Texas runs on energy. From the Gulf Coast to South Texas, oil refineries power our vehicles, support thousands of jobs, and drive a large part of the state’s economy. Some of the biggest refineries in Texas process hundreds of thousands of barrels of crude oil every day. That fuel keeps cars moving, planes in the air, and businesses running across the country.
But large facilities also come with serious risk.
When a refinery operates at this scale, one equipment failure can cause an explosion, fire, or chemical release. For workers and families across South Texas, including many here in San Antonio, the consequences can be life changing.
Below is a closer look at the biggest refineries in Texas, where they are located, how much they produce, and why size matters when safety failures lead to serious injuries.
Texas: A National Refining Leader
Texas leads the nation in oil refining. According to the U.S. Energy Information Administration (EIA), the state accounts for more than 25 percent of total U.S. refining capacity. That means millions of barrels of crude oil are processed here every single day.
Most of this refining activity is concentrated along the Gulf Coast, particularly near Houston, Beaumont, Texas City, and Port Arthur.
When facilities operate at this level, even one serious incident can affect workers, contractors, nearby communities, and supply chains across the state.
The Biggest Refinery in Texas: Motiva Port Arthur
The Motiva Port Arthur Manufacturing Complex is widely recognized as the largest refinery in Texas.
The facility processes heavy, light, and sour crude oils. It produces large volumes of petroleum coke and base oils used in lubricants.
Safety History
Like many large refineries, Motiva Port Arthur has experienced serious incidents.
In October 2025, a contract worker died at the facility. A wrongful death lawsuit was later filed on behalf of the worker’s family.
In August 2017, a fire at the refinery injured multiple workers and resulted in one death. Litigation followed that incident as well.
These events highlight the risks involved in large scale refining operations, particularly for contractors working in high heat and high pressure environments.
Other Major Refineries in Texas
Texas is home to several of the largest refining facilities in the country.
Marathon Galveston Bay
The refinery has operated for decades and plays a major role in Gulf Coast fuel distribution.
Safety History
In May 2023, a fire at the facility resulted in the death of one worker. The family later filed a lawsuit.
ExxonMobil Beaumont
Safety History
In 2013, a refinery fire killed two workers and injured others. Federal regulators later announced a settlement related to Clean Air Act violations.
In May 2016, a crane accident led to a worker’s death. A jury later awarded approximately $44 million to the worker’s family.
ExxonMobil Baytown
Safety History
The Baytown complex has experienced several serious incidents.
A July 2019 plant explosion resulted in a jury verdict of $28.5M for injured workers.
Following a December 2021 fire, two injured employees filed a lawsuit seeking $10 million in damages.
Refineries Closer to San Antonio
While the largest facilities are located along the coast, several refining operations are closer to South Texas.
Valero Corpus Christi West Plant
Valero is headquartered in San Antonio. Its coastal refinery operations are an important part of the regional economy.
Phillips 66 Sweeny Refinery
Like other refineries, Sweeny operates high temperature units and handles flammable materials that require strict safety oversight.
Valero Three Rivers
Because of its proximity to San Antonio, this refinery is especially relevant to local workers.
Safety History
In January 2025, an explosion reportedly injured five workers, including two who suffered severe burns. A lawsuit seeking more than $1 million in damages was later filed.
Why Refinery Size Matters for Worker Safety
Refinery size is not just a statistic.
Larger facilities typically mean:
- More workers and contractors onsite
- More complex equipment and piping systems
- Greater volumes of flammable materials
- Higher potential impact if something fails
Many large refineries rely heavily on contractors. When multiple companies operate at the same site, determining responsibility after an accident can become complicated.
In some situations, injured workers may have options beyond standard workers compensation, particularly if a third party’s negligence contributed to the incident.
What This Means for San Antonio Families
Refineries play an important role in Texas. They also carry real risks.
When refinery accidents result in:
- Severe burns
- Brain injuries
- Crush injuries
- Chemical exposure
- Wrongful death
families are left facing medical bills, lost wages, and long term uncertainty.
If you or someone you love has been injured in a refinery or oilfield accident, it is important to understand your legal options. A thorough investigation can determine whether safety failures, defective equipment, or third party negligence played a role.
Toscano Law Firm has been advocating for injured Texans for more than 23 years. If you need guidance after a serious accident, you can call me directly at (210) 951-0696 to discuss your situation.
Understanding your rights is the first step toward making things right.
