WINFIELD RESOURCES LIMITED RAS LANUF REFINERY (EPC M ) FEASIBILITY PROPOSAL
WINFIELD RESOURCES LIMITED
RAS LANUF REFINERY(EPCM)
FEASIBILITY PROPOSAL
Certain statements herein may constitute “forward looking” statements that involve known and unknown risks, uncertainties and other factors that
may cause our actual results to be materially different from any future results expressed or implied by such forward looking statements. These
statements relate to future events and reflect the expectations of management regarding business prospects and opportunities. Such forward
looking statements reflect current beliefs of management or of the third parties to which they are attributed and are based on information currently
available to us. In some cases, the statements use such words as “may”, “will”, “intend”, “should”, “expect”, “believe”, “plan”, “anticipate”,
“estimate”, “predict”, “potential”, “continue” or the negative of these terms or other similar terminology. These statements reflect current
expectations regarding future events and speak only as of the date hereof, or in the case of third party statements as of the date on which they
were made. Forward looking statements involve significant risks and uncertainties, should not be read as guarantees of future results, and will
not necessarily be accurate indications of whether or not such results will be achieved, and there can be no assurance that actual results will be
consistent with these forward looking statements.
WINFIELD RESOURCES LIMITED
CONTENTS
EXECUTIVE SUMMARY.................................................................................................................................... 01
Vision....................................................................................................................................................................... 01..
BUSINESS PLANNING...................................................................................................................................... 07..
Phase.I.–.Opportunity.Evaluation........................................................................................................................ 07..
OPERATIONAL PLAN....................................................................................................................................... 08..
Benefits.of.Technical.and.Project.Management.Team........................................................................................ 08..
PROJECT EXECUTION..................................................................................................................................... 09..
Detailed.Design.Package.Phase.II......................................................................................................................... 09.
Engineering,.Procurement.And.Construction.Phase.III.................................................................................... 09.
PROJECT MANAGEMENT............................................................................................................................... 10
PROFESSIONAL PERSONNEL....................................................................................................................... 15
FINANCIAL ANALYSIS..................................................................................................................................... 16.
FINANCIAL REPORT......................................................................................................................................... 17..
Refinery.Economics................................................................................................................................. 17.
PROJECT FINANCE........................................................................................................................................... 18.
SUBCONTRATOR................................................................................................................................................ 19.
OPERATOR........................................................................................................................................................... 20.
SkILLS ASSESSMENT / TRAINING / LIBYAN INTEGRATION........................................................... 23.
HEALTH AND SAFETY..................................................................................................................................... 24.
PROJECT OVERSIGHT..................................................................................................................................... 25.
REFINERY OPTIMIZATION ............................................................................................................................ 28
TECHNICAL CONFIGURATION..................................................................................................................... 31.. .
WINFIELD RESOURCES LIMITED
EXECUTIVE SUMMARY
Winfield.Resources.Limited.wishes.to.engineer,.procure,.construct.and.manage.a.new.300,000.barrel.per.day.oil.refinery.to.be.located.near.Ras.Lanuf,.in.the.Great.Libyan.Jamahiriya.
Winfield Resources Limited Vision
Winfield.Resources.Limited.has.a.clear.understanding.of.clean.fuels.issues..Libyan.products.intended.for.external.markets.will.have.to.meet.the.specifications.of.those.markets..This.requires.processing.configurations.that.don’t.presently.exist.in.Libya.
The.Winfield.approach.to.work.related.to.these.facilities.is.one.of.best.practices..
While.a.generic.approach.can.be.applied.to.the.design.and.construction.phases,.each.facility.will.have.unique.constraints,.requirements.and.circumstances.that.impact.what.results.in.an.optimized.facility..
In.order.to.obtain.the.most.favorably.efficient.and.economical.design.or.construction,.all.pertinent.parameters.must.be.identified..Our.generic.approach.is.to.identify.the.needs.and.requirements.to.create.the.best.possible.facility.for.the.investment..
WINFIELD RESOURCES LIMITED
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FIGURE 1: REFINERY PROPOSAL ESTIMATEFIGURE 3: REFINERY PROPOSAL ESTIMATE
Based on an 300,000 BOPD case on a site unseen and ‘best guess’ analysis of a re�nery. WINFIELD contemplates and estimates as follows :
This estimate is scaled from a curve quality estimate. The scaling is linear, designed to produce bottom -line “estimate” of $7.5 billion USD. The quality of the curve -quality base estimate is + / - 30 - 50 %
PROCESS BATTERY LIMITS COST
OFFSITES AND UTILITIES COST
CO-GENERATION FACILITIES COST
DESALINATION FACILITIES COST
OTHERS & CONTINGENCIES
GRAND TOTAL
3,165,000,000
2,592,000,000
382,000,000
90,000,000
1,116,000,000
7,345,000,000
COST BREAKDOWN - 300,000 BOPD CASE (mid 2010 forecast), USD
WINFIELD RESOURCES LIMITED
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OP
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C
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SULT
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egot
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CUTI
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Det
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Con
stru
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42 2 6 2 35
MO
NTH
S0
12
34
56
78
910
1112
42
6 3 3 1 36 368
FIGURE 2:
IMPLEMENTATION STRATEGY
Owner's Project Management
Total Project elapse time: 42 months
WINFIELD RESOURCES LIMITED
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FIGURE 3: REFINERY ECONOMICS FIGURE 4: REFINERY ECONOMICS
This is based on 333 days of operation per year.
FEEDSTOCKS TPA BOPD USD/bbl USD/Day USD/bbl USD/Day
PROPOSED 300KBOPD / 13.360 MTPA REFINERY CAPITAL COST = 7.5 BILLION USD
CASE BRENT @ 60 USD/BBL CASE BRENT @ 70 USD/BBL
ES SIDER
SARIR
AMNA
MTBE
NATURAL GAS
NETBACK COST
PRODUCTS
LPG
ULS GASOLINE
SR NAPHTHA
RAFFINATE
BENZENE
PARA-XYLENE
KEROSENE/JET
ULS DIESEL
LS FUEL OIL
SULPHUR
GREEN COKE*
LPG for H2 unit
Re�nery FUEL GAS
LOSSES
NETBACK REVENUE
GROSS HYDROCARBON MARGIN
OPERATING COST
CASH MARGIN
8,775,000
4,387,500
4,425,000
83,628
104,457
17,775,585
1,565,050
2,566,764
659,369
213,955
717,258
2,467,668
1,885,632
10,242,624
524,853
2,994
0
0
0
0
20,603,628
2,828,043
903,564
1,924,479
58.5
58.5
59.0
70.4
308
540
555
510
510
864
1013
560
560
318
30
0
0
0
0
9.4
3.0
6.4
10,275,000
5,137,500
5,175,000
100,063
127,180
20,814,742
1,811,400
3,075,492
769,264
249,614
850,084
2,381,664
2,171,844
11,779,018
637,085
2,994
0
0
0
0
24,062,515
3,247,772
903,564
2,344,209
68.5
68.5
69.0
84.2
375
625
665
595
595
1024
1224
645
644
386
30
0
0
0
0
10.8
3.0
7.8
300,000
150,000
150,000
1,188
-
33,142
40,398
11,616
4,000
5,933
17,410
26,472
136,945
11,162
6,679,264
3,332,881
3,339,632
48,432
112,936
528,879
1,588,010
408,391
287,472
277,562
873,526
1,121,278
6,090,703
549,610
33,229
534,585
283,747
856,343
79,714
Note; * Green Coke is consumed internally by cogeneration unit – indicated here only for information purposes
In each case, the cash margin must pay all taxes, amortize the investment and generate pro�t.
Class C estimate (+/- 30%) except for Capital investment (-40/+50%) and price forecast (no estimation accuracy given)
Cost Cost Cost Cost
USD/t USD/Day USD/t USD/Day Price Revenue Price Revenue
USD/bbl USD/day USD/dayUSD/bbl
USD/t USD/t
WINFIELD RESOURCES LIMITED
FIGURE 4: REFINERY PROPOSAL ESTIMATE
FIGURE 5: REFINERY FEASIBILITY REPORT
PROCESS BATTERY LIMITS COST Million TPA BBL/DAY COSTS Million USD
PROPOSED 300KBOPD / 13,360 MTPA REFINERYCAPITAL COST BREAKDOWN
Crude Distillation Unit
Vacuum Distillation Unit
LPG Gas Plant
Delayed Coker
Hydrocracker
GO HDS
Kerosene HDS/Merox
Naphtha HDT & Splitter
CCR Reforming
Isomerisation
Sulphur Removal
Hydrogen Production Unit
Tail Gas Treatment
Amine Regeneration
Sour Water Strippers
DC LPG Sweetening
Aromatics Complex
CCR Reforming
Extractive Distillation
B-T Fractionation
Xylenes Columns
p-Xylene Puri�cation
Xylenes Isomerisation
Toluene Transalkylation
TOTAL PROCESS UNITS
UTILITIES including COGENERATION and DESALINATION
STORAGE TANKS & MOVEMENTS
OFF-SITES & FACILITIES
BUILDINGS & INFRASTRUCTURES
OIL TERMINAL
OTHERS & CONTINGENCIES
GRAND TOTAL
13.360
6.560
0.210
2.620
4.010
4.370
0.820
3.190
0.840
0.430
0.023
300,000
135,300
7,100
50,000
86,100
99,900
19,600
84,500
21,400
12,100
349.9
173.3
39.0
256.5
677.8
132.2
23.5
142.8
175.9
47.5
35.8
127.0
Included
Included
Included
Included
314.8
36.4
35.5
122.2
213.8
129.5
131.9
3,165
729
612
918
554
250
1,116
7,345
WINFIELD RESOURCES LIMITED
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6
BUSINESS PLANNING
The.business.approach.to.be.taken.by.Winfield.Resources.Limited.is.as.follows:
Phase I – Opportunity Evaluation
. 1.. .Energy.audit.-.Determine.the.most.economic.energy.loads.by.establishing.the.basis.of.operation,.benchmarking,.identifying.options,.developing.conceptual.projects,.preparing.process.packages,.preparing.screening.packages.and.developing.the.base.case.project.slate.
. 2.. Feasibility.Evaluation
. 3.. Preliminary.simulation.
. 4.. Feasibility.study.(Class.“C”,.-/+30%),.including.Capital.Cost.Estimate.(-40/+50%)
. 5.. Review.and.Assessment.of.Base.Case
. 6.. Schedule.and.DBM.for.Phase.II.is.prepared.
. 7.. Commercial.and.Financial.Closing
Any.commercial.negotiations.leading.to.the.preparation.and.execution.of.all.commercial.agreements,.including,..as.appropriate,.financing.packages.
Winfield.Resources.Limited.has.access.to.technologies;.and.knowledge.of.the.market.and.its.requirements...These.markets.being.low.sulfur.gasoline,.benzene.and.aromatics.limits.in.gasoline,.and.ultra-low.sulfur.diesel..
We.pride.ourself.in.bringing.a.value.added.approach.to.design,.wherein.the.enhanced.net.cash.flow.is.an.integral.
part.of.our.design,.engineering.activities.
WINFIELD RESOURCES LIMITED
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OPERATIONAL PLAN
To.engineer,.procure,.construct.and.manage.a.new.300,000.-.barrel.per.day.oil.refinery.there.are.a.number.of.front.end.planning.activities.associated.with.preparing.to.undertake.the.Ras.Lanuf.Refinery.Project.
. 1.. Identify.and.obtain.all.necessary.regulatory.approvals.
. 2... Site.Survey.and.development.evaluation.
. 3... Site.preparation.
. 4... Evaluation.and.selection.of.appropriate.licensor.for.the.Ras.Lanuf.Refinery.
. 5... Determine,.evaluate.and.secure.all.funding.sources.
. 6... .Develop.lists.of.potential.contractors.for.the.construction.of.the.various.component.portions.or.modules.comprising.the.Ras.Lanuf.Refinery..In.turn,.determine.which.of.these.contractors.will.receive.requests.to.submit.bids.for.such.component.portions.or.modules..For.bidding.and.personnel.staffing.purposes,.
Benefits of Winfield Resources Limited technical and Project Management Team:
. 1.. .The.team.will.act.as.plant.operators.to.ensure.the.desired.production.rates.and.product.quality.meets.all.market.requirements.until.the.plant.costs.are.paid.out.in.full.within.the.targeted.time.frame.or.early.if.possible.
. 2.. .The.team.will.implement.the.most.recent.design.and.safety.practices.that.meet.any.potential..financier.requirements.
. 3.. .The.team.will.train.client.operations.personnel.for.safe.and.efficient.operation.of.plant.and.plan..safe.transition.for.hand.over.according.to.client.and.investor.requirements.
. 4.. .The.team.will.provide.on.going.consulting.services.for.the.life.for.the.plant..All.facilities/plant.design.and.safety.requirements.will.meet.all.local.and.international.codes.and.standards.
WINFIELD RESOURCES LIMITED
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PROJECT EXECUTION
Detailed Design Package Phase II
. 1.. Develop.basic.engineering.design.package
. 2.. HAZOP.and.Value.Improvement.reviews
. 3.. EPC.schedule.and.Project.Execution.Plan
. 4.. Home.office.Engineering.estimate,.cash.flow.analysis
. 5.. List.of.permits.and.approvals
. 6.. Detailed.scope.of.work
. 7.. Revise.capital.cost.estimate.(Class.“A”,.±10%)
Engineering, Procurement and Construction Phase III Engineering:
Engineering
Preparation.of.all.drawings.and.specifications.required.for.construction,.operating.procedures,.maintenance.manuals,.testing.procedures.and.commissioning.planning,.as.well.as.construction.schedule.
Construction
Construction.design;.work.packaging,.development.of.contract.scope.and.review.of.site.layouts...Construction.Execution;.planning,.cost.control,.site.procurement,.contract.administration,.labour.relations,..safety,.accounting.and.reporting.
Commissioning
Preparation.of.system.scope.packages,.scheduling.mechanical.completion.of.systems,.loop.checking,.testing,.flushing.and.cleaning,.first.fills.of.lubricants,.firing.of.specific.equipment.(i.e..turbines.and.steam.blows.for.a..Co-Generation.plant)..Training,.checkout.and.turnover.of.systems,.start-up.and.checkout.of.equipment.and.services,.coordination.of.vendor.reps,.troubleshooting,.co-ordination/negotiation.of.warranty.work,.transfer.of..as-built.drawings./.vendor.manuals,.and.turnover.to.owner.
WINFIELD RESOURCES LIMITED
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PROJECT MANAGEMENT
kBC
www.kbcat.com
KBC Approach
Owners’.Project.Management.or.OPM.where.the.Owner.manages.the.project.is.the.preferred.option..This.is.a.continuous.approach.adopted.by.several.of.the.major.oil.and.petrochemical.companies.who.do.the.initial.feasibility.studies.themselves.and.develop.their.own.project.definition.equivalent.to.DFS.and.continue.to.take.responsibility.for.the.project.definition.through.licensor.selection,.detailed.process.design.and.project.planning..The.Oil.Company.Project.Management.team.then.selects.the.EPC.Contractor.and.establishes.a.project.management.protocol.for.quality.assure.and.risk.management.which.involves.working.closely.with.an.EPC.contractor.to.ensure.effective.project.execution..This.gives.the.Owner.the.ability.to.better.manage.project.risk.through.the.exercise.of.significantly.more.control.over.project..Where.these.resources.are.not.available.to.the.project.owner,.there.may.be.a.need.to.involve.an.independent.consultant.with.the.requisite.skills.and.competency.to.accelerate.the.schedule.who.can.be.contracted.to.perform.the.functions.required.
If.a.consulting.company.is.employed.to.perform.this.role.in.the.capacity.of.Owners’.Project.Management.Consultant,.or.OPMC..The.Consultant.makes.this.Option.possible.by.supplying.the.resources.necessary.to.supplement.those.of.the.Owner.to.provide.the.project.management.and.stewardship.oversight.to.achieve.this.competitive.project.execution.advantage.
At.42.months.the.schedule.for.option.is.significantly.shorter.compared.to.the.alternative.ones.(Lump.Sum.Turn.Key.or.Separate.Lump.Sum.Contracts).because.several.of.the.early.activities.can.take.place.in.parallel.as.shown.in.Figure.2.
Introduction to KBC
KBC.is.the.leading.independent.refining.and.petrochemical.consultancy.group,.operating.worldwide,.providing.specialised.services.and.software.designed.to.improve.the.competitive.position.of.our.clients.in.the.hydrocarbon.processing.industry...KBC.has.worked.closely.with.over.300.clients.in.areas.including.yield.and.energy.efficiency.improvement;.loss.control.and.value.recovery;.planning,.economics.and.scheduling;.reliability,.availability.and.maintenance;.risk.analysis;.operations.and.technical.support;.process.design.services.and.human.performance.improvement...KBC’s.client.base.includes.national.oil.companies,.major.multi-national.oil.companies.and.independent.refiners.
WINFIELD RESOURCES LIMITED
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KBC Capital Investment ExperiencekBC Capital Excellence (CapX) Methodology
KBC’s.simulation.capability.and.refining.expertise.enables.the.generation.of.optimum.capital.solutions.for.new.refinery.projects.of.this.type,.with.high.return.on.capital.employed,.and.minimum.operational.lifecycle.costs..
KBC’s.approach.is.to.study.the.entire.complex.as.a.whole.using.our.unique.combination.of.extensive.refining.expertise.and.world-leading.simulation.tools..This.approach.enables.inter-unit.synergies.and.trade-offs.to.be.evaluated.effectively.and.in.detail.ensuring.the.right.investment.decision.is.made..KBC’s.TotalSite.approach.focuses.on.smart,.low-cost.investments.that.would.enable.project.objectives.to.be.met.while.minimising.capital.investment...This.will.ensure:
•. Only.high-ROCE-yielding.new.plants.are.built
•. The.optimal.technology.solution.for.the.specific.site.is.identified.
•. .The.assets.built.will.incorporate.an.inherent.level.of.reliability,.consistent.with.the.project.business.case.availability.of.the.plant.and.will.be.designed.with.full.consideration.of.maintenance.aspects.(run.length.targets,.on-stream.maintenance.capability.etc.)
•. .The.new.assets.selected.will.focus.on.maximizing.the.total.lifetime.return.on.investment,.by.establishing.the.optimum.trade-off.between.capital.and..operating.costs.from,.for.example,.adopting.a.highly.energy.efficient.design.
•. .The.methodology.employed.would.use.a.fully.functional.and.rigorous.simulation.tool.that.could.subsequently.be.used.to.support.the.site’s.efforts.to.achieve.Operational.Excellence..
KBC Refinery Operation ExperiencekBC Operational Excellence (OpX) Methodology
KBC’s.technical.support.and.consulting.activities.are.based.around.helping.a.client.establish.and.sustain.Operational.Excellence...In.order.to.give.direction.and.structure.to.this.technical.support,.KBC.have.developed.an.Operational.Excellence.(OpX).Model...This.Model.emphasises.the.need.to.build.and.maintain.world.class.manufacturing.standards.that.will.maximise.production.effectiveness.and.profitability.by.achieving.safe,.reliable.and.profitable.production..
The.KBC.OpX.Model.describes.operational.excellence.supported.by.a.continuous.improvement.process.to.deliver.safe,.reliable.and.profitable.production...In.short.the.model.encompasses.the.full.array.of.systems..Processes.and.practices.in.manufacturing.leadership,.management.strategies.and.process.optimisation.to.achieve.and.sustain.Operational.Excellence.(OpX)..
WINFIELD RESOURCES LIMITED
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Leadership and Management System:.The.Leadership.and.Management.System.focuses.on.identifying.the.factors.that.will.drive.the.changes.in.future.business.strategies.and.then.managing.plant.activities.to.achieve.the.strategic.goals.of.the.plant...This.system.provides.the.basis.for.clearly.defining.the.strategic.direction.of.the.plant.and.developing.an.improvement.strategy.for.realizing.that.direction...Additionally,.this.system.provides.the.framework.for.managing.plant.work.activities.and.improvement.efforts.in.a.manner.that.drives.effectiveness.and.efficiency...
Production Optimization System:.The.Production.Optimization.System.focuses.on.economically.optimizing.the.planned.production.(i.e.,.capacity,.yields,.quality,.and.energy).of.the.plant,.while.ensuring.that.operating.conditions.are.further.optimized.within.the.plant’s.capability...The.purpose.of.this.system.is.to.effectively.plan.the.future.operation.based.on.economic.driving.forces.and.to.further.optimize.the.production.within.the.operating.plan.and.physical.constraints.
Reliability and Maintenance System:.The.Reliability.and.Maintenance.System.is.the.foundation.to.improving.plant.performance.through.enhanced.unit.reliability...Effective.reliability.will.reduce.the.cost.of.operations.and.improve.safety.by.providing.tools.and.methodologies.that.can.be.used.to.understand.and.manage.plant.risk.and.performance.concerns...This.system.is.based.on.a.holistic.reliability.and.maintenance.strategy.that.focuses.on.the.entire.equipment.life.cycle..
Human Performance System:.The.Human.Performance.System.focuses.on.optimizing.the.performance.capabilities.of.the.employees.that.operate.and.support.a.production.plant...This.system.provides.consistent,.comprehensive.mechanisms.(i.e.,.staffing,.training,.performance.management,.and.performance.support.systems).for.ensuring.that.all.employees.possess.the.required.competencies.to.effectively.perform.their.job.functions...
Loss Prevention and Control System:.The.Loss.Prevention.and.Control.System.focuses.on.the.protection.of.personnel,.the.environment,.and.the.plant,.which.underpin.OpX...This.system.provides.direction.for.plant.safety,.health,.and.environmental.stewardship.efforts.
Process Information and Control System:.The.Process.Information.and.Control.System.focuses.on.the.control.and.information.management.systems.associated.with.the.efficient.and.effective.execution.of.production-related.activities...This.system.provides.plant.personnel.with.the.tools,.information,.and.procedures.needed.to.control.and.optimize.plant.operations.
Continuous Improvement Process: The.Continuous.Improvement.Process.focuses.on.providing.mechanisms.for.identifying.and.evaluating.opportunities.to.develop.and.implement.performance.improvement.solutions...Recognizing.that.OpX.is.continually.evolving,.this.holistic.approach.ensures.that.the.plant.constantly.advances.in.terms.of.safety,.reliability,.and.profitability...
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KBC’s.client.support.activities.and.consulting.will.always.take.into.account.our.client’s.unique.environment.(business,.cultural,.location.etc.)..Combining.this,.with.knowledge.gained.from.KBC’s.experience.from.working.for.many.companies.and.on.many.sites.which.is.reflected.in.the.OpX.model,.KBC.will.ensure.that.they.develop.a.tailored.solution.and.product.for.their.client.that.meets.best.their.requirements..
All.of.KBC.services.are.targeted.at.helping.our.clients.maintain.and.improve.their.competitive.advantage.and.the.return.on.capital.employed..KBC.also.ensure.that.benefits.are.sustainable.by.transferring.knowledge.and.best.practices.to.our.client’s.organisations.
KBC.will.conduct.a.Phase.1.OpX.assessment.study.of.the.JVCO.assets.to.evaluate.current.plant.work.processes,.practices,.technologies.and.recommended.areas.for.efficiency.and.productivity.improvements.covering.the.six.systems.of.the.KBC.OpX.model...In.this.phase.of.the.program.KBC.will.identify.gaps.as.compared.to.industry.best.practices.and.provide.a.strategy.for.improving.efficiency.and.effectiveness.of.the.JVCO.facilities.
The.assessment.will.generate.practical.implementable.recommendations.to.achieve.increased.safety,.reliability.and.profitability.for.the.site.through.optimisation.of.plant.work.processes.and.improved.operating.and.maintenance.practices.and.skill.levels.
Recommendations.will.include:
•. Identification.of.work.processes.that.can.be.restructured.or.streamlined.to.improve.proficiency
•. .Identification.of.areas.that.can.be.improved.by.the.introduction.of.industry.best.practices.or.via.the.use.of.proven.new.technologies
•. Identification.of.mechanisms.for.improving.organisational.alignment
An.important.aspect.of.the.breadth.of.the.proposed.study.is.KBC’s.recognition.that.the.efficacy.of.study.and.follow-up.initiatives.depends.on.the.following.characteristics:
•. Consistency.with.ongoing.initiatives,.management.practices,.local.constraints
•. .Be.prioritised.to.maximise.return.on.investment.(focus.will.be.on.strategic.development.while.taking.advantage.of.quick.wins.that.are.supportive.of.long.term.improvement)..
•. Prioritised.for.logical.and.practical.development
•. Manageable.change.at.an.achievable.pace
Through.this.approach.KBC.will.develop.recommendations.for.maximum.value.and.practical.implementation..
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FIGURE 6: PROJECT HIERARCHY
SPONSOR
HEALTH & SAFETY OFFSITE TRAINING
WINFIELD RESOURCES MANAGEMENT TEAM
Michael Foley
CRUDE OIL FEED PRE-TREATMENT FRACTIONATION
PROJECT MANAGER
MECHANICAL ELECTRICAL PROCESS COMPUTER/COMMUNICATIONS
COST / SCHEDULING CIVIL STRUCTURAL INSTRUMENT / CONTROLS SPARE PARTS COORDINATOR
PROCUREMENT INSPECTION DOCUMENT CONTROL QA / QC
OFFSITES & UTILITIES (STEAM/POWER)
PROJECT MANAGER
STORAGE, LOADING & MOORING
PROJECT MANAGER
INSTRUMENTATION & CONTROLS
(PLANT AUTOMATION) PROJECT MANAGER
PROJECT MANAGEMENTKBC
PROJECT EXECUTION / SUPPORT TEAM *
WINFIELD ENGINEERINGMANAGEMENT TEAM
David McClement, P.ENG
NATIONAL AUTHORITY
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PROFESSIONAL PERSONNEL
Winfield.Resources.Limited.has.assembled.a.world.class.team.of.engineers,.project.managers,.technicians,.support.staff.and.other.personnel.who.bring.valuable.and.unique.insight.and.design.knowledge.to.any.given.petrochemical.project.in.the.fields.of.chemical.engineering.and.heat.transfer..
The.team.is.considered.as.“Best.In.Class”.that.can.be.offered.by.any.EPCM.company..With.extensive.experience.in.the.design,.procurement.and.construction.of.Refineries,.LNG.facilities,.Co-Generation.facilities.and.various.associated.components.
The.team.will.develop.a.technical.design.that.reflects.market.demands.of.products.generated.in.concert.with.the.fastest.pay-down.of.investment.to.enable.the.client.to.assume.full.ownership.of.the.plant.by.saving.build.time.(via.improved.management.and.construction.strategies).and.improving.returns.on.produced.products.
Winfield.Resources.Limited.is.confident.that.it.can.successfully.manage,.oversee.and.perform.all.engineering,.design.and.construction.management.functions.to.ensure.that.any.petrochemical.plant.or.facility.is.built.on.time.and.at.or.below.budgeted.cost,.bearing.in.mind.the.following.in.relation.to.key.WINFIELD.personnel:
. •. They.are.familiar.with.international.codes.and.standards.(i.e..ASME,.BS,.DIN,.etc.).
. •. .Each.member.has.worked.as.a.part.of.a.large.task.force,.and.some.have.led.project.task.forces..of.250.or.more.personnel.
. •. .They.have.worked.together.on.many.large-scale.petrochemical.projects.throughout.the.world,.including.North.America,.Europe,.the.Far.East.and.the.Middle.East.
. •. They.have.executed.numerous.projects.where.values.have.exceeded.USD$1.billion.
. •. .They.have.established.contacts.and.are.knowledgeable.as.to.strategically.accessing.and.utilizing.key.suppliers.of.equipment.and.materials.from.around.the.world..
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FINANCIAL ANALYSIS
Project.investment.is.split.over.4.years.period,.with.the.following.ratio:.0.25./.0.40./.0.25./.0.10
Assuming.a.Weighted.Average.Cost.of.Capital.(WACC).of.11.2%,.the.project.Net.Present.Value.(NPV),.Internal.Rate.of.Return.(IRR).and.Pay.Out.Time.(POT).are.presented.in.the.following.table.for.3.different.price.scenarii.
Conservative.price.scenario.developped.by.KBC.assumes.a.Brent.benchmark.crude.oil.price.drop.until.years..2009-2010.when.it.reaches.the.bottom.value.of.USD.60.per.barrel.before.increasing.again.
Project schedule and capital cost breakdown
We.have.planned.a.42.month.construction.period.starting.with.being.successful.in.financing.and.the.award.of..the.new.300,000.barrel.per.day.oil.refinery..
Figure.2.demonstrates.this.timeline.based.on.major.activities.of.planning.and.construction..Within.the.first.three.months.many.major.project.decisions.will.be.made.allowing.the.construction.to.follow..
NPV (USD)
IRR (%)
POT (years)
NPV / Invest. ratio
4,350,000,000
17.59%
7.62
0.44
Brent at 60 USD/bbl + linear 3% inflation
Brent at 70 USD/bbl + linear 3% inflation
Conservative Price Scenario (non linear)
6,470,000,000
20.16%
6.17
0.65
2,870,000,000
15.63%
9.47
0.29
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FINANCIAL REPORT
Refinery Economics
The.overall.economics.or.viability.of.a.refinery.depends.on.the.interaction.of.three.key.elements:.
The.choice.of.crude.oil.used.(crude.slates).the.complexity.of.the.refining.equipment.(refinery.configuration)..and.the.desired.type.and.quality.of.products.produced.(product.slate)..
Refinery.utilization.rates.and.environmental.considerations.also.influence.refinery.economics.
Using.more.expensive.crude.oil.(lighter,.sweeter).requires.less.refinery.upgrading.but.supplies.of.light,..sweet.crude.oil.are.decreasing.and.the.differential.between.heavier.and.more.sour.crudes.is.increasing..
Using.cheaper.heavier.crude.oil.means.more.investment.in.upgrading.processes.
Payback.periods.for.refinery.processing.units.must.be.weighed.against.anticipated.crude.oil.costs.and.the..projected.differential.between.light.and.heavy.crude.oil.prices.
Crude.slates.and.refinery.configurations.must.take.into.account.the.type.of.products.that.will.ultimately.be..needed.in.the.marketplace..
The.quality.specifications.of.the.final.products.are.also.increasingly.important.as.environmental.requirements.become.more.stringent.
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PROJECT FINANCE
DEVEREUX PROJECT FINANCE
www.dpf.biz
Devereux.Project.Finance.is.a.private.equity.finance.consultancy.who.are.located.in.London.and.Buckinghamshire.
Our.partners.have.been.in.structured.finance.since.1987
Our.core.competence.lies.in.identifying.the.real.needs.of.our.clients,.arranging.project.senior.debt.and.equity.finance;.assisting.with.initial.project.administration.whilst.delivering.overall.client.satisfaction.by.executing.our.best-in-class.services
We.offer.various.consultancy.services.to.assist.our.clients.with.the.success.of.their.projects.such.as.planning.consultants;.full.project.or.interim.management.and.risk.analysis.which.is.a.process.that.brings.together.the.consequences.and.frequency.of.adverse.scenarios.to.estimate.the.level.of.risk.
Our.company.represents.a.wide.range.of.clients.as.in:.developers,.project.owners,.sponsors,.contractors,.project.investors.and.operators.
Our.company.will.provide.assistance.in.several.ways.according.to.the.needs.of.the.client..We.will.assist.clients.with.preparation.of.information.of.memorandum;.structuring.the.project;.advising.on.joint.ventures;.and.arranging.the.necessary.finance.to.complete.the.project.and.its.objectives.
Our.funds.are.sourced.globally.which.includes.or.equity.participators.
In.addition.we.have.forged.alliances.with.various.professional.firms.globally.through.whom.we.celebrate..shared.successes.
We.offer.a.wide.range.of.advisory.services.for.projects.including.financial.modelling..We.provide.optimal.financing.structures.incorporating.credit.and.asset.support,.interim.and.permanent.capital,.and.deliver.broad.investor.support.for.successful.financings..Our.experience.gives.us.the.ability.to.develop,.analyse.and.negotiate.optimal.financing.and.project.support.structures.
Our.skilful.resource,.extensive.financing.experience.and.organizational.culture.place.us.in.a.unique.position.to.assist.our.clients..We.are.found.to.be.approachable,.flexible,.responsive.and.innovative.whilst.extremely.professional.
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SUBCONTRATOR
Sk ENGINEERING & CONSTRUCTION
www.skec.co.kr
SKEC.has.applied.its.E&C.System.since.1983,.when.it.started.work.on.the.Crude.Distillation.Unit.at.the.SK.Complex.in.Ulsan,.Korea..This.facility.was.enlarged.to.an.annual.production.capacity.of.810,000.BPSD.in.1996,.SKEC.successfully.completed.a.Heavy.Oil.Upgrading(HOU).Plant.with.an.annual.capacity.of.63000.BPSD,.a.Lube.Base.Oil.project.and.the.No.1,.2.and.3.Reformer.projects.along.with.a.45,000.BPSD.RFCC.project..With.these.large.scale.projects,.SKEC.has.gained.a.reputation.for.its.application.of.high.technology..Throughout.its.accumulated.technology.and.experience.in.the.domestic.market,.SKEC.has.been.venturing.overseas.and.is.currently.working.on.a.number.of.international.oil.and.gas.projects.worldwide.
SKEC’s.services.extend.from.project.feasibility.studies,.front-end.engineering.package.development,.detailed.engineering,.procurement.and.construction,.to.final.commissioning,.start-up,.and.operations.and.maintenance.services,.for.grassroots,.expansion.and.revamp.projects.
SKEC.has.executed.a.wide.range.of.design.and.construction.projects.for.the.petroleum.refining.industry,.from.single.unit.revamps.to.grassroots.complexes.worldwide..SKEC’s.experiences.in.refining.include.Crude.distillation.unit,.Vacuum.distillation.unit,.Heavy.oil.upgrading,.Hydrotreating.plant,.Gas.concentration,.Naphtha.reforming,.Coking,.Isomerization.Plant,.and.so.on.
SKEC.recently.has.completed.the.Cadereyta.oil.refinery.project.in.Mexico,.which.has.been.historically.the..largest.scale.project.in.refining.businesses.in.the.world,.and.been.executed.successfully.another.big.project.in.Madero,.Mexico..
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OPERATOR
PETROLEUM INDIA INTERNATIONAL
WITh KBC / SK MANAgEMENT SECONDMENT AT KEY POSITIONS
Petroleum.India.International.("PII").is.a.consortium.of.eight.India’s.top.ranking.public.and.private.sector.petroleum./.petrochemicals.industries.working.with.a.successfully.implemented.motto.of."Expertise.through.Experience"..After.offering.and.helping.hand.to.our.various.clients..Now.we.are.ready.to.untie.the.knots.of.numerous.challenging.problems.arising.related.to.petroleum/petrochemical/refineries.for.you..
PII.has.a.team.of.well.experienced.persons.from.HPCL,.Bharat.Petroleum,.IPCL.and.several.other.companies..The.consultancy.is.well.equipped.with.excellent.infrastructure.in.upstream,.downstream.&.IT.services..Company’s.turnover.touches.somewhere.around.US.$.30.billions.
Deputation of Experts / Technical Back-up Services
Deputation.of.qualified/experienced.personnel.drawn.from.India's.onshore/offshore.oil/.gas.fields,.production.installations,.offshore.platforms,.reservoir.engineering.and.all.other.departments.of.E&P.company.like.BPCL,.from.refineries,.petrochemicals.units,.pipelines.and.network.of.petroleum.marketing.facilities.for.operations.and.maintenance.technical.back-up.services..(On.long.&.Short.Term.Basis.and.with.minimum.mobilization.period.)
The advantages of PII experts:
. •.. .High.quality.of.experts.with.very.exhaustive.hands.on.experience..These.personnel.have.been.trained.extensively.in.India.and.abroad.
. •.. .High.commitment.and.motivation.of.experts.sent.on.deputation.
. •.. .This.is.a.unique.concept.since.these.deputed.personnel.continue.to.be.employees.of.the.parent.company.at.India.and.draw.their.salaries.and.perk.during.their.deputation.
. •.. .Online.database.of.thousands.of.experts.working.in.our.member.companies.is.available.with.PII.
. •.. .Availability.for.Short.&.Long-term.(even.experts.can.be.deputed.by.us.for.as.less.as.15.days.to.any.length.of.period.
. •.. .No.terminal.benefits.are.payable.by.client.after.completion.of.deputation..As.on.completion.of.deputation.these.experts.come.back.and.take.over.their.jobs.in.parent.companies.
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Expertise in Downstream
PII.member.companies.operate.seven.refineries.in.India..All.the.seven.refineries.are.operating.at.a.capacity.utilization.of.over.100.%..The.maintenance.cost.of.the.refineries.by.PII.member.is.one.of.the.lowest.in.the.world..Six.of.the.seven.refineries.have.been.awarded.the.coveted.ISO.9002.certification,.thus.their.quality.systems.are.at.par.with.the.world.standards.
. •.. .Design./.Detailed.Engineering,.Construction.&.Commissioning
. •.. .Commissioning./.Startup.&.Operation.services.for.refinery.petrochemical.Plants.&.Pipeline
. •.. .Utilities.&.Services.
. •.. .Maintenance.and.Inspection
. •.. .Environmental.Engineering.
. •.. .Energy.Conservation.
. •.. .Risk.Analysis./.Safety.Audits
. •.. .Marketing.&.Distribution.Services
. •.. .Training.of.Manpower
. •.. .Other.downstream.activities
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Competitive Advantage of TAM
PII.refineries.have.vast.and.rich.experience.in.handling.Turn.Around.Maintenance.
Main.strength.of.Turn.Around.Execution.is.highly.skilled,.knowledgeable,.experienced.and.capable.engineers.&.technician..
The.present.strength.of.engineers.&.technician.have.experience.of.handling.various.turn.arounds.of.crackers,.distillation.&.other.units..
High.degree.of.expertise.gained.over.last.40.years.of.maintaining.various.refineries..
Adoption.of.latest.maintenance.tools.&.techniques.for.preventive,.predictive.proactive.and.turn..around.maintenance..
Dedicated.team.of.engineers.and.technicians..
PII.has.deputed.maintenance.experts.to.refineries.of.various.Middle.East.and.Far.East.countries.such.as.Nigeria,.Kuwait,.Malaysia.&.UAE..
The.performance.on.all.these.assignments.was.excellent.and.left.a.mark.of.their.skill.and.dedication..
Detailed.data.bank.on.rotary.equipment..
Analysis.of.various.failures..
Modifications.to.suit.process.conditions..
Expertise.in.welding.exotic.material.-.Successfully.developing.welding.procedures..
Capabilities.of.fabrication.on.intricate.spares.&.exchangers.tube.bundles..
Mastery.of.machining.components.to.high.degree.of.accuracy..
Expert.knowledge.on.overhauling.to.high.degree.of.accuracy..
Specialised.techniques.in.repairs.to.internal.cyclones..
Top.class.knowledge.on.maintaining.various.electrical.equipment.and.instrument..
Capability.of.providing.and.repairing.any.refractory.&.civil.facilities..
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18.
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SkILLS ASSESSMENT / TRAINING / LIBYAN INTEGRATION
Winfield.Resources.Limited.recognizes.the.importance.of.assimilating.local.Libyan.personnel.into.the.ongoing.operations.of.the.Ras.Lanuf.Refinery.following.start.up..
To.this.end,.Winfield.Resources.Limited.is.committed.to.ensuring.ongoing.skills.assessments.are.undertaken,.and.training.programs.provided,.during.the.execution.Phase.of.the.Ras.Lanuf.Refinery.Construction.to.ensure.a.smooth.and.orderly.Integration.and.transition.of.local.Libyan.personnel.into.plant.operations..
Winfield.Resources.Limited.intends.to.hand.over.the.Ras.Lanuf.Refinery.to.fully.trained.and.integrated.Libyan.nationals.as.operating.and.management.personnel.
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HEALTH AND SAFETY
. •. The.requirements.of.applicable.insurance.companies.will.be.met.or.exceeded
. •. .It.is.contemplated.that.the.Ras.Lanuf.Refinery.will.be.centrally.controlled.via.a.Honeywell..TDC3000.series.distributed.control.system
. •. .The.overall.system.will.include.a.100%.spare.protection.system.by.duplicating.all.critical..control.loops
. •. .All.key.emergency.shut.down.devices.will.be.constantly.and.continually.self.checking.and..monitoring.(i.e..SMART.systems)
. •. .The.plant.design.will.be.such.that,.in.the.event.of.malfunction,.applicable.portions.of.the..Ras.Lanuf.Refinery.facility.will.be.quickly.segregated,.isolated.and.depressurized
. •. .The.plant.design.will.be.based.on.the.latest.safety.standards.applicable.for.a.similar.plant..and.will.meet.all.applicable.national.or.international.codes.and.standards
. •. .HAZOP.(hazards.&.operability).review.will.be.conducted.at.the.10%,.30%.and.60%.completion.stages.or.intervals.during.the.execution.of.the.Ras.Lanuf.Refinery.
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PROJECT OVERSIGHT
D.M..McClement,.P.Eng.. . . .
EDUCATION
B.Sc..Mechanical.Engineering,..University.of.Saskatchewan.(Canada),.1968
Certificate,.Operations.Research./.Management.Sciences,.University.of.Michigan,.1969
Certificate,.Business.Administration,..University.of.Saskatchewan.(Canada),.1972
Certificate.in.Technical.Writing,..Mount.Royal.College,.2003
ADDITIONAL COURSES AND SEMINARS
Probability.and.Statistics. .Strategic.Planning
Risk.Analysis./.Contingency.Planning. .Decision.Making.(Kepner.-.Tregoe)
Management.by.Objectives. .Linear.Programming.for.Refinery.Optimization
Project.Procurement.Cycle. .UOP.Technical.Conferences
PROFESSIONAL AFFILIATIONS
Association.of.Professional.Engineers,..Geologists.and.Geophysicists.of.Alberta
Association.of.Professional.Engineers.of.Saskatchewan
EMPLOYMENT HISTORY
1984 - Present
President,.Endeco.International.Ltd.
1996 - 2001
President,.NANA/Colt.Engineering.LLC..(a.joint.venture.between.Colt.Engineering..and.the.NANA.Corp.)
1993 - 1994
President,.CoAxia.Inc..(a.joint.venture.between..Colt.Companies.and.Axia.Inc.)
1982 - 1984
Vice-President,.Oil.Sands.Division,..Techman.International.Ltd.
1981 - 1982
Senior.Project.Manager,.Cord.Projects.Ltd.
1980 - 1981
Project.Manager,.Bechtel.Canada.Ltd.
1977 - 1980
Senior.Manager,.Project.Management.and..Project.Services,.Associated.-.Pullman.Kellogg.Ltd.
1976 - 1977
Project.Manager,.Consumers’.Co-Operative..Refineries.Ltd.
1973-1976
Project.Manager,.Associated.Engineering.Services.Ltd..(seconded.to.Bechtel.Inc..in.San.Francisco.and.Edmonton)
1958- 1973
Consumers’.Co-Operative.Refineries.Ltd.
•.Senior.Plant.Engineer,.Regina.Refinery
•..Mechanical.Superintendent./.Interim.Plant.Manager,.Saskatoon.Chemical.Plant
•.Operations.Research.Analyst,.Saskatoon.Home.Office
•.Shift.Operator,.Regina.Refinery
WINFIELD RESOURCES LIMITED
25
REFINERY PROJECT MANAGEMENT EXPERIENCE
Project.Manager.for.Primary.Upgrading.on.a.major.oilsands.project..The.scope.of.work.encompassed.all.of.the.primary.bitumen.processing.units,.excluding.hydrotreating,.and.included.facilities.with.an.estimated.capital.cost.of.$2.2.billion.Canadian.
Manager.of.Projects.and.Project.Services.for.a.major.EPC.company.with.operations.in.Edmonton,.Calgary.and.Toronto..(I.was.responsible.for.project.operations.in.all.three.operating.centers)..
Project.Manager.for.a.major.expansion.at.a.B.C..Oil.Refinery..The.scope.of.work.included.modifications.to.all.refinery.units.including.the.Platformer,.Unifiners,.FCCU,.Crude.Distillation,.and.Plant.Utilities.and.Offsites..Managed.the.process.design.in.the.Licensors’.offices.and.then.provided.detailed.engineering,.procurement.and.direct-hire.construction.services.
Project.Manager.for.a.major.expansion.to.a.Saskatchewan.Oil.refinery..The.scope.of.work.included.new.Atmospheric.and.Vacuum.Distillation.units,.a.Saturate.Gas.Plant.and.modifications.to.all.plant.utility.systems.and.offsite.facilities.
Project.Manager.for.a.project.to.relocate.a.surplus.Naphtha.Hydrotreater.and.Catalytic.Reformer.Units.from.Corpus.Christie,.Texas,.to.Regina..The.units.were.successfully.dismantled,.moved,.re-erected.and.commissioned.under.my.direction.
Project.Manager.responsible.for.co-ordinating.and.monitoring.the.work.of.Canadian.engineering.firms.contracting.to.the.Managing.Contractor.on.a.major.oilsands.project..The.scope.of.work.included.the.Sulfur.and.Amine.Units,.the.Froth.Treatment.Plant,.Waste.Treatment.and.Disposal.Facilities.and.the.Athabasca.River.Bridge.
Project.Engineer.responsible.for.the.design.of.the.principal.conversion.units.for.a.major.oilsands.project..
Project.Director./.Construction.Manager.responsible.for.the.detailed.design,.fabrication.and.field.construction.of.a.project.to.convert.a.surplus.Platformer.to.an.Isomerization.Unit..My.responsibilities.included.co-ordination.the.Licensor’s.Schedule.“A”.package.work,.and.all.EPC.activities.for.the.Isomerization.Unit.and.for.required.changes.to.ancillary.units.–.the.Naphtha.Hydrotreater,.and.offsite.facilities.
Project.Manager.for.the.process.design.phase.of.a.project.to.construct.an.Isomerization.unit.at.an.Alberta.refinery..We.conducted.the.process.selection.studies,.completed.the.process.design.of.the.Naphtha.Hydrotreater.unit.and.co-ordinated.the.Licensor’s.process.design.activities.for.the.Isomerization.unit.
Project.Manager.for.process.selection.studies.for.a.proposed.heavy.oil.upgrading.project.for.a.major.heavy.oil.upgrader..
WINFIELD RESOURCES LIMITED
26
INTERNATIONAL CONSULTING SERVICES
In.connection.with.a.proposed.project.to.relocate.a.surplus.refinery.from.Naples,.Italy.to.Pondicherry,.India,.I.constructed.an.LP.model.of.the.refinery.and.used.the.model.to.evaluate.proposed.operations.on.various.feedstocks..Also,.I.prepared.cost.estimate.for.the.project.and.constructed.an.economic.model.to.examine.the.expected.economics.of.the.project.and.assisted.the.proponents.in.making.submissions.to.Indian.financial.agencies.and.licensing.authorities.
Provided.services.to.a.Canadian.company,.operating.in.Nizhnevartovsk,.Siberia,.in.connection.with.a.proposed.crude.topping.plant..I.characterized.the.crude.oil.feedstock,.simulated.the.topping.operations.and.prepared.a.conceptual.design.and.preliminary.cost.estimate.for.the.facilities.
Assisted.a.large.US-based.client.in.evaluating.a.proposed.investment.in.a.facility.to.manufacture.ammonia.from.a.purge.hydrogen.stream.at.a.location.in.the.Gulf.Coast.
Prepared.a.preliminary.design.and.associated.cost.estimate.and.constructed.an.economic.model.of.a.facility.to.extract.wax.from.vacuum.gas.oil.for.a.refiner.in.Chile.
Provided.consulting.services.to.several.groups.in.their.evaluation.of.plans.to.relocate.a.surplus.Canadian.refinery.to.various.third-world.locations..Sites.included.Vietnam,.India,.Chile.and.China..Clients.were.investors.and.state.oil.companies.
Provided.consulting.services.to.a.major.Canadian.energy.company.considering.an.investment.in.a.proposed.gas.recovery.project.in.the.South.China.Sea.offshore.Vietnam..Our.services.included.cost.estimation,.economic.modeling.and.contract.negotiations.
Provided.consulting.services.to.a.company.considering.an.investment.in.a.lube.oil./.wax.recovery.refinery..in.Vietnam..Our.services.included.the.preparation.of.conceptual.designs,.cost.estimates,.optimization.and.economic.modeling.
Provided.consulting.services.to.the.Government.of.Vietnam.and.to.the.state.oil.company,.PetroVietnam.in..soliciting.and.evaluating.proposals.from.eighteen.major.international.oil.companies.in.connection.with.a..proposed.fuels.refinery.in.Vietnam..
WINFIELD RESOURCES LIMITED
27
REFINERY OPTIMIZATION
Linear Programming
. •. .Almost.all.petroleum.refineries.in.the.world.use.some.form.of.economic.modeling.for.operations.planning.and.project.evaluation.
. •. .Linear.Programming,.a.special.branch.of.mathematical.programming,.is.the.method.adopted.by..most.refiners.
. •. .Linear.Programming.(LP).involves.developing.a.mathematical.model.of.a.particular.refinery.(or.a.proposed.refinery).by.modeling.all.of.the.feedstock.purchases,.processing.operations,.product.treating.and.blending,.and.product.sales.operations.in.a.mathematical.format.
. •. .The.model.evolves.into.a.matrix.format,.wherein.all.of.the.material.balances,.constraints,.specifications.and.requirements.are.represented.by.mathematical.relationships.
. •. .Variable.operating.costs.of.each.“activity”.are.also.included.and.the.model.is.then.optimized.using.a.special.mathematical.algorithm.
. •. .Optimization.therefore.involves.selecting.the.value.for.each.variable.that.results.in.either.the.maximum.profit.or.minimum.cost.for.the.entire.operation..Of.course.the.optimized.model.must.also.comply.with.all.constraints,.specifications.and.other.requirements.and.the.material.balance.must.be.internally.consistent.
. •. .The.art.of.using.LP.lies.in.the.building.of.successful.models.
. •. .To.be.useful.a.model.must.include.all.of.those.activities,.constraints,.specifications,.requirements.and.variable.costs.that.are.necessary.to.completely.describe.the.expected.performance.of.the.entire.refinery..Factors.that.are.extraneous.to.essential.operation.of.the.facilities,.should.be.omitted.from..the.model.
. •. .To.validate.a.model,.we.test.it.using.typical.data.(from.past.operations,.if.possible)..A.valid.model..will.generate.expected.results,.or.at.least.explainable.outcomes.
WINFIELD RESOURCES LIMITED
28
Another.way.to.look.at.LP.modeling.is.that.it.provides.a.method.of.manipulating.large.amounts.of.data...A.typical.oil.refinery.may.have.several.hundred,.or.even.thousands.of.variables,.and.a.similar.number.of.constraints..(Variables.are.the.columns.of.our.matrix,.while.constraints.are.the.rows)..Carefully.constructing.the.model.is.the.first.step.in.achieving.success.in.this.form.of.operational.planning;.computers.can.provide.the.means.to.work.with.the.large.amount.of.data.to.generate.useful.answers.from.the.huge.database.
. .•. Common.applications.for.LP.within.the.refining.industry.include.the.following:
. . –..Operational.planning.and.production.budgeting
. . –..Facilities.and.project.planning.and.evaluation
. . –..Feedstock.evaluation
. . –..Process.selection
. . –..Product.blending
. •. .For.the.proposed.North.African.refineries,.Winfield.Resources.plans.to.use.LP.initially.for.facilities.planning.and.project.evaluation.
. •. .To.do.this,.we.will.start.with.an.assay.of.the.proposed.crude.oil.feedstock(s).to.determine.what.straight-run,.virgin.products.can.be.recovered.in.a.crude.distillation.unit.
. •. .We.will.then.assemble.the.required.product.specifications.for.our.proposed.markets.
. •. .The.third.step.will.require.some.process.design.to.determine.what.additional.processing,.beyond..basic.distillation,.is.required.to.convert.the.straight-run.products.into.finished.products.suitable.for.the.market.
. . .At.this.point,.the.first.comprehensive.LP.can.be.constructed.to.model.the.refinery.(including.feedstock.purchases,.process.operations,.product.blending.and.product.sales)..Optimization.of.this.first.model.will.confirm.whether.we.are.on.the.right.track.or.whether.adjustments.in.the.refinery.configuration.are.required.to.achieve.the.“best”.performance.….where.“best”.means.highest.profit..or.lowest.production.cost.
. •. .Using.the.model,.we.can.test.different.process.configurations.and.evaluate.project.staging.opportunities..A.typical.refinery.development.might.proceed.as.follows:
. . –...Start.with.a.simple.atmospheric.distillation.unit.
. . –...Add.a.catalytic.reformer.to.convert.heavy.naphtha.to.reformate,.a.high.octane.gasoline.blending.component.
. . –...Add.an.isomerization.unit.to.convert.light.straight-run.naphtha.to.isomerate,.another.high.quality.gasoline.blending.component.
. . –...Add.a.cracking.unit,.to.convert.all.of.the.heavy-boiling.fractions.(all.fractions.heavier.than.diesel.fuel).to.lighter-boiler.materials.and.thus.maximize.the.total.recovery.of.liquid.transportation.fuels.from.the.crude.oil.
. •. A.ll.of.the.above.possibilities.and.options.can.be.examined.on.paper,.using.LP,.to.ensure.that.we.develop.the.entire.project.in.an.optimal.way.
WINFIELD RESOURCES LIMITED
29
Personnel.on.Winfield’s.staff.have.provided.refinery.optimization.services.for.refiners.in.many.parts.of.the.world..Two.very.relevant.case.studies.are.1).a.nation-wide.optimization.study.for.CUPET,.the.Cuban.national.oil.company.and.2).another.comprehensive.study.for.the.Government.of.Bolivia.
CUPET.operates.four.refineries.in.Cuba..The.country.produces.some.indigenous.crude.oil,.but.not.enough.for.its.refineries..The.refineries,.even.operating.at.full.capacity,.cannot.supply.all.of.the.country’s.hydrocarbon.energy.needs..Cuba.therefore.imports.both.products.and.crude.oil..Our.mission.was.to.optimize.the.refinery.operations,.along.with.the.crude.oil.and.product.imports,.to.minimize.the.cost.of.supplying.petroleum.products.to.the.entire.country..
To.do.this.we.constructed.a.comprehensive.model.which.included.all.four.refineries,.all.product.and.crude.oil.imports,.transportation.and.marketing.activities..We.then.ran.the.model.to.find.the.“best”.way.to.operate.the.country’s.refineries..In.our.study,.we.discovered.that.the.refineries.were.not.able.to.achieve.a.global.optimum.due..to.a.disconnect.between.the.refineries.and.the.people.responsible.for.purchasing.imported.crude.oil..
The.importers.simply.looked.for.the.cheapest.available.feedstock.….or.for.a.seller.who.would.provide.crude.oil.in.exchange.for.sugar….and.the.refineries’.processing.limitations.were.not.considered..Rectification.of.this.problem.resulted.in.major.cost.improvements.for.CUPET.
Bolivia.has.four.refineries.which.process.Bolivia’s.light.crude.oil.to.produce.products.required.for.the.nation.al.market..Any.product.shortfall.requires.importation.of.products.and,.because.Bolivia.subsidizes.all.petroleum.products.within.the.national.market,.importation.of.products.is.very.expensive.for.the.Government..Our.mission.was.to.optimize.the.refineries.and.the.importation.activities.to.ensure.that.the.Bolivian.national.market.was.being.provided.with.products.at.the.lowest.possible.cost.
Winfield.Resources.Limited.is.commited.to.operating.its.refineries.in.a.way.that.makes.the.operation.economically.viable,.and.meets.the.needs.of.its.market.and.the.objectives.of.the.host.country..Tools.such.as.LP,.will.be.part.of.our.approach.to.ensure.that.these.ends.are.achieved.
WINFIELD RESOURCES LIMITED
30
TECHNICAL CONFIGURATION
FIGURE 7: Local Market Environment
FIGURE 8: EU: Gasoline Specifications
FIGURE 9: EU: Diesel Specifications
LPG
SR NAPHTHA
GASOLINE
KEROSENE
DIESEL
FUEL OIL 1%S
OTHERS
699
1169
-1489
762
87
4284
868
24
32
-38
18
2
87
20
LIBYA 2007NET TRADE BALANCE kbpd ktpa
SARIR
ES SIDER
AMNA
MTBE
HYDROGEN
NATURAL GAS
TOTAL FEEDSTOCKS
438.4
437.5
441.2
575
1078.1
308.0
58.5
58.5
59.0
70.4
6.5 $/MMBTU
59.5
FEEDSTOCKS $/t $/bbl
LPG
NAPHTHA
RAFFINATE
GASOLINE 10ppmS
BENZENE
P-XYLENE
KEROSENE/JET
DIESEL 10ppmS
HEATING OIL 0.1%S
LS FUEL OIL
HS FUEL OIL
GREEN COKE
SULPHUR
REFINERY FUEL GAS
LOSSES
TOTAL PRODUCTS
540
510
510
555
1059
1082
560
560
520
318
281
50
0
0
0
47.2
56.8
53.5
63.5
148.2
151.4
71.2
73.0
69.5
47.0
41.5
7.95
0
0
0
PRODUCTS $/t $/bbl
LPG 252,196 8,660
NAPHTHA 0 0
GASOLINE 10ppmS 2,914,877 76,462
KEROSENE/JET 739,134 17,450
DIESEL 10ppmS 7,901,035 177,649
HEATING OIL 0.1%S 0 0
LS FUEL OIL 0 0
HS FUEL OIL 193,549 3,931
GREEN COKE 625,945 11,822
SULPHUR 5,506 104
REFINERY FUEL GAS 551,767 12,556
LOSSES 95,892 2,182
TOTAL PRODUCTS 13,279,902 310,816
PRODUCTS tpa bpd / MMscfd
SARIR 6,665,763 150,000
MESSLA 6,614,139 150,000
MTBE
HYDROGEN
NATURAL GAS
TOTAL FEEDSTOCKS 13,279,902 300,000
FEEDSTOCKS tpa bpd / MMscfd
AROMATICS, vol% max
OLEFINS, vol% max
BENZENE, vol% max
OXYGEN, wt% max
SULFUR, ppm max
RVP, kPa
LEAD, g/l MAX
-
-
5
-
500
35-100
0.013
42
18
1
2.7
150
60/70
none
35
18
1
2.7
50/10
60/70
none
35
18
1
2.7
10
60/70
none
EN 2281993Euro II
Dir 98/702000Euro III
Dir 98/702005Euro IV
Dir 98/702009Euro V
POLY AROMATICS, vol% max
SULFUR, ppm max
CETANE NUMBER, min
DENSITY @ 15OC, kg/m3
DISTILLATION, T95 OC, max
n/a
2,000
49
820-860
370
11
350
51
845
360
11
50/10
51
845
360
8
10
51
845
360
EN 2281993Euro II
Dir 98/702000Euro III
Dir 98/702005Euro IV
Dir 98/702009Euro V
LPG
SR NAPHTHA
GASOLINE
KEROSENE
DIESEL
FUEL OIL 1%S
OTHERS
699
1169
-1489
762
87
4284
868
24
32
-38
18
2
87
20
LIBYA 2007NET TRADE BALANCE kbpd ktpa
SARIR
ES SIDER
AMNA
MTBE
HYDROGEN
NATURAL GAS
TOTAL FEEDSTOCKS
438.4
437.5
441.2
575
1078.1
308.0
58.5
58.5
59.0
70.4
6.5 $/MMBTU
59.5
FEEDSTOCKS $/t $/bbl
LPG
NAPHTHA
RAFFINATE
GASOLINE 10ppmS
BENZENE
P-XYLENE
KEROSENE/JET
DIESEL 10ppmS
HEATING OIL 0.1%S
LS FUEL OIL
HS FUEL OIL
GREEN COKE
SULPHUR
REFINERY FUEL GAS
LOSSES
TOTAL PRODUCTS
540
510
510
555
1059
1082
560
560
520
318
281
50
0
0
0
47.2
56.8
53.5
63.5
148.2
151.4
71.2
73.0
69.5
47.0
41.5
7.95
0
0
0
PRODUCTS $/t $/bbl
LPG 252,196 8,660
NAPHTHA 0 0
GASOLINE 10ppmS 2,914,877 76,462
KEROSENE/JET 739,134 17,450
DIESEL 10ppmS 7,901,035 177,649
HEATING OIL 0.1%S 0 0
LS FUEL OIL 0 0
HS FUEL OIL 193,549 3,931
GREEN COKE 625,945 11,822
SULPHUR 5,506 104
REFINERY FUEL GAS 551,767 12,556
LOSSES 95,892 2,182
TOTAL PRODUCTS 13,279,902 310,816
PRODUCTS tpa bpd / MMscfd
SARIR 6,665,763 150,000
MESSLA 6,614,139 150,000
MTBE
HYDROGEN
NATURAL GAS
TOTAL FEEDSTOCKS 13,279,902 300,000
FEEDSTOCKS tpa bpd / MMscfd
AROMATICS, vol% max
OLEFINS, vol% max
BENZENE, vol% max
OXYGEN, wt% max
SULFUR, ppm max
RVP, kPa
LEAD, g/l MAX
-
-
5
-
500
35-100
0.013
42
18
1
2.7
150
60/70
none
35
18
1
2.7
50/10
60/70
none
35
18
1
2.7
10
60/70
none
EN 2281993Euro II
Dir 98/702000Euro III
Dir 98/702005Euro IV
Dir 98/702009Euro V
POLY AROMATICS, vol% max
SULFUR, ppm max
CETANE NUMBER, min
DENSITY @ 15OC, kg/m3
DISTILLATION, T95 OC, max
n/a
2,000
49
820-860
370
11
350
51
845
360
11
50/10
51
845
360
8
10
51
845
360
EN 2281993Euro II
Dir 98/702000Euro III
Dir 98/702005Euro IV
Dir 98/702009Euro V
LPG
SR NAPHTHA
GASOLINE
KEROSENE
DIESEL
FUEL OIL 1%S
OTHERS
699
1169
-1489
762
87
4284
868
24
32
-38
18
2
87
20
LIBYA 2007NET TRADE BALANCE kbpd ktpa
SARIR
ES SIDER
AMNA
MTBE
HYDROGEN
NATURAL GAS
TOTAL FEEDSTOCKS
438.4
437.5
441.2
575
1078.1
308.0
58.5
58.5
59.0
70.4
6.5 $/MMBTU
59.5
FEEDSTOCKS $/t $/bbl
LPG
NAPHTHA
RAFFINATE
GASOLINE 10ppmS
BENZENE
P-XYLENE
KEROSENE/JET
DIESEL 10ppmS
HEATING OIL 0.1%S
LS FUEL OIL
HS FUEL OIL
GREEN COKE
SULPHUR
REFINERY FUEL GAS
LOSSES
TOTAL PRODUCTS
540
510
510
555
1059
1082
560
560
520
318
281
50
0
0
0
47.2
56.8
53.5
63.5
148.2
151.4
71.2
73.0
69.5
47.0
41.5
7.95
0
0
0
PRODUCTS $/t $/bbl
LPG 252,196 8,660
NAPHTHA 0 0
GASOLINE 10ppmS 2,914,877 76,462
KEROSENE/JET 739,134 17,450
DIESEL 10ppmS 7,901,035 177,649
HEATING OIL 0.1%S 0 0
LS FUEL OIL 0 0
HS FUEL OIL 193,549 3,931
GREEN COKE 625,945 11,822
SULPHUR 5,506 104
REFINERY FUEL GAS 551,767 12,556
LOSSES 95,892 2,182
TOTAL PRODUCTS 13,279,902 310,816
PRODUCTS tpa bpd / MMscfd
SARIR 6,665,763 150,000
MESSLA 6,614,139 150,000
MTBE
HYDROGEN
NATURAL GAS
TOTAL FEEDSTOCKS 13,279,902 300,000
FEEDSTOCKS tpa bpd / MMscfd
AROMATICS, vol% max
OLEFINS, vol% max
BENZENE, vol% max
OXYGEN, wt% max
SULFUR, ppm max
RVP, kPa
LEAD, g/l MAX
-
-
5
-
500
35-100
0.013
42
18
1
2.7
150
60/70
none
35
18
1
2.7
50/10
60/70
none
35
18
1
2.7
10
60/70
none
EN 2281993Euro II
Dir 98/702000Euro III
Dir 98/702005Euro IV
Dir 98/702009Euro V
POLY AROMATICS, vol% max
SULFUR, ppm max
CETANE NUMBER, min
DENSITY @ 15OC, kg/m3
DISTILLATION, T95 OC, max
n/a
2,000
49
820-860
370
11
350
51
845
360
11
50/10
51
845
360
8
10
51
845
360
EN 2281993Euro II
Dir 98/702000Euro III
Dir 98/702005Euro IV
Dir 98/702009Euro V
-..Libya.would.need.to.produce.about.40.kbpd.incremental.gasoline.which.is.currently.imported
-..Proposed.refinery.crude.processing.capacity.is.300.kbpd
WINFIELD RESOURCES LIMITED
31
FIGURE 10: ECONOMIC INDICATORS
Pricing.Scenario.-.Brent.benchmark.crude.oil.at.60.$/bbl
LPG
SR NAPHTHA
GASOLINE
KEROSENE
DIESEL
FUEL OIL 1%S
OTHERS
699
1169
-1489
762
87
4284
868
24
32
-38
18
2
87
20
LIBYA 2007NET TRADE BALANCE kbpd ktpa
SARIR
ES SIDER
AMNA
MTBE
HYDROGEN
NATURAL GAS
TOTAL FEEDSTOCKS
438.4
437.5
441.2
575
1078.1
308.0
58.5
58.5
59.0
70.4
6.5 $/MMBTU
59.5
FEEDSTOCKS $/t $/bbl
LPG
NAPHTHA
RAFFINATE
GASOLINE 10ppmS
BENZENE
P-XYLENE
KEROSENE/JET
DIESEL 10ppmS
HEATING OIL 0.1%S
LS FUEL OIL
HS FUEL OIL
GREEN COKE
SULPHUR
REFINERY FUEL GAS
LOSSES
TOTAL PRODUCTS
540
510
510
555
1059
1082
560
560
520
318
281
50
30
0
0
47.2
56.8
53.5
63.5
148.2
151.4
71.2
73.0
69.5
47.0
41.5
0
0
PRODUCTS $/t $/bbl
LPG 252,196 8,660
NAPHTHA 0 0
GASOLINE 10ppmS 2,914,877 76,462
KEROSENE/JET 739,134 17,450
DIESEL 10ppmS 7,901,035 177,649
HEATING OIL 0.1%S 0 0
LS FUEL OIL 0 0
HS FUEL OIL 193,549 3,931
GREEN COKE 625,945 11,822
SULPHUR 5,506 104
REFINERY FUEL GAS 551,767 12,556
LOSSES 95,892 2,182
TOTAL PRODUCTS 13,279,902 310,816
PRODUCTS tpa bpd / MMscfd
SARIR 6,665,763 150,000
MESSLA 6,614,139 150,000
MTBE
HYDROGEN
NATURAL GAS
TOTAL FEEDSTOCKS 13,279,902 300,000
FEEDSTOCKS tpa bpd / MMscfd
AROMATICS, vol% max
OLEFINS, vol% max
BENZENE, vol% max
OXYGEN, wt% max
SULFUR, ppm max
RVP, kPa
LEAD, g/l MAX
-
-
5
-
500
35-100
0.013
42
18
1
2.7
150
60/70
none
35
18
1
2.7
50/10
60/70
none
35
18
1
2.7
10
60/70
none
EN 2281993Euro II
Dir 98/702000Euro III
Dir 98/702005Euro IV
Dir 98/702009Euro V
POLY AROMATICS, vol% max
SULFUR, ppm max
CETANE NUMBER, min
DENSITY @ 15OC, kg/m3
DISTILLATION, T95 OC, max
n/a
2,000
49
820-860
370
11
350
51
845
360
11
50/10
51
845
360
8
10
51
845
360
EN 2281993Euro II
Dir 98/702000Euro III
Dir 98/702005Euro IV
Dir 98/702009Euro V
WINFIELD RESOURCES LIMITED
32
FIGURE 11:
TECHNICAL CONFIGURATION
HDk DCU
WINFIELD RESOURCES LIMITED
33
FIGURE 12: TECHNICAL CONFIGURATION
Main.items.to.be.confirmed:
-.Potential.crude.oils:.Sarir.and.Messla.similar.to.existing.Ras.Lanuf.refinery.-.Available.crude.oil.pipeline.and.harbour.facilities.for.products.off-take
TECHNOLOGIES – VDU
WINFIELD RESOURCES LIMITED
34
H2 H2 H2 N2 N2
N2 to filters
UPPERSURGEDRAIN
LOCKHOPPER
LOWERHOPPER
LIFT POT
N2 to filters
UPPER HOPPERSELUTRIATOR
REDUCTION CHAMBER
H2
R-1 R-2 R-3 R-4REGENERATOR
HYDROGEN
C5C5 FEED
OFF GAS
ISOMERATE
MP + nC6
MCP + CH + C7
Deisohexanizer Application
iC5 + DMB + nC5 + MCP + CH + C7
iC5 + nC5 + DMB
ISOMERIZATION DIH
FIGURE 12 CONT'D: TECHNICAL CONFIGURATION TECHNOLOGIES - LN ISOMERIZATION
FIGURE 12 CONT'D: TECHNICAL CONFIGURATION TECHNOLOGIES - CCR
WINFIELD RESOURCES LIMITED
35
FIGURE 12 CONT'D: TECHNICAL CONFIGURATION
TECHNOLOGIES - HYDROTREATMENTS
-.Naphtha.Hydrotreatment.-.Kerosene.Hydrotreatment.or.Sweeting.-.Gasoil.Hydrodesulphurisation.-.DC.Naphtha.and.Gasoil.HDT.
TECHNOLOGIES - VGO HDk
TECHNOLOGIES - DCU
HDS
HDN
HDA
HDC
PRE-TREATING HYDROCRACKING
Feed Products
WINFIELD RESOURCES LIMITED
36
FIGURE 12 CONT'D: TECHNICAL CONFIGURATION
TECHNOLOGIES - SRU
TECHNOLOGIES
-.Off-sites.&.Utilities.. -.Storage.tank.farm.(~100.tanks).. -.Usual.refinery.assets.(Boilers,.BFW,.CW,.WWT,.Flare.Gas.Network,.Fire.Fighting,…)
-.Co-generation.for.power.&.hydrogen.production.from.petroleum.coke
-.Desalination.plant(s)
To Fuel Gas or Recycle
Tall Gas
H3S
H3S+NH3+H2O
Air / O2
S
S
Sexport
Sour Gases
Sour Water
AMINO
CLAUSCLAUSPOLSULTIMATE
INCINERATOR THERMALOR CATALYTIC
SULPHUR DEGASSINGSTORAGE, FORMINGSOUR
WATER STRIPPING
REFINING UNITSHDS, HDT, ...
WINFIELD RESOURCES LIMITED
37
We.truly.appreciate.the.opportunity.to.serve.the.National.Oil.Company..
Winfield.Resources.Limited.looks.forward.to.working.with.the.Government.of.Libya,.the.NOC,.applicable..Insurance.Companies,.as.well.as.all.contractors.and.financing.sources.in.the.successful.construction.of.the..Ras.Lanuf.Oil.Refinery.
Respectfully.submitted,
WINFIELD.RESOURCES.LIMITED
...
Robert.Michael.Foley.President.Winfield.Resources.Limited
WINFIELD RESOURCES LIMITED
38