Beaver County | Energy Companies | Ethane | Industrywide Issues | Pennsylvania | Pipelines | Processing Plants | Shell
Shell Pa. Cracker Ready for Prime Time, but Has an Achilles’ Heel
Last Friday, RBN Energy published a blog post declaring that the Shell ethane cracker in Monaca (Beaver County), PA, is now “firing on all cylinders.” The post retrospectively covers the project’s history, from construction through recent problems as the plant was commissioned to the present day. We learned something interesting: Shell, a petrochemical giant and owner of other cracker plants producing various products, had exited the plastic pellets business years ago. The Monaca cracker is Shell reentering that market. Read More “Shell Pa. Cracker Ready for Prime Time, but Has an Achilles’ Heel”
For the week of August 5 – 11, a total of 26 permits were issued to drill new shale wells in Marcellus/Utica, with the vast majority issued in Pennsylvania. The Keystone State had 21 new permits, with an eye-popping 19 going to EQT split between Greene and Washington counties (in the southwestern part of the state), and two issued to Range Resources in Beaver County. Ohio issued five new permits last week, with four going to Ascent Resources in Jefferson County and one to Encino Energy (EAP) in Guernsey County. West Virginia’s online data service is currently out of order, and there is no ETA for when it will be fixed, so we have no permits to report for the Mountain State. 
The mighty Shell ethane cracker plant in Monaca (Beaver County), PA, has a new person in charge: Emma Lewis, senior vice president of U.S. chemicals and products at Shell. We told you Lewis had replaced Hilary Mercer back in January (see 
In March, MDN told you that the Pennsylvania Dept. of Environmental Protection (DEP) told Shell to file for a Title V air permit for its ethane cracker in Monaca no later than June 21 of this year or risk being shut down (see 
Patience is a rare commodity these days. We live in a day and age of instant gratification. Our food is made and delivered in minutes. The latest gizmo we want can be on our doorstep the next day (or, in some cases, the same day) from Amazon and any number of other retailers. Entertainment and distractions are everywhere! Just lift your eyes from your own phone and observe everyone else around you staring at their phones. So perhaps it is no surprise that some people feel lied to because the mighty Shell ethane cracker plant in Beaver County, PA, hasn’t instantly delivered the promised thousands of extra jobs and dozens of relocated companies.
The Pennsylvania Dept. of Environmental Protection (DEP) has extended three temporary air permits for the Shell ethane cracker plant in Monaca, PA, which would have expired at the end of April. The extended permits will suffice until Shell files for and receives what is called a federal Title V Operating Permit for air emissions from the cracker plant. In March, we told you that the DEP had told Shell to file for a Title V permit no later than June 21 of this year or risk being shut down (see 
Although Shell maintains flaring and accidental emissions from its multi-billion-dollar ethane cracker in Beaver County, PA, have not violated state and federal air standards, the Pennsylvania Dept. of Environmental Protection (DEP) says they have — on numerous occasions. Shell didn’t argue the point, and in May 2023, the company agreed to pay nearly $10 million in fines and “contributions” to benefit the local community (see 
The Pennsylvania Dept. of Environmental Protection (DEP) sent a letter to the Shell ethane cracker plant on Feb. 22 essentially saying, “You’re time is up.” The cracker plant facility has 120 days from Feb. 22 (until Jun. 21) to file for a federal Title V Operating Permit for air emissions. If the facility doesn’t at least file for the permit, it’s lights out until it does.
Although Shell maintains flaring and accidental emissions from its new multi-billion-dollar ethane cracker in Beaver County, PA, have not violated state and federal air standards, the Pennsylvania Dept. of Environmental Protection (DEP) says they have — on numerous occasions. Shell didn’t argue the point, and last May, the company agreed to pay nearly $10 million in fines and “contributions” to benefit the local community (see 
Although Shell maintains flaring and accidental emissions from its new multi-billion-dollar ethane cracker in Beaver County, PA, have not violated state and federal air standards, the Pennsylvania Dept. of Environmental Protection (DEP) says they have — on numerous occasions. Shell didn’t argue the point, and in May 2023, the company agreed to pay nearly $10 million in fines and “contributions” to benefit the local community (see 
In 2021, PennEnergy Resources made a request to the Pennsylvania Dept. of Environmental Protection (DEP) to withdraw up to 3 million gallons of water a day from Big Sewickley Creek and one of its tributaries for shale fracking (see 
Yesterday, Shell’s new CEO, Wael Sawan, spilled some major beans about the company’s ethane cracker in Monaca (Beaver County), Pennsylvania. Sawan’s comments about the cracker came during a quarterly conference call with analysts to discuss the company’s performance during the fourth quarter of 2023. Until yesterday, Shell had steadfastly declined to disclose how much money it spent to build the Monaca ethane cracker facility. Sawan said yesterday the number was a massive $14 billion, far more than the estimated $6-$10 billion that had been bandied about for years.
The Shell ethane cracker plant in Monaca, PA (Beaver County) just hit a milestone: It’s been up and running (in a manner of speaking) for one year. Except during that one year, quite a bit of the time was spent NOT running due to various technical and equipment issues. According to a review done by the Pittsburgh Post-Gazette, “the plant’s polyethylene units — the three clusters of pipes and vessels that turn ethylene into lentil-sized plastic beads — were down as much as they were running in that first year.”