Exxon selected Fluor to perform the design, engineering and procurement scope to make their Baytown, Texas, refinery the largest of its kind in the United States. The Baytown expansion was the largest part of an overall Exxon expansion program to add an additional 250,000-barrels-per-day (BPD) capacity at their domestic refineries.

We had responsibility for this major expansion to increase capacity from 350,000 BPD to 600,000 BPD with process capability for domestic or foreign high-sulfur crude. Product output included low-sulfur residual fuel oil, low-sulfur heating oil, diesel fuel, gasoline and jet fuel.

Given the large scale of this project, we leveraged our U.S. execution platform. Our Houston and Irvine offices shared the design and engineering effort, with Houston managing the large procurement purchases and logistics.

Process units in the project included:

• 250,000-BPD atmospheric crude unit with light ends processing

• Large catalytic reformer

• Naphtha hydrofiner

• LGO hydrofiner

• Kerosene hydrofiner

• Residfiner for desulfurization of atmospheric residuum with some vacuum resid

• Fluor aqueous monoethanolamine (MEA) scrubbers with MEA regeneration facilities

• Hydrogen plant, utilizing MEA-scrubbed refinery gas as a feedstock

• Sulfur units with an aggregate capacity of 847 tons per day

• Offsites, including four 600-psi waste heat boilers with feed water treating facilities, four gas turbine generators, a 60-million-gallons-per-minute refinery cooling water system, an 8-10-million-gallons-per-day industrial water treating and distribution system and two 8000-standard-cubic-feet-per-minute centrifugal compressors for refinery air service

The local task force reached peaked with over 250 personnel, with over 2.8 million home office hours for engineering and procurement activities.