Processing Plants

Beaver County | Energy Companies | Ethane | Industrywide Issues | Litigation | Pennsylvania | Processing Plants | Shell

Shell Asks Court to Toss Big Green Cracker Suit: DEP Already Acted
October 14, 2026October 14, 2026

Shell Chemical Appalachia wants a federal judge in Pittsburgh to throw out a lawsuit Philadelphia-based Big Green group Clean Air Council filed more than three years ago over air emissions at Shell’s ethane cracker plant in Monaca (Beaver County), PA. Shell’s main argument is simple: the PA Department of Environmental Protection (DEP) has already gone after Shell for the very same violations, not once but twice, collecting nearly $25 million in penalties and “community” payments. Federal law, says Shell, doesn’t let a private group pile on when the state is already on the case. Shell also argues the Council never showed that a single member was actually harmed. Shell filed its motion last Friday, Oct. 9, and the Council has agreed to pause the case while the judge decides. Read More “Shell Asks Court to Toss Big Green Cracker Suit: DEP Already Acted”
Air Quality | Beaver County | Energy Companies | Ethane | Industrywide Issues | Pennsylvania | Processing Plants | Regulation | Shell

DEP Approves New Shell Cracker Air Permit, NOx Limit Goes Up
September 28, 2026September 28, 2026

Back in April, we told you the PA Department of Environmental Protection (DEP) had once again extended the three “temporary” air permits for Shell’s ethane cracker plant in Monaca (Beaver County) while the agency slogs through Shell’s full Title V permit application (see PA Extends Temporary Shell Cracker Air Quality Permits Until Oct.). At the end of that post, we mentioned a separate permit pending before DEP, one covering flares, the wastewater treatment plant, and “as-built” pollution controls. The public comment period on it had just closed. On Sept. 22, DEP issued that permit, formally called Plan Approval No. 04-00740D. And yes, it raises Shell’s allowed emissions of nitrogen oxides (NOx) and several other pollutants. Cue the outrage from the usual suspects. Read More “DEP Approves New Shell Cracker Air Permit, NOx Limit Goes Up”
Accidents | Beaver County | Energy Companies | Ethane | Industrywide Issues | Pennsylvania | Processing Plants | Shell

Shell Cracker Blast: 6 Minutes from Wrong Click to $95M Explosion
September 22, 2026September 22, 2026

The U.S. Chemical Safety and Hazard Investigation Board (CSB) last Wednesday, Sept. 16, released its final report on the June 4, 2025, explosion and fire at Shell Polymers Monaca, the ethane cracker plant in Beaver County, PA (see PA DEP Says Shell Ethane Plant Fire May Have Released Carcinogens). The finding, boiled down to one sentence: an engineer who had never done the job before opened the wrong valve on a computer screen where three nearly identical valves were stacked on top of each other, and six minutes later Furnace 5 blew apart. Damage: $95 million. Injuries: none. OSHA’s fine: $26,480. Read More “Shell Cracker Blast: 6 Minutes from Wrong Click to $95M Explosion”
Beaver County | Energy Companies | Ethane | Industrywide Issues | M&A | Pennsylvania | Processing Plants | Shell

Four Bidders Circle Shell’s Monaca, PA Ethane Cracker Plant
August 25, 2026August 25, 2026

For a year and a half, MDN has tracked the on-again, on-again saga of Shell trying to unload its chemicals business — including the $14 billion Monaca (Beaver County, PA) ethane cracker complex that turns Marcellus/Utica ethane into plastic pellets. We first flagged the rumor in March 2025 (see Shocker: Shell Considers Selling Beaver County, PA Ethane Cracker). CEO Wael Sawan confirmed it that August, saying Shell is “not the natural operator and owner of that asset.” As recently as May, Sawan was still saying “maybe.” Now we finally have names. Read More “Four Bidders Circle Shell’s Monaca, PA Ethane Cracker Plant”
Energy Services | Industrywide Issues | MarkWest Energy | Pennsylvania | Processing Plants | Regulation | Washington County

PA DEP Issues Permit for Expansion of MarkWest Harmon Creek Plant
June 1, 2026June 1, 2026

The Pennsylvania Department of Environmental Protection issued an air quality permit on May 18, 2026, to MarkWest Liberty Midstream, authorizing the expansion of its Harmon Creek Natural Gas Processing Plant in Washington County. The MarkWest name is still used, although the company is now MPLX. The DEP permit approval allows the addition of a third cryogenic plant and a second de-ethanization plant. A number of Big Green groups colluded in an attempt to block the permits, but their demands were ignored. Read More “PA DEP Issues Permit for Expansion of MarkWest Harmon Creek Plant”
Beaver County | Energy Companies | Ethane | Industrywide Issues | Pennsylvania | Processing Plants | Shell

Shell Still Pondering Sale of Chemicals Div., Including PA Cracker
May 11, 2026May 11, 2026

In March 2025, the Wall Street Journal reported that Shell is “exploring a potential sale of its chemicals assets in Europe and the U.S.,” which includes the Monaca (Beaver County, PA) ethane cracker complex (see Shocker: Shell Considers Selling Beaver County, PA Ethane Cracker). In August 2025, during a quarterly earnings call with analysts, Shell CEO Wael Sawan confirmed the rumor, saying Shell is “not the natural operator and owner of that asset” referring to the Monaca cracker plant (see Shell Looks to Sell All or Part of Monaca, PA Ethane Cracker Plant). Last Thursday, during Shell’s latest quarterly update, Sawan once again reiterated the desire to sell the company’s chemicals division, including the PA cracker, but only if it creates “shareholder value.” Read More “Shell Still Pondering Sale of Chemicals Div., Including PA Cracker”
Energy Companies | Ethane | Industrywide Issues | Processing Plants | Regulation | Shell

PA Extends Temporary Shell Cracker Air Quality Permits Until Oct.
April 27, 2026April 27, 2026

The Pennsylvania Department of Environmental Protection (DEP) has extended three temporary air permits for the Shell ethane cracker plant in Monaca, PA, which would have expired on April 28, 2026. The DEP did the same thing in May 2024 (see Shell Cracker Air Quality Permits from PA DEP Temporarily Extended). The extended permits will suffice until the DEP reviews and issues a federal Title V Operating Permit for air emissions by the cracker plant. Read More “PA Extends Temporary Shell Cracker Air Quality Permits Until Oct.”
Anti-Drilling/Fossil Fuel | Beaver County | Energy Companies | Ethane | Industrywide Issues | Litigation | Pennsylvania | Processing Plants | Shell

Key Issue for Shell PA Cracker: What Constitutes Emissions Data?
March 9, 2026March 9, 2026

click for larger version

Shell’s $15 billion petrochemical complex in Beaver County faces intense scrutiny following new emissions data highlighting persistent operational problems. Since opening, the facility has received 80 malfunction reports and 43 state violation notices. From 2020 to 2024, the plant emitted 17.9 billion pounds of “pollutants,” including nearly 400 million pounds of unexpected emissions during malfunctions involving hazardous chemicals like benzene and naphthalene. Despite Shell’s efforts, ongoing issues such as flaring, equipment breakdowns, and a 2025 fire continue to concern regulators and residents, while the local economy has unexpectedly shrunk since the plant’s inception. Read More “Key Issue for Shell PA Cracker: What Constitutes Emissions Data?”
Beaver County | Energy Companies | Ethane | Industrywide Issues | Pennsylvania | Processing Plants | Shell

Shell Weighs PA Cracker Plant Future as Chemical Losses Hit $66M
February 6, 2026February 6, 2026

Yesterday, Shell’s chemical division reported a $66 million fourth-quarter loss, driven by weak margins and operational hurdles at its $14 billion Beaver County ethane cracker plant complex. Shell CEO Wael Sawan acknowledged the chemicals business is underperforming, making a turnaround a “top priority” for 2026. Although Shell is exploring a sale or joint venture for the Monaca facility due to its geographic isolation and high costs, no specific updates were shared during the latest earnings call. Read More “Shell Weighs PA Cracker Plant Future as Chemical Losses Hit $66M”
Anti-Drilling/Fossil Fuel | Beaver County | Energy Companies | Ethane | Industrywide Issues | Pennsylvania | Processing Plants | Regulation | Shell

Antis Hound PA DEP for More Notifications & Fines re Shell Cracker
August 6, 2025August 6, 2025

Two days ago, MDN brought you the news confirming that Shell is looking to sell all or part of its Beaver County, PA, ethane cracker plant operation (see Shell Looks to Sell All or Part of Monaca, PA Ethane Cracker Plant). We remain somewhat incredulous that it wants to sell an asset like the cracker plant. The question is, why? We said this: “We still think Shell is just plain tired of dealing with all of the CRAP from the environmental left and the Pennsylvania Department of Environmental Protection, which declares a new emergency or violation at the plant about every other day.” Right on cue, a group of radicals is hammering the DEP, claiming the cracker plant is polluting everything in sight and that the DEP is not being hard enough on Shell. Read More “Antis Hound PA DEP for More Notifications & Fines re Shell Cracker”
Beaver County | Energy Companies | Ethane | Industrywide Issues | Pennsylvania | Processing Plants | Shell

Shell Looks to Sell All or Part of Monaca, PA Ethane Cracker Plant
August 4, 2025August 4, 2025

Back in March, the Wall Street Journal reported that Shell is “exploring a potential sale of its chemicals assets in Europe and the U.S.,” which includes the recently completed Monaca (Beaver County, PA) ethane cracker complex (see Shocker: Shell Considers Selling Beaver County, PA Ethane Cracker). It looks like the rumors were right. Last week on an earnings call with analysts, Shell CEO Wael Sawan said, concerning the Monaca cracker, that Shell is “not the natural operator and owner of that asset.” Read More “Shell Looks to Sell All or Part of Monaca, PA Ethane Cracker Plant”
Accidents | Beaver County | Energy Companies | Ethane | Industrywide Issues | Pennsylvania | Processing Plants | Shell

PA DEP Says Shell Ethane Plant Fire May Have Released Carcinogens
June 6, 2025June 6, 2025

Footage of Shell’s ethane cracker in Monaca, Pa. shows smoke coming off the site. Image: Beaver County Marcellus Awareness Community

Another incident happened Wednesday afternoon at the Shell ethane cracker plant facility in Beaver County, PA. This isn’t the first problem at the plant (see our cracker problem stories here). An explosion and fire (with smoke) were reported at the ethane cracker on Wednesday. A company spokesperson stated that smoke was seen coming off of a furnace unit at the plant around 2:20 p.m. She said the incident was managed by site personnel, and the smoke dissipated. However, the Pennsylvania Department of Environmental Protection (DEP) has a concern that “a possible release of an unknown amount of 1,3-butadiene and benzene” —both hazardous air pollutants and known carcinogens (cancer-causing). Read More “PA DEP Says Shell Ethane Plant Fire May Have Released Carcinogens”
Energy Services | Industrywide Issues | MarkWest Energy | Pennsylvania | Processing Plants | Washington County

PA DEP Approves MarkWest Processing Plant Expansion in SWPA
May 19, 2025May 19, 2025

Last November, MDN brought you the great news that MPLX (aka MarkWest Energy) would file to build an expansion at its existing Harmon Creek facility in Smith Township, Washington County, PA (see MPLX to Build New Harmon Creek III Gas Processing in PA Marcellus). MPLX wants to add a 300 MMcf/d (million cubic feet per day) processing plant and 40,000 bbls/d (barrels per day) de-ethanizer to the facility. The Pennsylvania Department of Environmental Protection (DEP) announced via last Saturday’s PA Bulletin that it has issued the necessary air permit for the project. Read More “PA DEP Approves MarkWest Processing Plant Expansion in SWPA”
Beaver County | Energy Companies | Ethane | Industrywide Issues | Pennsylvania | Processing Plants | Shell

Shocker: Shell Considers Selling Beaver County, PA Ethane Cracker
March 4, 2025March 4, 2025

According to the Wall Street Journal, Shell is “exploring a potential sale of its chemicals assets in Europe and the U.S.,” according to “people familiar with the matter.” The review and potential sale are part of a continuing drive to refocus the company’s business on its most profitable operations. One of the petchem assets that may be on the auction block is the recently completed Monaca (Beaver County, PA) ethane cracker complex. Our heads are officially exploding. Read More “Shocker: Shell Considers Selling Beaver County, PA Ethane Cracker”
Butler County | Energy Services | Industrywide Issues | Marathon Petroleum | MarkWest Energy | Pennsylvania | Processing Plants | Regulation

MPLX PA Bluestone Gas Processing Plant Gets Big Sloppy Kiss from EPA
January 17, 2025January 17, 2025

Marathon Petroleum’s MPLX, formerly MarkWest, operates five complexes in the Marcellus shale. One of the five is the Bluestone Complex in Butler County, PA. Bluestone gathers 200 million cubic feet per day (MMcf/d) of natural gas. Bluestone processes 400 MMcf/d of natural gas, separating methane from other hydrocarbons. The facility then further separates ethane (C2H6) from other NGLs like propane and butane in a process called C2+ fractionation—producing some 81,000 barrels per day. Yesterday, MPLX announced that the Bluestone plant has become the only U.S. natural gas processing facility to achieve the EPA’s ENERGY STAR Challenge for Industry. Read More “MPLX PA Bluestone Gas Processing Plant Gets Big Sloppy Kiss from EPA”
Belmont County | Energy Services | Ethane | Industrywide Issues | Ohio | Processing Plants | PTT Global

PTT Investing $21.25B in 2025 to 2029, But Not in Ohio Cracker
January 3, 2025January 3, 2025

This is your friendly (somewhat snarky) semi-regular reminder from MDN that the PTT ethane cracker project in Ohio is dead (see Facing Reality – PTT Ohio Cracker Plant Project is Dead). We periodically look for signs of life in the project, and it has been a flat line for YEARS. Nothing. Local and state leaders in Ohio used to pop their heads up to tell us to have hope, that it will still happen. Not anymore. While PTT still chips in donations to the town now and again, no one seriously thinks there will be a cracker plant on the site in Dilles Bottom (Belmont County), Ohio. We have more evidence to support our view… Read More “PTT Investing $21.25B in 2025 to 2029, But Not in Ohio Cracker”