Oil Refinery Lawsuit [2025 Guide] | Occupational & Community Exposure

An oil refinery is a type of large-scale petrochemical facility where crude oil is separated, converted, and upgraded into a variety of usable fuels and industrial materials.

In the modern oil industry, these facilities operate around the clock, processing massive volumes of crude through an intricate network of towers, tanks, pipelines, and refinery units.

The end result is the production of refined petroleum products such as gasoline, diesel, jet fuel, kerosene, asphalt, lubricants, and chemical feedstocks used to make plastics and other essential goods.

Achieving this transformation requires a combination of heat, pressure, catalysts, and carefully controlled chemical reactions to break down, rearrange, or purify the components of crude oil.

These industrial processes run at extreme temperatures and pressures, often handling flammable, volatile, and toxic substances that must be carefully contained.

Refining operations are organized into sequential stages (initial separation, further conversion, and finishing or blending) each taking place in specialized units connected throughout the site.

Every stage carries potential for emissions or leaks if not properly maintained, making operational safety a constant priority.

While refineries are indispensable to global energy and manufacturing, they also generate hazardous byproducts and air pollutants.

Major units include:

• Atmospheric and vacuum distillation splits crude by boiling range; heavy fractions move to deeper processing.
• Catalytic cracking and hydrocracking break long hydrocarbon chains into lighter fuels.
• Reforming and isomerization improve octane; generate aromatics like benzene, toluene, and xylene (BTX/BTEX) as intermediates.
• Hydrotreating removes sulfur, nitrogen, and metals using hydrogen and catalysts.
• Coking thermally cracks heavy resid into lighter products and petroleum coke.
• Alkylation combines light gases into high-octane components (some sites use hydrofluoric acid or sulfuric acid).

During distillation, transfer, storage, and maintenance, hydrocarbons can escape as volatile organic compound (VOC) emissions or liquid leaks.

Flares control pressure and burn off gases during upsets, but flaring itself produces combustion byproducts.

Tanks “breathe” with temperature changes, releasing vapors.

Pumps, valves, connectors, and loading racks are common leak points.

Oil refineries rely on a wide range of chemicals to process crude oil into usable fuels and industrial materials, and many of these substances are hazardous to human health.

Some occur naturally in crude oil, while others are created or concentrated during refining processes such as cracking, reforming, or hydrotreating.

These chemicals can be found in liquid fuels, process streams, exhaust gases, and waste products, often in forms that are volatile, toxic, or carcinogenic.

The most concerning refinery pollutants (like benzene, polycyclic aromatic hydrocarbons, and hydrogen sulfide) are recognized by health agencies worldwide for their potential to cause cancer, respiratory damage, and other serious illnesses.

Others, such as sulfur dioxide, nitrogen oxides, and fine atmospheric particulate matter, can aggravate existing health problems and contribute to long-term disease.

Several hazards stand out for both workers and communities:

• Benzene (BTEX family) – a known human carcinogen tied to leukemias and bone‑marrow toxicity. Found in crude oil, gasoline, and many process streams.
• Toluene, ethylbenzene, and xylenes (BTEX) – solvents and fuel components that can affect the central nervous system and cause irritation at high concentrations.
• Polycyclic aromatic hydrocarbons (PAHs) – combustion‑related compounds linked to cancer risk; present in flares, coking, and diesel emissions.
• Hydrogen sulfide (H₂S) – highly toxic gas with neurologic and respiratory effects; common in sour crude processing and wastewater.
• Sulfur dioxide (SO₂) and nitrogen oxides (NOₓ) – irritating gases that worsen asthma and contribute to particulate formation.
• Particulate matter (PM2.5/PM10) – fine particles that penetrate deep into the lungs and are associated with cardiovascular and respiratory disease.
• Other notable hazards – carbon monoxide, formaldehyde, 1,3‑butadiene, ozone (secondary), heavy metals from catalysts, and acids used in alkylation.

These substances may be present continuously at low levels or spike during planned shutdowns, startups, maintenance “turnarounds,” and unplanned upsets.

Oil Refinery Processes that Drive Exposure

Some refinery activities, while routine, are high‑risk for emissions:

• Startup and shutdown – unstable operations and venting.
• Turnarounds – opening equipment, draining lines, catalyst handling.
• Flaring – emergency pressure control that can create combustion byproducts.
• Tank cleaning and roof work – concentrated VOC vapors.
• Wastewater treatment – off‑gassing of VOCs and H₂S.
• Loading/unloading – vapor releases at racks, barges, and rail.

For neighbors, the most noticeable moments are visible flares, strong odors, or public alerts. For workers, exposure often occurs during tasks that feel routine.

Refinery operations release a broad spectrum of hazardous chemicals into air, water, and soil, placing both workers and nearby communities at significant risk.

These pollutants are generated during routine processes, equipment maintenance, accidental releases, and emergency events like fires or explosions.

Harmful substances can travel through the air as gases or fine particles, seep into groundwater through leaks or waste disposal practices, and accumulate in soil near industrial sites.

For workers inside the facility, exposure often comes from inhaling vapors, handling contaminated materials, or working near emission points.

For surrounding neighborhoods, long-term contact can occur from breathing polluted air, drinking contaminated water, or living near areas with historical industrial waste.

Studies and environmental monitoring have documented elevated levels of toxic chemicals—such as benzene, hydrogen sulfide, and particulate matter—around many refineries.

These exposures are linked to a range of serious health problems, from cancer and blood disorders to respiratory and neurological conditions.

Workers (Occupational Exposure)

Inside refinery gates, exposure happens through:

• Inhalation of vapors near tanks, process units, loading racks, and flares.
• Dermal contact with fuels, solvents, and process streams during sampling, line breaking, or cleanup.
• Confined space work where gases accumulate.
• Maintenance turnarounds when equipment is opened and emissions surge.

Job roles with frequent contact include operators, maintenance and turnaround crews, tank farm personnel, laboratory staff, contractors, and truck/rail loading teams.

Workers from partner companies (e.g., scaffolders, insulators, industrial cleaners) often face risks without direct control over site practices.

Communities (Environmental Exposure)

People living near refineries can experience:

• Downwind air exposure from stacks, fugitive leaks, and flaring.
• Short‑term spikes during upsets, power loss, or emergency releases.
• Groundwater and soil contamination from historical spills or waste units.
• Cumulative traffic emissions from associated terminals, shipping, and rail.

Fence‑line monitoring programs and community air networks sometimes detect benzene and other VOCs near residential areas.

Even when daily averages look modest, repeated peaks can contribute to long‑term risk.

Documented Cases of Air Pollution from Oil Refineries

Air pollution from oil refineries has been repeatedly documented in both chronic monitoring data and acute incident reports.

Emissions often include benzene, sulfur dioxide, nitrogen oxides, hydrogen sulfide, and fine particulate matter: pollutants linked to cancer, respiratory illness, cardiovascular disease, and neurological damage.

These pollutants can escape during normal operations, equipment malfunctions, or large-scale industrial accidents, affecting both workers and communities downwind.

The following cases highlight the scale and impact of refinery-related air pollution:

• Pemex Deer Park Refinery – Pasadena, Texas: A hydrogen sulfide leak forced shelter-in-place orders for nearby neighborhoods, with residents reporting nausea, headaches, and throat irritation following the incident.
• Husky Energy Refinery Explosion – Superior, Wisconsin: An explosion and subsequent fire released plumes of toxic smoke, prompting evacuation orders for residents within a 10-mile radius.
• Suncor Refinery – Commerce City, Colorado: EPA data identified this facility as having the highest number of sulfur dioxide and hydrogen sulfide air pollution incidents among 12 comparable U.S. refineries.

Documented Cases of Water Pollution from Oil Refineries

Refinery wastewater often contains a cocktail of toxic substances that can infiltrate rivers, lakes, and groundwater—posing a serious threat to ecosystem and community health.

Much of the discharge from refineries remains weakly regulated, allowing pollutants like heavy metals, salts, and chemicals to flow daily into waterways with minimal oversight.

Local investigations and environmental watchdog reports reveal longstanding contamination and elevated pollutants that disproportionately affect nearby populations.

Below are several notable case studies illustrating the widespread nature and serious impacts of water pollution caused by oil refinery operations:

• Chicago-area refineries (Exxon Mobil Joliet, Citgo Lemont): Identified by the Environmental Integrity Project as among the worst polluters in the U.S., these facilities discharge high levels of toxics—including selenium, sulfates, and chlorides—into the Great Lakes watershed, often evading federal standards that don’t cover many of these pollutants.
• BP Whiting (northern Indiana): Former residents report crude oil plumes entering Lake Michigan and penetrating soil and groundwater. Amoco (now BP) acknowledged a multi-million-gallon underground leak that locals believe contributed to basement oil seepage and contamination in adjacent neighborhoods.
• Phillips 66 Carson Refinery (California): Charged under the Clean Water Act for improperly discharging industrial wastewater with excessive oil and grease into the local sewer system in 2020–2021, leading to federal legal action and potential multimillion-dollar penalties.

Documented Cases of Soil Contamination from Oil Refineries

Refineries often generate hazardous waste that seeps into soil through leaks, sludge disposal, and accidental spills, creating long-lasting contamination risks.

In many instances, this pollution goes beyond facility boundaries, impacting groundwater, crops, and residential land.

Soil contamination from oil refineries includes petroleum hydrocarbons, heavy metals, PAHs, VOCs, and chemical sludge that persist for years and resist natural breakdown.

Below are documented cases that illustrate the scale and impact of such contamination:

• Greenpoint, Brooklyn (New York City) – Decades of oil processing around Newtown Creek resulted in massive soil saturation, with an estimated spill exceeding 30 million gallons impacting over 100 acres, making it one of the largest soil contamination events in U.S. history.
• Former refinery site in Hermantown, Minnesota (Arrowhead Refinery) – A waste oil recycling facility was placed on the Superfund list after acidic, metal-laden sludge leached into surrounding wetlands and raised concerns over off-site drinking water well contamination.
• Lima, Ohio refinery (RCRA corrective action site) – A former sludge pond and disposal area associated with refinery operations required detailed remediation due to legacy soil contamination encompassing hydrocarbons, heavy sludge, and industrial waste covering multiple acres.

Oil refinery emissions contain a mix of hazardous substances that can have serious and long-lasting effects on human health.

Studies have found a statistically significantly increased risk of certain diseases among populations living or working near oil and gas facilities, where ongoing contact with fossil fuels and their byproducts is common.

According to the Environmental Protection Agency, refineries release toxic air pollution such as benzene, lead, and other harmful compounds, alongside greenhouse gas emissions that impact both environmental and public health.

While some of these gases contribute to climate change, their immediate concern for nearby communities is the potential for direct harm through inhalation, ingestion, or skin contact.

Benzene exposure, lead exposure, and other chemical hazards have been linked in research to elevated health risks, including higher rates of incident cancer diagnosis in affected populations.

Even with environmental regulations in place, gaps in enforcement and unplanned releases mean that people can still face dangerous levels of pollutants.

Oil refinery emissions are not only a byproduct of industrial processes but a significant public health issue with potentially devastating consequences for workers and residents alike.

Types of Cancer Linked to Oil Refineries

Oil refinery emissions have been associated with an elevated risk of cancer among both refinery workers and nearby residents.

Epidemiological studies consistently report higher rates of leukemia (especially acute myeloid leukemia (AML)) among workers exposed to benzene in refinery settings

Moreover, proximity to active refineries has been linked with a statistically significantly increased risk for several cancer types, including lymphoma and bladder cancer, particularly in populations living within 0–10 miles of these facilities.

Reviews of petroleum industry workers also identify elevated incidences of mesothelioma, multiple myeloma, and certain cancers of the skin, prostate, and bladder.

Globally, occupational cohort studies reflect a consistent pattern: refinery workers face greater cancer risk compared to general populations.

Still, causation often involves a combination of chemical exposures (benzene, heavy metals, PAHs, and asbestos) rather than a single agent.

Documented cancers and their associated oil refinery chemicals include:

• Acute Myeloid Leukemia (AML) – Strongly linked to systemic benzene exposure, showing higher incidence among oil refinery workers and chemically exposed populations.
• Leukemia (other forms) – Elevated rates of acute lymphocytic leukemia (ALL), chronic lymphocytic leukemia (CLL), and myelodysplastic syndrome (MDS) also observed in workers exposed to benzene and complex hydrocarbon mixtures.
• Lymphoma – Statistically significant increases in lymphoma diagnoses have been observed in communities living near refineries, likely tied to airborne benzene and BTEX pollutants.
• Bladder Cancer – Elevated risk associated with refinery proximity; probable exposure from aromatic compounds and PAHs in emissions.
• Lung Cancer – Associated with long-term exposure to diesel exhaust, polycyclic aromatic hydrocarbons (PAHs), and fine particulate matter (PM2.5) from refinery operations (as well as other hazardous air pollutants), with elevated rates documented in refinery workers and populations living near oil and gas facilities.
• Mesothelioma and Multiple Myeloma – Among refinery workers, these have been linked to historical exposure to asbestos (mesothelioma) and benzene-related hematoxicity (multiple myeloma).

Cancer risk is influenced by cumulative dose, peak exposures, co‑exposures, genetic susceptibility, and smoking history.

The absence of a single “big spill” does not rule out causation.

Many refinery‑related cancers arise from chronic, routine contact over years.

Non‑Cancer Health Effects Linked to Oil Refineries

Refining operations at industrial facilities, including petrochemical complexes, release not only cancer-causing agents but also a range of non-cancer health hazards that affect multiple systems in the body.

Acute exposures can trigger irritation of the eyes, skin, and respiratory tract, as well as headaches, dizziness, and nausea.

Chronic exposure is associated with functional disruptions in the hematopoietic (blood-forming), immune, nervous, reproductive, cardiovascular, and respiratory systems.

Children living near refineries, for example, show higher rates of asthma, wheezing, and impaired lung function, while women in these communities have been found to experience more preterm births and impaired liver function in some studies.

The toxicity of petrochemical emissions has been clearly documented as a public health threat, particularly in densely populated areas near refinery operations.

These non-cancer health effects can be immediate and reversible, or progressive and debilitating, depending on the nature and duration of chemical exposure.

Non-cancer health effects associated with oil refineries include:

• Neurological Effects (dizziness, headaches, confusion) – Linked to acute exposure to benzene, hydrogen sulfide, and carbon monoxide typically encountered during distillation, flaring, and maintenance tasks.
• Respiratory Irritation and Asthma – Frequently tied to sulfur dioxide (SO₂), nitrogen oxides (NOₓ), particulate matter (PM), and acid vapors; chronic exposure triggers breathing difficulties and worsened asthma.
• Hematopoietic and Immune Dysfunction – Benzene exposure impairs bone marrow, suppresses blood cell production, and weakens immunity, especially in refinery workers or residents in exposure zones.
• Reproductive and Developmental Effects – Communities living near refineries show increased rates of preterm birth and developmental problems, due in part to maternal exposure to volatile organic compounds (VOCs) and PAHs.
• Cardiovascular and General Health Decline – Fine particulates and chemical byproducts stress the heart and lungs, leading to elevated risks of respiratory and cardiovascular disease in exposed populations.

The regulatory landscape for oil refineries in the United States has evolved over decades in response to growing evidence of the health and environmental impacts of refinery operations.

Early rules focused narrowly on worker safety and basic emission controls, but as industrial plants in the refining sector expanded and public health data mounted, federal and state agencies adopted more comprehensive standards.

The U.S. Environmental Protection Agency (EPA), in coordination with the Department of Health and Human Services, now enforces regulations designed to protect air quality, water resources, and community health.

Under the Clean Air Act, refineries that produce high octane gasoline must meet strict limits on hazardous air pollutants and implement control technologies to capture and destroy harmful emissions.

These requirements address pollutants that can produce acid rain, contribute to smog, and cause serious respiratory and cardiovascular harm.

Additional chemical safety and health programs target refinery hazards that can lead to catastrophic releases (such as refinery explosions), promoting safer operations for both workers and the surrounding community.

Regulations also consider the role of refineries in the broader transportation sector, as fuel production and quality standards influence vehicle emissions nationwide.

While progress has been made in reducing emissions, ongoing enforcement, technological upgrades, and transparency remain essential to safeguarding communities living near these facilities.

Laws and regulations enforced nationwide include:

• Clean Air Act (CAA) – Sets national standards for air quality, mandates control technologies for hazardous pollutants, and limits refinery emissions to protect public health.
• Clean Water Act (CWA) – Regulates wastewater discharges from refineries into surface waters, including oil, grease, and toxic chemicals.
• Resource Conservation and Recovery Act (RCRA) – Governs hazardous waste generation, transport, treatment, and disposal from refinery operations.
• Emergency Planning and Community Right-to-Know Act (EPCRA) – Requires industrial plants to report chemical storage and releases to inform emergency planning and public awareness.
• Occupational Safety and Health Act (OSHA Process Safety Management Standards) – Implements Chemical Safety and Health protections for workers handling highly hazardous chemicals.
• Energy Policy Act – Addresses fuel quality, refining capacity, and environmental standards affecting the refining sector and transportation sector.

People who have been harmed by toxic exposures from refinery operations may have grounds to take legal action against those responsible.

This includes both individuals who worked inside refinery facilities and members of nearby communities who lived with ongoing emissions, leaks, or contamination.

Gianaris Trial Lawyers is actively investigating cases in Illinois and Missouri where oil refinery operations have been linked to serious illnesses and environmental damage.

Our focus in these states reflects the high concentration of refining and petrochemical activity, as well as documented concerns about community and worker health near our main law offices.

However, if you believe your health has been affected by refinery-related exposure in another state, we would still like to hear your story.

Oil refinery lawsuits can arise from both chronic, long-term exposure and acute incidents such as explosions, fires, or large-scale chemical releases.

These cases seek to hold companies accountable for unsafe practices, inadequate safety measures, or failures to control harmful emissions.

By sharing your experience with us, we can determine whether the facts of your situation align with legal avenues for pursuing justice.

You may have a potential claim if you:

• Worked at or serviced an oil refinery and later developed a serious health condition linked to chemical exposure (e.g., leukemias/MDS, certain lymphomas, lung disease, severe blood disorders).
• Lived near a refinery and faced long‑term air exposure or property contamination followed by serious illness.
• Experienced an acute exposure event (large release, sustained flaring, shelter‑in‑place incident) and developed lasting respiratory or neurologic problems.
• Lost a loved one to a diagnosis associated with refinery pollutants.

Qualifying does not require a single catastrophic spill.

Many successful cases involve years of routine exposure supported by employment records, medical documentation, and environmental evidence.

Note: If you were a railroad worker servicing refineries, your cancer claim may arise under the Federal Employers’ Liability Act (FELA). Separate rules apply, and our team can evaluate FELA and third‑party claims together.

Legal Theories Used in Oil Refinery Exposure Cases

Oil refinery exposure lawsuits are built on established legal principles that allow injured individuals and affected communities to seek accountability from those responsible.

The specific legal theory applied in a case depends on the nature of the exposure, the relationship between the parties, and the type of harm suffered.

In many instances, multiple theories are used together to address both personal injury and property damage claims.

Below are the primary legal avenues our firm may pursue when representing clients in oil refinery exposure cases:

• Negligence and gross negligence – unsafe operations, inadequate maintenance, or failure to control emissions.
• Premises liability – dangerous conditions on refinery property affecting workers, contractors, or visitors.
• Product liability – dangerous chemicals, defective equipment, or inadequate warnings from manufacturers/suppliers.
• Public nuisance and trespass – community contamination affecting property use and value.
• Wrongful death and survival actions – for families who lost a loved one to exposure‑related disease.
• Medical monitoring (where allowed) – court‑ordered screening for at‑risk populations.

Applicable theories and defendants vary by state and by the facts of each case.

Evidence That Strengthens an Oil Refinery Case

A strong oil refinery case relies on clear, well-documented proof connecting the source of exposure to the harm suffered.

This evidence can come from multiple sources, including workplace records, environmental monitoring, and medical documentation.

For workers, detailed job history and safety data can establish where and when exposure occurred, while community members benefit from air and water testing that reflects local contamination.

Medical records and expert opinions bridge the gap between the exposure and the resulting illness, creating a persuasive link for courts or settlement negotiations.

Collecting this information early helps preserve crucial details and supports a thorough investigation into the refinery’s role in causing the damage.

Occupational Evidence (Workers and Contractors):

• Job titles, unit assignments, and shift records.
• Safety Data Sheets (SDS) for fuels, solvents, and intermediates.
• Personal exposure monitoring results, fit‑testing, and PPE logs.
• Maintenance and turnaround schedules; work orders; confined‑space permits.
• Incident reports, hot‑work permits, and lockout/tagout records.
• OSHA citations, internal audits, and process safety reviews.

Community Evidence (Neighbors and Property Owners):

• Fence‑line exposure data and local air monitoring results.
• Complaint logs, public alerts, and shelter‑in‑place notices.
• Emissions inventories, flaring records, and release reports.
• Groundwater, soil, or indoor‑air sampling data; plume maps.
• Property records and appraisal impacts where contamination is proven.

Medical Evidence:

• Diagnoses from oncology/hematology or pulmonary specialists.
• Complete treatment records and lab results.
• Expert opinions linking exposure history to disease.
• Documentation of symptoms, limitations, and prognosis.

The earlier this material is preserved, the stronger the case. We guide clients on collecting and safeguarding records from day one.

Potential Recoverable Damages in an Oil Refinery Lawsuit

An oil refinery lawsuit is not only about proving exposure.

It is also about securing compensation that addresses the full scope of harm caused.

Damages can cover both the financial costs of treatment and recovery, as well as the personal and emotional impact of living with a serious illness or property contamination.

In some cases, recovery may also include losses related to a family member’s death, or the expense of restoring or relocating from damaged property.

The categories below outline the types of compensation that may be pursued depending on the facts of the case and applicable state law:

• Medical costs – past and future treatment, hospitalization, medications, rehabilitation.
• Lost income – wages, benefits, and reduced earning capacity.
• Non‑economic harm – pain, suffering, and loss of enjoyment of life.
• Household and care needs – in‑home assistance, medical equipment, transportation.
• Property damages – cleanup costs and diminished value in contamination cases.
• Wrongful death damages – funeral costs and losses to surviving family members.

State law controls available categories and calculations.

Our attorneys work with medical, economic, and life‑care experts to capture the full impact of the harm.

If you believe you’ve been harmed by chemicals from an oil refinery, taking prompt and organized action can help protect both your health and your legal rights.

Medical evaluation is the first priority, as early testing can document health impacts before they worsen or become harder to link to exposure.

Keeping thorough records of where you live or work, the conditions you’ve observed, and any symptoms you’ve experienced can also be crucial.

It’s equally important to preserve evidence such as photographs, community alerts, or environmental test results that reflect exposure.

Following the steps below can strengthen your ability to pursue a claim and hold responsible parties accountable:

1. Seek immediate medical attention and inform your provider about your potential refinery exposure.
2. Document your work history or residential location, noting proximity to refinery operations.
3. Record symptoms, their onset dates, and any changes over time.
4. Save physical and digital copies of environmental reports, community alerts, or test results.
5. Contact an experienced refinery exposure attorney to review your situation and guide next steps.

Toxic emissions and unsafe practices at oil refineries can leave a lasting mark on the health of workers, families, and entire neighborhoods.

These cases demand thorough investigation, credible expert analysis, and a willingness to take on powerful corporate interests.

At Gianaris Trial Lawyers, we combine deep knowledge of refinery operations with a commitment to protecting the people whose lives have been upended by exposure.

Our work focuses primarily on Illinois and Missouri, but we are ready to listen to anyone who believes their illness or property damage may be linked to refinery activity.

If you or a loved one has been harmed, your story matters, and it may help drive change as well as secure the compensation you deserve.

Contact Gianaris Trial Lawyers for a free consultation.

Use the chat feature on this page to find out if you qualify for an oil refinery lawsuit.