Safe, reliable operations lay foundation for MPLX gas processing record

Business News

logistics, business, sustainability, safety
A natural gas processing plant.
MPLX’s Sherwood, West Virginia, natural gas processing plant is the largest in North America with a processing capacity of 2.6 billion cubic feet per day. 

Key Points

  • Marathon Petroleum’s midstream segment, MPLX, has set a company performance record through its Natural Gas and NGL Services assets.
  • For the first time ever, these assets processed natural gas over a 24-hour period at a rate equal to 10 billion cubic feet per day.
  • Company leaders attribute the milestone to safe and reliable operations, which helped garner a top ranking in a recent industry survey.

A new record within Marathon Petroleum’s midstream segment, MPLX, illustrates the ongoing growth and development of its Natural Gas and NGL Services component. In late 2024, MPLX processed natural gas over a 24-hour period at a rate equal to 10 billion cubic feet per day, marking the first time it had ever reached this sustained volume milestone.

MPLX has repeated this feat several times since then. The volume milestone amounts to processing about 10% of the natural gas produced daily in the U.S. MPLX touches another approximately 4% via gathering lines.

A natural gas processing plant.
The Preakness natural gas processing plant (above) is part of MPLX’s expanding footprint across the Permian basin in West Texas and New Mexico where a new processing plant, Secretariat, is expected to come online in the fourth quarter of 2025.

Gathering and Processing Strategy & Administrative Services Senior Director Chad Corcoran attributes the record to effective responses to market conditions, recently added natural gas processing plants in Pennsylvania and Texas, and performance that gives customers the confidence to make this MPLX segment their midstream provider of choice.

“Safety and reliability have built our reputation. With this reputation, our producer customers have continued to put their trust in us to gather, treat, process and move their products to market,” Corcoran said. “We’ve maintained strong customer retention and built strong partnerships that promote shared success.”

The strength of the Natural Gas and NGL Services segment’s business relationships is evident from a 2024 survey by the market research firm Mastio & Company, which asked 126 companies to assess their midstream service providers. MPLX ranked first out of 63 rated providers in meeting needs, such as overall system reliability, timely well connections and trustworthiness.

A natural gas processing plant.
Much of MPLX’s record natural gas processing volume has been driven by assets, like the Bluestone processing plant (above), that are in the Marcellus basin, which includes large portions of Pennsylvania, West Virginia and eastern Ohio.  

Beyond customer service, an emphasis on continuous improvement throughout the segment’s operations is also contributing to its success.

“We understand the broader impact of operating our plants efficiently, so our teams are constantly assessing our processes to find untapped energy savings,” said Vice President, Gathering and Processing Head of Operations, Jonathan Jackson. “Efficiency not only enhances production and dependability, using less electricity reduces the overall emissions related to our work.”

A map of the United States with icons that represent company assets.
MPLX’s Natural Gas and NGL Services segment operates midstream assets that are spread across 14 states, ranging from Pennsylvania out to Utah and North Dakota down to Texas. (The dark gray shaded areas above represent natural gas gathering systems and the adjacent red icons represent natural gas processing plants.)

This dedication to efficiency recently led to an unprecedented accomplishment. MPLX’s Bluestone, Pennsylvania, natural gas processing plant became the first facility of its kind to achieve the U.S. Environmental Protection Agency’s ENERGY STAR® Challenge for Industry, which requires facilities to reduce their energy intensity at least 10% within a five-year period. Processing plants in Houston, Pennsylvania, and Sherwood, West Virginia, are currently pursuing the challenge for industry. These plants are all part of a broader group of midstream assets that MPLX’s Natural Gas and NGL Services segment operates across 14 states.

“We have a collection of centralized service teams who provide various support services across our asset base while helping ensure we’re operating at peak performance,” Corcoran said. “With all groups aligned on a common mission, we’re able to deliver on our commitments.”