TABLE-U.S. refinery expansion plans

Thu Jul 19, 2007 6:20pm BST
 
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 (Updates Placid Refining in PADD 3)
 In recent years, oil refiners in the United States have announced plans to add millions of
barrels of new capacity to capitalize on sharply higher refining margins. However, rising capital
costs for new refinery units coupled with concerns that biofuels could erode growth opportunities
for oil-based fuels have led to plans being scaled back.
 Some 500,000 barrels per day of planned capacity expansions have been cut since mid-2006,
according to the U.S. government's Energy Information Administration. The EIA now estimates that
refineries will add only 1 million barrels of daily capacity by 2012. The following is a list of
some reported U.S. refinery expansion plans:
REFINERY        CAPACITY     UNIT  COMPLETION
=============================================================================
EAST COAST (PADD 1)
=============================================================================
CONOCOPHILLIPS CORP. (COP.N)
Bayway, NJ       5,800 bpd   FCC     N/A    Revamp, conversion up 4 percent
                          CDU     N/A    Revamp   
SUNOCO INC. (SUN.N)
Phila., PA      15,000 bpd+  FCC   Apr-07   Costs rose from $300 million to
                                         $520 million amid industry-wide
                                         cost pressures and design changes
          40-50,000 bpd   HDS   early-09 up to $275 million to convert an
                                         idle HCU to process heating oil
                                         into ultra-low sulphur diesel 
VALERO CORP. (VLO.N)
Del. City, DE  20,000 bpd    CDU     N/A    Company seeking permits
=============================================================================
MIDWEST (PADD 2)
=============================================================================
BP PLC (BP.L)
Whiting, IN     N/A        refinery 2011    $3 billion revamp to increase
                                         heavy crude processing, motor
                                         fuels output to rise 55,000 bpd
COFFEYVILLE RESOURCES
Coffeyville, KS 15,000 bpd   CDU  late-06
FLINT HILLS RESOURCES
Rosemount, MN   50,000 bpd   CDU   Q4-07
                N/A       DCU    N/A     Larger coker drums being installed
FRONTIER OIL CORP. (FTO.N)
El Dorado, KS       N/A    CDU/VDU Q2-08    $50 million heavy crude revamp
              2,500 bpd   DCU   Q2-08    Two new coker drums
              5,000 bpd   FCC   Q2-09    $78 million expansion
                          HTU   Q2-09    $77 million expansion
MARATHON OIL CORP (MRO.N)
Catletssburg, KY    N/A   refinery  N/A     150,000 bpd heavy oil project.
                                         Conceptual study started
Detroit, MI         N/A   refinery  N/A     Convert refinery to run
                                         100,000 bpd heavy oil. Front-end
                                         engineering studies underway
Robinson, IL        N/A   refinery  N/A     180,000 bpd heavy oil project.
                                         Feasibility study started.
MURPHY OIL CORP (MUR.N)
Superior, WI        N/A   refinery  N/A     Seeking Canadian oil sands partner
                                         for possible expansion
SINCLAIR OIL CORP. 
Tulsa, OK       30,000 bpd   DCU   2009
             40,000 bpd refinery N/A     Planned expansion, no timetable
SUNOCO
Toledo, OH      20,000 bpd   CDU Jun-07     $40 million expansion, on budget
          10-15,000 bpd   HCU end-08     $30 million expansion
            20,000 bpd   CDU   2008     On hold due to costs
             24,000 bpd   FCC   2008     On hold due to costs
WRB REFINING LLC (ConocoPhillips and EnCana joint venture)
Wood River, IL  32,000 bpd   GDS   2007     S-Zorb unit
             70,000 bpd   CDU   2009     CDU, DCU projects are $1.9                 65,000 bpd
  DCU   2009     billion first phase of oil sands                     N/A    CDU/DCU 2013
 Further 100,000 bpd bitumen
                                         $2 billion capital cost
WYNNEWOOD REFINING (GARY-WILLIAMS ENERGY)
Wynnewood, OK   15,000 bpd   CDU   Q1-07
             20,000 bpd   DHT    N/A
=============================================================================
GULF COAST (PADD 3)
=============================================================================
CHEVRON CORP. (CVX.N)
Pascagoula, MS  16,000 bpd   FCC   Late-06  Completed December 2006
             N/A          CCR    N/A     Permitting underway, construction
                                         to start in early 2008 if approved.
                                         Replaces two older reformers, boosts
                                        gasoline output by 12,000 bpd
            200,000 bpd refinery N/A     Applied for permits. Work seen in
                                         2008, 2009
HOLLY CORP. (HOC.N)
Navajo, NM      15,000 bpd   CDU   Q4-08    revamp
             20,000 bpd   HCU   Q4-08    $225 million total outlay
               N/A        CDU    2011    40,000 bpd heavy crude revamp
MARATHON OIL CORP. (MRO.N)
Garyville, LA  180,000 bpd   CDU   Q4-09    $3.2 billion expansion
             44,000 bpd   DCU   Q4-09  
             70,000 bpd   HCU   Q4-09
             65,000 bpd   CCR   Q4-09
             47,000 bpd   KHT   Q4-09
MOTIVA ENTERPRISES LLC (RDSa.L)
Pt. Arthur, TX  45,000 bpd   DHT    2008    Construction began June 2006
            325,000 bpd refinery 2010    Decision expected in 2007, some
                                         long-lead time equipment ordered
PASADENA REFINING SYSTEM INC.
Pasadena, TX      N/A    refinery   2010    revamp to run 70,000 bpd Marlim                    N/A
    CDU     N/A    future 100-200,000 bpd expansion
PLACID REFINING COMPANY LLC
Port Allen, LA    N/A        FCC   Q2-08    Gasoline output increased 7,000 bpd
               N/A        CDU   Q3-08    Heavy oil revamp
             25,000 bpd   CDU     N/A    Planned expansion
TOTAL SA (TOTF.PA)
Pt. Arthur, TX    N/A        DCU    2009    $1 billion project studied
VALERO ENERGY CORP. (VLO.N)
C. Christi, TX      N/A      ISE    Q2-07   MTBE unit conversion
Houston, TX         N/A      HCU    Q2-07   Mild hydrocracker  
Pt. Arthur, TX  75,000 bpd   CDU    Q1-07   completed and in operation
            125,000 bpd refinery  2009   $1.3 billion project, engineering
                                         underway, not yet sanctioned
St Charles, LA  50,000 bpd refinery  N/A    Permitting underway
Tx. City, TX    20,000 bpd   CDU     N/A    Expansion canceled on costs
             12,000 bpd   DCU     N/A    Expansion canceled on costs
WRB REFINING LLC
Borger, TX      20,000 bpd   DCU   Q2-07    Bitumen phase 1, $500 million
         debottleneck  refinery 2009    Bitumen phase 2, $300 million                 54,000
bpd   CDU    2012    Bitumen phase 3, $600 million
=============================================================================
ROCKY MOUNTAINS (PADD 4)
=============================================================================
CONOCOPHILLIPS
Billings, MT    10,000 bpd CDU/VDU Q2-07    Heavy crude capacity up 46,000 bpd
FRONTIER
Cheyenne, WY     4,500 bpd   DCU    Q3-07   $89 million expansion
              N/A         CDU    Q2-07   $8 million revamp
HOLLY
Woods Cross, UT  5,000 bpd   CDU    Q4-08
             15,000 bpd   HCU    Q4-08   $100 million for both projects
SINCLAIR  
Salt Lake, UT   60,000 bpd   DCU    2009
Sinclair, WY    20,000 bpd   CDU   late-06
             20,000 bpd   DCU   late-06  coker purchased from idle refinery
=============================================================================
WEST COAST (PADD 5)
=============================================================================
BIG WEST OIL LLC
Bakersfield, CA 19,200 bpd   FCC    2008    $680 million conversion capacity
             25,000 bpd   DHT    2008    project to double CARB diesel and
              9,000 bpd   ALK    2008    gasoline output.
CHS INC. (CHSCP.O)
Laurel, MT      15,000 bpd   DCU   Aug-08   $325 million
CONOCOPHILLIPS
Ferndale, WA    25,000 bpd   DCU     N/A    Adds 25,000 bpd heavy oil capacity
              5,000 bpd   CDU     N/A
Rodeo, CA       20,000 bpd   HCU
              5,000 bpd   CDU
Los Angeles        N/A       DCU    N/A/    Revamp, clean yields up 2 percent
TESORO CORP. (TSO.N)  
Los Angeles       N/A        DCU    N/A     revamp
               N/A        DHT    N/A     revamp
Martinez, CA      N/A        DCU    N/A     Conversion of existing fluid
                                         coker,costs as high as $525
                                         million from $275 million initial
                                         estimate
Anacortes, WA   25,000 bpd   DCU            canceled July 2006 on costs                  N/A
                                         refinery H2-07   $34 million sour crude revamp
VALERO
Benicia, CA      N/A         DHT    Q3-07   ULSD unit, $105 million
Wilmington, CA   N/A         ALK    Q4-07   $195 million project
=============================================================================
KEY: FCC: Fluid Catalytic Cracker; CDU: Crude Distillation Unit; VDU: Vacuum Distillation Unit;
DCU: Delayed Coker Unit; DHT: Distillate Hydrotreater; HTU: Hydrotreater; HCU: Hydrocracker; CCR:
Catalytic Reformer; KHT: Kerosene Hydrotreater; GDS: Gasoline Desulphurization Unit; ALK:
Alkylation unit ISE: Iso-Octene unit

 

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