? Pacific Northwest Refineries: Cheap Crude and a Captive Market Margins Helped by Advantaged Crude and Less Competition Executive Summary The five refineries in the U.S. Pacific Northwest performed better in 2016 than rivals on the East or Gulf coasts for two main reasons. First, the changing pattern of North American crude supply has worked to their advantage. Faced with the threat of dwindling mainstay crude supplies from Alaska, refiners in Washington state replaced 22% of their slate with North Dakota Bakken crude shipped in by rail. They have also enjoyed advantaged access to discounted crude supplies delivered from nearby western Canada. Second, Northwest refiners face less competition for refined product customers than rivals on the East and Gulf coasts, meaning they have a captive market that often translates to higher margins. Future opportunities for these refineries abound, due to recently approved upcoming expansion of the Trans Mountain crude pipeline that delivers Canadian crude from Edmonton, Alberta, to Vancouver, British Columbia, and the Puget Sound refineries. Although there are still hurdles for this project to overcome, if the expansion goes ahead, then owner Kinder Morgan will nearly triple the line’s capacity to 890 thousand barrels per day. This will significantly increase access to western Canadian crude supplies and could encourage Northwest refinery upgrades or expansion with a view to exporting more refined product from the region. This outlook details the changing crude supply picture for Washington state refineries as well as regional refined product demand and margin performance. We also detail operations and prospects for each refinery, concluding with a summary of winners and losers. Key Takeaways × The five refineries in the Pacific Northwest primarily serve demand in Washington state and Oregon as well as British Columbia. × The downstream market for refined products in this region is less competitive, meaning fuel prices are generally higher than in the Gulf and East coast regions, boosting refinery margins. × Refiners have adapted to several structural changes in their crude supply, the most significant being continued decline in the output of Alaskan North Slope crude. × ANS is being replaced with light sweet shale crude from the Bakken formations in North Dakota, delivered by rail. × Even as crude price differentials narrowed to make crude by rail less competitive at Gulf and East coast refineries, higher product yields for Bakken crude compared with ANS on the West Coast mean that supplies from North Dakota continue to play a significant part in the Northwest refinery slate. Morningstar Commodities Research 5 January 2017 Sandy Fielden Director, Oil and Products Research +1 512-431-8044 [email protected]Data Sources for this Publication gAlaska Dept. of Revenue gCalifornia Energy Commission gClipperData gCME Group gCrude Postings gEIA To discover more about the data sources used Click Here
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? Pacific Northwest Refineries: Cheap Crude and a Captive Market Margins Helped by Advantaged Crude and Less Competition
Executive Summary
The five refineries in the U.S. Pacific Northwest performed better in 2016 than rivals on the East or Gulf
coasts for two main reasons. First, the changing pattern of North American crude supply has worked
to their advantage. Faced with the threat of dwindling mainstay crude supplies from Alaska, refiners in
Washington state replaced 22% of their slate with North Dakota Bakken crude shipped in by rail. They
have also enjoyed advantaged access to discounted crude supplies delivered from nearby western
Canada. Second, Northwest refiners face less competition for refined product customers than rivals on
the East and Gulf coasts, meaning they have a captive market that often translates to higher margins.
Future opportunities for these refineries abound, due to recently approved upcoming expansion of the
Trans Mountain crude pipeline that delivers Canadian crude from Edmonton, Alberta, to Vancouver,
British Columbia, and the Puget Sound refineries. Although there are still hurdles for this project to
overcome, if the expansion goes ahead, then owner Kinder Morgan will nearly triple the line’s capacity
to 890 thousand barrels per day. This will significantly increase access to western Canadian crude
supplies and could encourage Northwest refinery upgrades or expansion with a view to exporting more
refined product from the region.
This outlook details the changing crude supply picture for Washington state refineries as well as
regional refined product demand and margin performance. We also detail operations and prospects for
each refinery, concluding with a summary of winners and losers.
Key Takeaways
× The five refineries in the Pacific Northwest primarily serve demand in Washington state and Oregon as
well as British Columbia.
× The downstream market for refined products in this region is less competitive, meaning fuel prices are
generally higher than in the Gulf and East coast regions, boosting refinery margins.
× Refiners have adapted to several structural changes in their crude supply, the most significant being
continued decline in the output of Alaskan North Slope crude.
× ANS is being replaced with light sweet shale crude from the Bakken formations in North Dakota,
delivered by rail.
× Even as crude price differentials narrowed to make crude by rail less competitive at Gulf and East coast
refineries, higher product yields for Bakken crude compared with ANS on the West Coast mean that
supplies from North Dakota continue to play a significant part in the Northwest refinery slate.
Morningstar Commodities Research
5 January 2017
Sandy Fielden Director, Oil and Products Research +1 512-431-8044 [email protected]
Data Sources for this Publication
gAlaska Dept. of RevenuegCalifornia Energy CommissiongClipperDatagCME GroupgCrude PostingsgEIA
To discover more about the data sources used Click Here
Pacific Northwest Refineries 5 January 2017 Page 19 of 28
Exhibit 14 Refined Product Distribution
Source: Morningstar, EIA
Product moves into eastern Washington and Oregon from Salt Lake City, Utah, via the Northwest
Pipeline, purchased by Tesoro in June 2013 from Chevron. The 760-mile 84 mb/d pipeline connects Utah
refineries to Idaho, Oregon, and Spokane, Washington. The 725-mile 66 mb/d Yellowstone Pipeline
connects refineries in Billings, Montana, with eastern Washington. The Yellowstone Pipeline is operated
by Phillips 66, which is a joint owner with Sunoco Logistics and ExxonMobil. EIA data shows that
movements of refined product on the Yellowstone and Northwest pipelines increased by 78% from an
annual average of 32 mb/d in 2010 to 57 mb/d in 2015.
Refineries
This section provides detail on the configuration and ownership of the five Puget Sound refineries.
Exhibit 15 shows their throughput capacity.
Major oil companies, large independent refiners, and one smaller independent player own the five
Washington refineries. The two most sophisticated plants with coking units to process heavy crude
belong to major oil companies— the 145 mb/d Shell Anacortes and 227 mb/d BP Ferndale plants. Shell
is a significant West Coast refinery player, owning two additional plants in California. BP has reduced its
refining presence in the U.S. since the 2010 Gulf of Mexico Macondo disaster, but its Ferndale plant is
Pacific Northwest Refineries 5 January 2017 Page 20 of 28
the largest in the region and sources nearly 50% of crude supply from the company’s equity ANS
production. Large independent refiners own two more plants: the 120 mb/d Tesoro Anacortes and the
101 mb/d Phillips 66 Ferndale refineries. Tesoro is the largest refiner in the western U.S., owning five
plants in California, Washington, and Alaska as well as logistics assets throughout the West and (since
its recent acquisition of Western Refining) the Southwest. Phillips 66 owns another refinery in California
as well as eight more plants worldwide and like BP, has equity ownership in ANS crude via its upstream
affiliate ConocoPhillips. Both Phillips and Tesoro own gathering assets in North Dakota. Trailstone
Group, a company funded by Riverstone Private Equity Group, owns Washington’s smallest refinery, the
41 mb/d U.S. Oil and Refining plant near Tacoma.
Exhibit 15 Washington State Refineries
Source: EIA,
Refinery investment by the owners of these plants has been limited in recent years to the build-out of
crude-by-rail receipt facilities and limited additions to secondary capacity by Tesoro. We do not expect
additional expansion of the refineries or new construction based on limited regional demand for refined
products and the present constraints on crude oil delivery. This picture may change if new crude sources
emerge, such as additional Canadian supplies.
Refinery Location Capacity (mb/d)BP West Coast Products Ferndale, WA 227Shell Oil Products Anacortes, WA 145Tesoro Anacortes, WA 120Phillips 66 Ferndale, WA 101US Oil & Refining Tacoma, WA 41Total 634
Pacific Northwest Refineries 5 January 2017 Page 21 of 28
BP Ferndale
The 227 mb/d BP refinery is the largest in the Pacific Northwest and the third-largest on the West Coast.
This refinery is the most complex of Washington’s plants, with coker and hydro-treater units capable of
significant upgrading of residual fuel oil from primary processing. The refinery supplies calcined coke
from the coker unit to aluminum plants that are in Washington state to take advantage of cheap
hydroelectric power. The refinery meets about 20% of regional gasoline demand and is the largest
supplier of jet fuel to Vancouver, Seattle, and Portland international airports.
As an equity production owner in Alaska, BP uses ANS to meet nearly half of its crude needs but has
also taken advantage of Bakken crude delivered by rail to meet 25% of its needs. BP has retreated from
the downstream arena since the Macondo disaster in 2010, and the Ferndale refinery is its only plant in
PADD 5.
Shell Anacortes
The 145 mb/d Shell Puget Sound Refinery was built in the late 1950s by Texaco to take advantage of
Canadian crude delivered on the Trans Mountain pipeline, but now processes a roughly 50/50 mix of
ANS and Canadian crude. Like BP, this refinery is a sophisticated plant, with secondary processing
capacity that includes a 23 mb/d delayed coker and fluid cat cracker. Shell Oil Products U.S., a subsidiary
of Royal Dutch Shell, operates the refinery that it acquired as part of a merger with Texaco. At that point,
Shell owned both Anacortes refineries and was required to sell the smaller plant to Tesoro in 1998.
Shell’s failure to acquire a permit for a rail unloading terminal has prevented the company from using
significant supplies of Bakken crude, potentially putting it at a competitive disadvantage. With ANS
supply declining and Canadian crude supply limited by congestion on the Trans Mountain pipeline, Shell
is more vulnerable to supply disruption.
Tesoro Anacortes
The 120 mb/d Tesoro Anacortes plant is part of a fleet of five plants the company owns and operates in
PADD 5, including three in California and the largest refinery in Alaska. The Anacortes plant is relatively
sophisticated but does not have a coker unit to process heavy crude, although the refinery processed an
average 44 mb/d of medium and light Canadian crude in 2015. Tesoro is investing in upgrades to
increase the quantity and quality of gasoline the refinery produces with a clean product upgrade project
underway and a new isomerization unit expected on line in 2018. In part, these projects are designed to
meet tighter Tier III federal gasoline standards that come into force in January 2017.
Tesoro was the first Puget Sound refiner to build out a rail terminal in 2012 to deliver Bakken crude, and
the company has a strong presence in North Dakota, including a gathering system and the only two
refineries in that state at Mandan and Dickinson. Bakken crude has almost entirely replaced ANS at the
Anacortes Tesoro refinery (we estimated only 7 mb/d of ANS was processed on average in 2015). Tesoro
now processes a mixture of Canadian and Bakken crude, and the refinery is therefore somewhat
dependent on the economics of crude by rail from the Bakken. However, as part of a large chain of West
Coast refineries (recently expanded with the acquisition of Western Refining), Tesoro has plenty of
alternative supply options, including imports.
Pacific Northwest Refineries 5 January 2017 Page 22 of 28
Phillips 66 Ferndale
The 101 mb/d Phillips 66 Ferndale refinery is similar in complexity to the Tesoro Anacortes plant, with no
coker unit but a number of secondary units to boost gasoline, which accounts for 50% of output. The
refinery also produces distillate (28% of output) and fuel oil. Phillips is a large independent refiner with
nine U.S. refineries, two of which are in California.
Like BP, Phillips 66 has an equity interest in ANS crude (via Conoco Phillips) and the refinery ran a mix of
45% ANS, 45% Canadian crude, and 10% Bakken during 2015. Unlike Tesoro and BP, Phillips has limited
its processing of Bakken crude even though subsidiary Phillips 66 Partners operates the 100 mb/d
Palermo rail terminal in North Dakota that was completed in 2015.
Trailstone U.S. Oil Refining
The 41 mb/d U.S. Oil refinery in Tacoma is the smallest refinery in the Pacific Northwest and the least-
sophisticated, with no secondary conversion. As well as gasoline and diesel, the refinery produces jet
fuel that is delivered by pipeline to the nearby Joint Base Lewis-McChord Army and Air Force base and
the SeaTac airport. The company also has an asphalt business.
In 2015, U.S. Oil relied heavily on Bakken crude delivered by rail that accounted for 77% of its feedstock,
with Canadian crude providing the balance. U.S. Oil did not receive any ANS in 2015 but received some
shipments from Alaska during 2016. The Tacoma refinery is not connected to the Puget Sound pipeline
and therefore relies on barges to receive Canadian crude supplies from the Westridge dock. Congestion
at that dock that has a limited 80 mb/d capacity, has led U.S. Oil to query the Trans Mountain allocation
of dock space with the Canadian National Energy Board regulator.
Refining Margins
In this section, we look first at price differentials for the three main crude types processed by Puget
Sound refineries and then estimate refining margins for these crudes based on local product pricing. The
analysis is subjective given that individual refineries perform differently and incur different costs, but it
does identify broad trends. Our analysis produced two conclusions. The first is that those refineries able
to process heavy Canadian crudes (BP and Shell) have seen the best returns because of the discounted
prices available for such crude. Second, the crude costs and refining margins for crude railed in from
North Dakota have meant better returns for processing Bakken than for ANS.
Crude Prices
Exhibit 16 shows monthly average crude price premiums (discounts) versus West Texas Intermediate for
ANS, Brent, Bakken, and Western Canadian Select between January 2013 and November 2016. WTI is
used as the baseline for the differentials because it is the benchmark U.S. crude price and generally
represents inland domestic crude pricing. Brent is shown for reference because it is the international
crude benchmark that reflects the cost of imported crude. The ANS price is a delivered price to Los
Angeles that we assume is equivalent to the cost of ANS delivered to Puget Sound. The Bakken price is
a posted value that Flint Hills Resources offered to pay for North Dakota light sweet crude at the
Pacific Northwest Refineries 5 January 2017 Page 23 of 28
wellhead. WCS is a blended mix of heavy and light Canadian crude components used as a benchmark
for heavy Canadian crude. The WCS price we used is delivered at Hardisty, Alberta.
Based purely on the crude prices, the Bakken and WCS crudes are discounted versus WTI and ANS
throughout most of this period (see Exhibit 17).
Looking at Bakken first, the average price discount to WTI was $11.57/barrel in 2013, $16.43/barrel in
2014, $13.60/barrel in 2015, and $11.04/barrel in 2016 through November. But these are posted
wellhead Bakken prices, so we must factor in terminal and rail transport costs that we estimate at
roughly $10/barrel. Therefore, if Puget Sound refiners could acquire Bakken crude at the wellhead
(through gathering systems, for example) then the delivered cost compares favorably with WTI
throughout the period. Since ANS was trading at a premium to WTI during 2013-15, that meant Bakken
crude delivered by rail was consistently cheaper than ANS and the higher rail transport cost was
justified.
Exhibit 16 Crude Price Premiums to WTI
Source: CME Group, Alaska Department of Revenue, Flint Hills, Morningstar
-40
-30
-20
-10
0
10
20
30
Jan-
13
Mar
-13
May
-13
Jul-1
3
Sep-
13
Nov-
13
Jan-
14
Mar
-14
May
-14
Jul-1
4
Sep-
14
Nov-
14
Jan-
15
Mar
-15
May
-15
Jul-1
5
Sep-
15
Nov-
15
Jan-
16
Mar
-16
May
-16
Jul-1
6
Sep-
16
Nov-
16
$/ba
rrel
ANS Brent Bakken WCS WTI
Pacific Northwest Refineries 5 January 2017 Page 24 of 28
Exhibit 17 Crude Price Premiums to WTI $/barrel
Source: Morningstar, CME Group, Flint Hills, Alaska Department of Revenue
Looking next at WCS, this crude is representative of heavy Canadian crude price. As noted earlier,
congestion on pipelines out of Canada, including the Trans Mountain, forced Canadian producers to
accept discounts to get their crude to market. These discounts reflect higher costs to bypass pipeline
congestion using rail, so for those buyers able to secure limited pipeline supplies, the Canadian crude
prices are a bargain. For example, the published tariff on the Trans Mountain pipeline from Edmonton to
Puget Sound via the Sumas lateral is $2.60/barrel versus a rail cost equivalent of more than $10/barrel.
So if Puget Sound refiners have the ability to process heavy crude (BP and Shell) and they have
allocation on the pipeline, they have a built-in incentive to process as much heavy crude as possible
because it is so cheap compared with alternatives.
However, our earlier analysis showed that Canadian crude imported to Washington state on the Trans
Mountain pipeline is mostly medium or light crude, rather than heavy crude. This reflects the fact that
only two of the five Puget Sound refineries are equipped to process heavy crude. Because there is
demand in Canada for medium and light Canadian crude grades, their discounts have been narrower
than for the more abundant heavy crude. This means Puget Sound refiners are likely paying higher
prices. In the case of Canadian sweet or synthetic crude, prices have stayed close to WTI. That means
these crude grades have typically been cheaper than ANS, but their advantage over ANS has been
smaller than for Bakken equivalent barrels.
The Brent price is higher than ANS throughout the period analyzed. Since Brent is a light sweet crude
grade like WTI, this shows why Puget Sound refiners have reduced the volume of imported crude they
process in recent years. Equivalent imported light grades are not competitive—at least once transport
costs are factored in. This is another important indicator that Northwest U.S. refineries have a
geographic advantage over similar plants on the East Coast that are now importing more light crude
because it competes on price with Bakken barrels sent by rail (see East Coast Refining After the Shale
Boom).
Refining Margins
Our refining margin analysis shows that Bakken crude produces better gasoline and diesel yields than
ANS crude, explaining why Puget Sound refiners have increased their consumption of North Dakota
crude so significantly in the past few years. We also estimated margins for WCS crude processed by a
coking refinery to show how access to these discounted grades translates to the bottom line.