daily life.
Will the U.S. Build More Refineries?
Despite high demand, the U.S. has not built a new large‑scale refinery since 1977. While industry discussions continue around expanding capacity, new construction faces steep financial, regulatory, and environmental hurdles. Experts note that even if expansions occur, they are unlikely to dramatically reduce fuel prices in the short term. The long‑term outlook is further shaped by the rise of renewable energy, electric vehicles, and decarbonization policies, which may shift future refining needs.
Still, existing refineries are expected to remain essential for decades. Ongoing investments in infrastructure upgrades, process optimization, and advanced technologies help maintain efficiency and competitiveness in a rapidly evolving global energy market.
How the Refining Process Works
Oil refining transforms crude oil into usable fuels and chemicals through a series of complex steps:
Distillation – Crude oil is heated and separated by boiling point into lighter and heavier fractions.
Cracking, reforming & alkylation – Heavier hydrocarbons are broken down or restructured to increase gasoline and diesel yields.
Treatment & purification – Impurities like sulfur and nitrogen are removed to meet environmental standards.
Storage & distribution – Finished products are stored in tanks and transported via pipelines, tankers, and trucks.
Refineries operate 24/7, ensuring a continuous supply of fuel to meet national and global demand.
Hazards and Safety Concerns in Refinery Operations
Oil refineries handle high pressures, extreme temperatures, and flammable materials, making safety a top priority. Potential hazards include:
Vapor releases and fires
Equipment failures
Human error
Toxic chemical exposure (e.g., benzene, hydrogen sulfide)
Historical incidents highlight the risks. The 2005 BP Texas City explosion killed 15 workers and injured 180, while the 2012 Chevron Richmond fire sent thousands of residents to hospitals due to chemical fumes. These events underscore the need for rigorous safety protocols, equipment maintenance, and regulatory oversight.
Agencies such as OSHA and the EPA enforce strict safety and environmental standards, requiring companies to implement risk‑management programs. While safety has improved, the potential for accidents remains a significant industry challenge.
T
exas and U.S. Refinery Production Information from 2015
- Layer
- U.S. Petroleum Refineries
- Abstract
- Production output for 2015 sorted by state and name
- Information
- 141 lines
| Co Name | Corp | Site | State | PADD | AD_Mbpd |
|---|---|---|---|---|---|
| GOODWAY REFINING LLC | GOODWAY REFINING LLC | ATMORE | Alabama | 3 | 5 |
| HUNT REFINING CO | HUNT CONSLD INC | TUSCALOOSA | Alabama | 3 | 40 |
| SHELL CHEMICAL LP | ROYAL DUTCH/SHELL GROUP | SARALAND | Alabama | 3 | 90 |
| BP EXPLORATION ALASKA INC | BP PLC | PRUDHOE BAY | Alaska | 5 | 13 |
| CONOCOPHILLIPS ALASKA INC | CONOCOPHILLIPS | PRUDHOE BAY | Alaska | 5 | 16 |
| PETRO STAR INC | ARCTIC SLOPE REGIONAL CORP | NORTH POLE | Alaska | 5 | 22 |
| PETRO STAR INC | ARCTIC SLOPE REGIONAL CORP | VALDEZ | Alaska | 5 | 60 |
| TESORO ALASKA PETROLEUM CO | TESORO CORP | KENAI | Alaska | 5 | 72 |
| CROSS OIL REFINING & MARKETING INC | MARTIN RESOURCE MANAGEMENT GRP | SMACKOVER | Arkansas | 3 | 8 |
| LION OIL CO | DELEK GROUP LTD | EL DORADO | Arkansas | 3 | 85 |
| ALON BAKERSFIELD OPERATING INC | ALON ISRAEL OIL COMPANY LTD | BAKERSFIELD | California | 5 | 0 |
| CHEVRON USA INC | CHEVRON CORP | EL SEGUNDO | California | 5 | 290 |
| CHEVRON USA INC | CHEVRON CORP | RICHMOND | California | 5 | 257 |
| EXXONMOBIL REFINING & SUPPLY CO | EXXON MOBIL CORP | TORRANCE | California | 5 | 156 |
| KERN OIL & REFINING CO | KERN OIL & REFINING CO | BAKERSFIELD | California | 5 | 27 |
| LUNDAY THAGARD CO | WORLD OIL CO | SOUTH GATE | California | 5 | 10 |
| PARAMOUNT PETROLEUM CORPORATION | ALON ISRAEL OIL COMPANY LTD | PARAMOUNT | California | 5 | 90 |
| PHILLIPS 66 COMPANY | PHILLIPS 66 COMPANY | RODEO | California | 5 | 128 |
| PHILLIPS 66 COMPANY | PHILLIPS 66 COMPANY | WILMINGTON | California | 5 | 147 |
| SAN JOAQUIN REFINING CO INC | SAN JOAQUIN REFINING CO INC | BAKERSFIELD | California | 5 | 25 |
| SANTA MARIA REFINING COMPANY | GREKA ENERGY | SANTA MARIA | California | 5 | 10 |
| Shell Oil Products US | ROYAL DUTCH/SHELL GROUP | MARTINEZ | California | 5 | 158 |
| TESORO REFINING & MARKETING CO | TESORO CORP | CARSON | California | 5 | 276 |
| TESORO REFINING & MARKETING CO | TESORO CORP | WILMINGTON | California | 5 | 107 |
| TESORO REFINING & MARKETING CO | TESORO CORP | MARTINEZ | California | 5 | 170 |
| VALERO REFINING CO CALIFORNIA | VALERO ENERGY CORP | BENICIA | California | 5 | 149 |
| VALERO REFINING CO CALIFORNIA | VALERO ENERGY CORP | WILMINGTON ASPHALT PLANT | California | 5 | 6 |
| VALERO REFINING CO CALIFORNIA | VALERO ENERGY CORP | WILMINGTON REFINERY | California | 5 | 87 |
| SUNCOR ENERGY (USA) INC | SUNCOR ENERGY INC | COMMERCE CITY EAST | Colorado | 4 | 38 |
| SUNCOR ENERGY (USA) INC | SUNCOR ENERGY INC | COMMERCE CITY WEST | Colorado | 4 | 72 |
| CALUMET LUBRICANTS CO LP | CALUMET SPECIALTY PRODUCTS PARTNERS | L.P. | COTTON VALLEY | Louisiana | 3 |
| DELAWARE CITY REFINING CO LLC | PBF ENERGY CO LLC | DELAWARE CITY | Delaware | 1 | 190 |
| CALUMET MONTANA REFINING LLC | CALUMET SPECIALTY PRODUCTS PARTNERS | L.P. | GREAT FALLS | Montana | 4 |
| CHEVRON USA INC | CHEVRON CORP | HONOLULU | Hawaii | 5 | 57 |
| PAR PETROLEUM CORP | PAR PETROLEUM INC | EWA BEACH | Hawaii | 5 | 95 |
| EXXONMOBIL REFINING & SUPPLY CO | EXXON MOBIL CORP | JOLIET | Illinois | 2 | 260 |
| MARATHON PETROLEUM CO LP | MARATHON PETROLEUM CORP | ROBINSON | Illinois | 2 | 225 |
| PDV Midwest Refining LLC | PDV AMERICA INC | LEMONT | Illinois | 2 | 185 |
| WRB REFINING LP | WRB REFINING LP | WOOD RIVER | Illinois | 2 | 353 |
| BP PRODUCTS NORTH AMERICA INC | BP PLC | WHITING | Indiana | 2 | 430 |
| COUNTRYMARK COOPERATIVE INC | COUNTRYMARK COOP INC | MOUNT VERNON | Indiana | 2 | 29 |
| COFFEYVILLE RESOURCES RFG & MKTG | CVR ENERGY | COFFEYVILLE | Kansas | 2 | 125 |
| FRONTIER EL DORADO REFINING CO | HOLLYFRONTIER CORP | EL DORADO | Kansas | 2 | 141 |
| NCRA | CHS INC | MCPHERSON | Kansas | 2 | 89 |
| CONTINENTAL REFINING COMPANY LLC | CONTINENTAL REFINING CO LLC | SOMERSET | Kentucky | 2 | 6 |
| MARATHON PETROLEUM CO LP | MARATHON PETROLEUM CORP | CATLETTSBURG | Kentucky | 2 | 261 |
| ALON REFINING KROTZ SPRINGS INC | ALON ISRAEL OIL COMPANY LTD | KROTZ SPRINGS | Louisiana | 3 | 83 |
| CALCASIEU REFINING CO | TRANSWORLD OIL USA INC | LAKE CHARLES | Louisiana | 3 | 85 |
| Chalmette Refining LLC | CHALMETTE REFINING LLC | CHALMETTE | Louisiana | 3 | 195 |
| CITGO PETROLEUM CORP | PDV AMERICA INC | LAKE CHARLES | Louisiana | 3 | 440 |
| EXCEL PARALUBES | EXCEL PARALUBES | WESTLAKE | Louisiana | 3 | 0 |
| EXXONMOBIL REFINING & SUPPLY CO | EXXON MOBIL CORP | BATON ROUGE | Louisiana | 3 | 523 |
| MARATHON PETROLEUM CO LP | MARATHON PETROLEUM CORP | GARYVILLE | Louisiana | 3 | 561 |
| Motiva Enterprises LLC | MOTIVA ENTERPRISES LLC | NORCO | Louisiana | 3 | 250 |
| Motiva Enterprises LLC | MOTIVA ENTERPRISES LLC | CONVENT | Louisiana | 3 | 255 |
| PELICAN REFINING COMPANY LLC | PELICAN REFINING CO LLC | LAKE CHARLES | Louisiana | 3 | 0 |
| PHILLIPS 66 COMPANY | PHILLIPS 66 COMPANY | BELLE CHASSE | Louisiana | 3 | 260 |
| PHILLIPS 66 COMPANY | PHILLIPS 66 COMPANY | WESTLAKE | Louisiana | 3 | 273 |
| PLACID REFINING CO | PLACID OIL CO | PORT ALLEN | Louisiana | 3 | 82 |
| SHELL OIL PRODUCTS US | ROYAL DUTCH/SHELL GROUP | SAINT ROSE | Louisiana | 3 | 46 |
| VALERO ENERGY CORPORATION | VALERO ENERGY CORP | MERAUX | Louisiana | 3 | 128 |
| VALERO REFINING NEW ORLEANS LLC | VALERO ENERGY CORP | NORCO | Louisiana | 3 | 220 |
| MARATHON PETROLEUM CO LP | MARATHON PETROLEUM CORP | DETROIT | Michigan | 2 | 144 |
| Flint Hills Resources LP | KOCH INDUSTRIES INC | SAINT PAUL | Minnesota | 2 | 339 |
| ST PAUL PARK REFINING CO LLC | NORTHERN TIER ENERGY LLC | SAINT PAUL | Minnesota | 2 | 98 |
| CHEVRON USA INC | CHEVRON CORP | PASCAGOULA | Mississippi | 3 | 360 |
| ERGON REFINING INC | ERGON INC | VICKSBURG | Mississippi | 3 | 25 |
| HUNT SOUTHLAND REFINING CO | HUNT CONSLD INC | SANDERSVILLE | Mississippi | 3 | 12 |
| Cenex Harvest States Coop | CHS INC | LAUREL | Montana | 4 | 61 |
| EXXONMOBIL REFINING & SUPPLY CO | EXXON MOBIL CORP | BILLINGS | Montana | 4 | 63 |
| PHILLIPS 66 COMPANY | PHILLIPS 66 COMPANY | BILLINGS | Montana | 4 | 63 |
| FORELAND REFINING CORP | FORELAND REFINING CORP | ELY | Nevada | 5 | 5 |
| AXEON SPECIALTY PRODUCTS LLC | LINDSAY GOLDBERG LLC | PAULSBORO | New Jersey | 1 | 75 |
| PAULSBORO REFINING CO LLC | PBF ENERGY CO LLC | PAULSBORO | New Jersey | 1 | 166 |
| PHILLIPS 66 COMPANY | PHILLIPS 66 COMPANY | LINDEN | New Jersey | 1 | 251 |
| NAVAJO REFINING CO LLC | HOLLYFRONTIER CORP | ARTESIA | New Mexico | 3 | 115 |
| WESTERN REFINING SOUTHWEST INC | WESTERN REFINING INC. | GALLUP | New Mexico | 3 | 26 |
| DAKOTA PRAIRIE REFINING LLC | DAKOTA PRAIRIE REFINING LLC | DICKINSON | North Dakota | 2 | 20 |
| Tesoro West Coast | TESORO CORP | MANDAN | North Dakota | 2 | 75 |
| BP-HUSKY REFINING LLC | BP HUSKY REFINING LLC | TOLEDO | Ohio | 2 | 160 |
| LIMA REFINING COMPANY | HUSKY ENERGY INC | LIMA | Ohio | 2 | 170 |
| MARATHON PETROLEUM CO LP | MARATHON PETROLEUM CORP | CANTON | Ohio | 2 | 100 |
| TOLEDO REFINING CO LLC | PBF ENERGY CO LLC | TOLEDO | Ohio | 2 | 175 |
| HOLLY REFINING & MARKETING CO | HOLLYFRONTIER CORP | TULSA WEST | Oklahoma | 2 | 90 |
| HOLLY REFINING & MARKETING CO | HOLLYFRONTIER CORP | TULSA EAST | Oklahoma | 2 | 76 |
| PHILLIPS 66 COMPANY | PHILLIPS 66 COMPANY | PONCA CITY | Oklahoma | 2 | 219 |
| VALERO REFINING CO OKLAHOMA | VALERO ENERGY CORP | ARDMORE | Oklahoma | 2 | 88 |
| WYNNEWOOD REFINING CO | CVR ENERGY | WYNNEWOOD | Oklahoma | 2 | 75 |
| AMERICAN REFINING GROUP INC | AMERICAN REFINING GROUP INC | BRADFORD | Pennsylvania | 1 | 12 |
| MONROE ENERGY LLC | DELTA AIR LINES INC | TRAINER | Pennsylvania | 1 | 190 |
| PHILADELPHIA ENERGY SOLUTIONS | CARLYLE GROUP | PHILADELPHIA | Pennsylvania | 1 | 355 |
| UNITED REFINING CO | UNITED REFINING INC | WARREN | Pennsylvania | 1 | 70 |
| CALUMET LUBRICANTS CO LP | CALUMET SPECIALTY PRODUCTS PARTNERS | L.P. | PRINCETON | Louisiana | 3 |
| CALUMET LUBRICANTS CO | CALUMET SPECIALTY PRODUCTS PARTNERS | L.P. | SAN ANTONIO | Texas | 3 |
| CALUMET SHREVEPORT LLC | CALUMET SPECIALTY PRODUCTS PARTNERS | L.P. | SHREVEPORT | Louisiana | 3 |
| Company_Name | Corporation | Site | State | PADD | AD_Mbpd |
| CALUMET LUBRICANTS CO LP | CALUMET SPECIALTY PRODUCTS PARTNERS | L.P. | SUPERIOR | Wisconsin | 2 |
| PREMCOR REFINING GROUP INC | VALERO ENERGY CORP | MEMPHIS | Tennessee | 2 | 185 |
| ALON USA ENERGY INC | ALON ISRAEL OIL COMPANY LTD | BIG SPRING | Texas | 3 | 73 |
| CITGO REFINING & CHEMICAL INC | PDV AMERICA INC | CORPUS CHRISTI | Texas | 3 | 164 |
| DEER PARK REFINING LTD PARTNERSHIP | DEER PARK REFINING LTD PTNRSHP | DEER PARK | Texas | 3 | 340 |
| DELEK REFINING LTD | DELEK GROUP LTD | TYLER | Texas | 3 | 65 |
| EQUISTAR CHEMICALS LP | ACCESS INDUSTRIES | CHANNELVIEW | Texas | 3 | 0 |
| EXXONMOBIL REFINING & SUPPLY CO | EXXON MOBIL CORP | BAYTOWN | Texas | 3 | 600 |
| EXXONMOBIL REFINING & SUPPLY CO | EXXON MOBIL CORP | BEAUMONT | Texas | 3 | 359 |
| Flint Hills Resources LP | KOCH INDUSTRIES INC | CORPUS CHRISTI | Texas | 3 | 304 |
| HOUSTON REFINING LP | ACCESS INDUSTRIES | HOUSTON | Texas | 3 | 302 |
| KINDER MORGAN CRUDE & CONDENSATE | KINDER MORGAN ENERGY PTNRS LP | GALENA PARK | Texas | 3 | 50 |
| LAZARUS ENERGY LLC | BLUE DOLPHIN ENERGY CO | NIXON | Texas | 3 | 12 |
| MARATHON PETROLEUM CO LP | MARATHON PETROLEUM CORP | GALVESTON BAY | Texas | 3 | 481 |
| MARATHON PETROLEUM CO LP | MARATHON PETROLEUM CORP | TEXAS CITY | Texas | 3 | 88 |
| Motiva Enterprises LLC | MOTIVA ENTERPRISES LLC | PORT ARTHUR | Texas | 3 | 635 |
| PASADENA REFINING SYSTEMS INC | PETROBRAS AMERICA INC | PASADENA | Texas | 3 | 106 |
| PHILLIPS 66 COMPANY | PHILLIPS 66 COMPANY | SWEENY | Texas | 3 | 260 |
| PREMCOR REFINING GROUP INC | VALERO ENERGY CORP | PORT ARTHUR | Texas | 3 | 415 |
| SOUTH HAMPTON RESOURCES INC | TEXAS OIL & CHEMICAL CO | SILSBEE | Texas | 3 | 0 |
| TOTAL PETROCHEMICALS & REFINING USA | TOTAL SA | PORT ARTHUR | Texas | 3 | 245 |
| VALERO ENERGY CORPORATION | VALERO ENERGY CORP | SUNRAY | Texas | 3 | 172 |
| VALERO ENERGY CORPORATION | VALERO ENERGY CORP | THREE RIVERS | Texas | 3 | 91 |
| VALERO REFINING CO TEXAS LP | VALERO ENERGY CORP | CORPUS CHRISTI | Texas | 3 | 210 |
| VALERO REFINING CO TEXAS LP | VALERO ENERGY CORP | HOUSTON | Texas | 3 | 103 |
| VALERO REFINING CO TEXAS LP | VALERO ENERGY CORP | TEXAS CITY | Texas | 3 | 231 |
| WESTERN REFINING COMPANY LP | WESTERN REFINING INC. | EL PASO | Texas | 3 | 131 |
| WRB REFINING LP | WRB REFINING LP | BORGER | Texas | 3 | 154 |
| BIG WEST OIL CO | FJ MANAGEMENT INC | NORTH SALT LAKE | Utah | 4 | 32 |
| CHEVRON USA INC | CHEVRON CORP | SALT LAKE CITY | Utah | 4 | 52 |
| HOLLY REFINING & MARKETING CO | HOLLYFRONTIER CORP | WOODS CROSS | Utah | 4 | 26 |
| Silver Eagle Refining | SILVER EAGLE REFINING INC | WOODS CROSS | Utah | 4 | 16 |
| Tesoro West Coast | TESORO CORP | SALT LAKE CITY | Utah | 4 | 60 |
| BP West Coast Products LLC | BP PLC | FERNDALE | Washington | 5 | 234 |
| PHILLIPS 66 COMPANY | PHILLIPS 66 COMPANY | FERNDALE | Washington | 5 | 108 |
| Shell Oil Products US | ROYAL DUTCH/SHELL GROUP | ANACORTES | Washington | 5 | 149 |
| Tesoro West Coast | TESORO CORP | ANACORTES | Washington | 5 | 125 |
| US OIL & REFINING CO | COMPAGNIE NATIONALE A PORTEFEUILLE | TACOMA | Washington | 5 | 42 |
| ERGON WEST VIRGINIA INC | ERGON INC | NEWELL | West Virginia | 1 | 23 |
| ANTELOPE REFINING LLC | GENESIS ENERGY LP | DOUGLAS | Wyoming | 4 | 4 |
| FRONTIER REFINING INC | HOLLYFRONTIER CORP | CHEYENNE | Wyoming | 4 | 52 |
| LITTLE AMERICA REFINING CO | SINCLAIR OIL CORP | EVANSVILLE | Wyoming | 4 | 26 |
| Silver Eagle Refining | SILVER EAGLE REFINING INC | EVANSTON | Wyoming | 4 | 3 |
| SINCLAIR WYOMING REFINING CO | SINCLAIR OIL CORP | SINCLAIR | Wyoming | 4 | 90 |
| WYOMING REFINING CO | BLACK ELK REFINING LLC | NEW CASTLE | Wyoming | 4 | 14 |
Feature field abbreviations and acronyms
PADD = Petroleum Administration for Defense District: A geographic aggregation of the 50 States and the District of Columbia into five Districts, with PADD 1 further split into three subdistricts. The PADDs include the States listed below:
PADD 1 (Location East Coast States):
PADD 1A (Location New England States): Connecticut, Maine, Massachusetts, New Hampshire, Rhode Island, and Vermont.
PADD 1B (Location Central Atlantic States): Delaware, District of Columbia, Maryland, New Jersey, New York, and Pennsylvania.
PADD 1C (Location Lower Atlantic States): Florida, Georgia, North Carolina, South Carolina, Virginia, and West Virginia.
PADD 2 (Location Midwest States): Illinois, Indiana, Iowa, Kansas, Kentucky, Michigan, Minnesota, Missouri, Nebraska, North Dakota, Ohio, Oklahoma, South Dakota, Tennessee, and Wisconsin.
PADD 3 (Location Gulf Coast States): Alabama, Arkansas, Louisiana, Mississippi, New Mexico, and Texas.
PADD 4 (Location Rocky Mountain States): Colorado, Idaho, Montana, Utah, and Wyoming.
PADD 5 (Location West Coast States): Alaska, Arizona, California, Hawaii, Nevada, Oregon, and Washington.
AD_Mbpd = The volume of crude oil, measured in thousands of barrels per day (Mb/d), processed by the atmospheric distillation chamber of a refinery
VDist_Mbpd = The volume of crude oil, measured in thousands of barrels per day (Mb/d), processed by the vacuum distillation chamber of a refinery
CaDis_Mbpd = The volume of crude oil, measured in thousands of barrels per day (Mb/d), processed by the catalytic disintegration chamber of a refinery
VRedu_Mbpd = The volume of crude oil, measured in thousands of barrels per day (Mb/d), processed by the viscosity reduction chamber of a refinery
CaRef_Mbpd = The volume of crude oil, measured in thousands of barrels per day (Mb/d), processed by the catalytic reformation chamber of a refinery
Isal_Mbpd = The volume of crude oil, measured in thousands of barrels per day (Mb/d), processed by the alkylation and isomerization chambers of a refinery
HDS_Mbpd = The volume of crude oil, measured in thousands of barrels per day (Mb/d), processed by the hydrodesulphurization chamber of a refinery
Cokin_Mbpd = The volume of crude oil, measured in thousands of barrels per day (Mb/d), processed by the coking chamber of a refinery
Asph_Mbpd = The maximum amount of asphalt products, measured in thousands of barrels per day (Mb/d), that can be produced at the refinery
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