Kim Foley
Executive Vice President, Intermediates and Derivatives and Refining at LyondellBasell Industries
Thank you, Ken. Please turn to Slide 11 as we look at the Intermediates & Derivatives segment. Exceptional oxyfuel margins resulted in record third quarter segment EBITDA of $708 million. During the quarter, unplanned industry downtime for oxyfuels production on the U.S. Gulf Coast led to higher blend premiums for oxyfuels relative to gasoline. When coupled with higher crude oil prices and relatively low cost for butane raw materials, oxyfuel margins expanded significantly in North America and Europe.
The outstanding performance of our oxyfuels business during the third quarter is an example of how our diverse global business portfolio is capable of providing resilient results through market cycles. With our new PO/TBA asset, LyondellBasell's global oxyfuels capacity is now as large as our North American polyethylene capacity, highlighting the diversity of our growing portfolio.
In our propylene oxide and derivatives business, additional volumes from the new PO/TBA asset were largely offset by the planned idling of two PO/SM assets in the U.S. and Europe for approximately two months at each asset. These actions reflect our disciplined approach to match production rates with the demands during challenging market conditions.
Looking ahead, we expect the end of summer driving season and the higher butane costs will cause oxyfuel margins to moderate towards levels seen in the first half of 2023. In line with our guidance from the beginning of the year, we are conducting planned maintenance during the fourth quarter at two of our existing propylene oxide assets. We expect to run our global I&D assets at approximately 70% of capacity in the fourth quarter.
In September, we expanded the range of our sustainable offerings with the launch of our +LC brand of low carbon solutions. These products are sourced from recycled and renewable feedstocks and offer our customers a solution for meeting their greenhouse gas emissions targets with propylene oxide, styrene, and other products that provide a lower carbon footprint than fossil-based alternatives.
Please turn to Slide 12, and let's review the progress of our new PO/TBA asset. As Peter mentioned earlier, the first pillar of our strategy is to grow and upgrade our core by investing in businesses that fit our long-term strategy. Our new PO/TBA asset in Houston, Texas is a key part of that growth. This facility is the world's largest single-train asset, increasing LyondellBasell's global propylene oxide and oxyfuels capacities by more than 35%.
Furthermore, we believe that PO/TBA technologies are highly advantaged relative to other widely used propylene oxide technologies. By our analysis, PO/TBA technologies have the lowest operating cost and the lowest carbon footprint for producing propylene oxide, and our strategically located U.S. Gulf Coast assets benefit from the shale-advantaged butane and propylene feedstocks.
During the commissioning and the startup of these assets, we achieved more than 4 million man hours of work without a recordable injury. This relentless focus on safety and the associated attention to detail is a key part of our success. Within two months of the plant startup, we completed the technical acceptance tests to prove out the full capacity of our new PO/TBA facilities.
In 2023, the ramp-up in our new capacity will be largely offset by planned maintenance at our existing PO/TBA assets, but we expect to see more meaningful volume contribution from the new PO/TBA asset in 2024 and beyond as the demand for durable goods returns. I am incredibly proud of what our team has accomplished to quickly reach these milestones and look forward to their continued success.
Now, let's turn to Slide 13 and discuss the results of the Refining segment. Third quarter EBITDA was $105 million. Modest improvements and the benchmark Maya 2-1-1 crack spread were offset by a mark-to-market impact from a distillate hedging program. As part of our ongoing risk management efforts, we will occasionally use derivatives to hedge commercial or financial risks. During the third quarter, refinery cracks, particularly distillate cracks, were highly favorable relative to historical levels, and we took the opportunity to lock in attractive margins for a portion of our refinery output through 2024. Distillate cracks in September outperformed our expectations, resulting in mark-to-market losses for our distillate hedging program.
In the near term, we expect seasonally slower demand for refined products and the Maya 2-1-1 spreads to decrease. Currently, we are executing planned maintenance on our catalytic cracker with an estimated EBITDA impact of $25 million in the fourth quarter. We expect crude throughputs at the refinery to be approximately 80% of capacity in the fourth quarter. We remain committed to the safe operation of these assets through no later than the end of the first quarter of 2025, with a focus on high reliability as we develop new projects to transform the site in support of our Circular & Low Carbon Solutions growth strategy.
With that, I will turn the call over to Torkel.