Chemicals Capability & Experience
Diammonium Phosphate Plant
Corporate Overview WorleyParsons is a leading global provider of professional services to the resources and energy sectors, and the complex process industries. We cover the full asset spectrum, both in size and lifecycle, from the creation of new assets, to services that sustain and improve operating assets. Our business has been built by working closely with our customers through longterm relationships, anticipating their needs, and delivering inventive solutions through streamlined, proprietary project delivery systems. Strong growth continues to characterize our performance both through organic development and through strategic acquisition as we strive to provide tailored services wherever our customers need us.
EcoNomics™ is our range of services and technologies that profitably embed environmental, social and financial sustainability into project delivery, across the asset lifecycle. It is a seamless extension of our established project delivery capability in the key areas of assessment, efficiency, and treatment & mitigation. We are committed to working with our customers to turn their sustainability objectives into good business practice.
Zero Harm is our corporate vision for health, safety & the environment (HSE). We are committed to our vision; it applies to all of our operations, at all times, in all locations, and at all levels of responsibility. We will actively work to align our expectations and behaviors with those required to achieve our vision through a dedication to continuous improvement. The launch of our integrity management framework, OneWay™, enables us to further align and consolidate our global systems and procedures and continue to work with our personnel to reinforce a culture that underpins our drive to achieve our corporate differentiator of industry leadership in HSE performance.
►►Minerals, Metals & Chemicals Hydrocarbons Power Infrastructure & Environment
Chemicals Execution of projects in challenging and competitive environments, proven local knowledge, and intellecutal property protection add to the many challenges facing the chemicals industry today. Our chemicals sub sectors include: • Petrochemicals • Plastics & Polymers • Inorganic Chemicals • Fertilizers • Specialty Chemicals
This makes it all the more important to choose a partner who not only has a sound understanding of these issues but is committed to delivering the most optimized and profitable solution for your project. We have a prominent position in the chemicals industry, delivering on mega projects, involving feasibility, design, procurement, construction management and total project management solutions, through to small studies. WorleyParsons is in the best position to offer tailored project solutions that meet our customers’ needs. We have developed a proven track record, successfully delivering 600 projects in 30 countries over six continents. We recognize our chemicals customers need immediate access to strong local technical expertise which is why we have strengthened our geographic presence. The benefit for customers is that we can put together the best people for their project, irrespective of where it is in the world or where our people are located.
WorleyParsons Project Phases
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Petrochemicals As petrochemical companies seek to capture growth opportunities from end markets they serve, we at WorleyParsons continually push ourselves to set high global standards for leading edge total project solutions that help our customers achieve their goals.
600+
petrochemical projects completed in 30 countries
59
process units for petrochemical mega projects
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Technology independent Our approach is technology neutral, providing customers with unbiased technology advice. Our strong relationships with technology providers, including all the major olefin, polyolefin, and other process licensors, means that we have intimate knowledge of all types of technology and are privy to innovations. This enables us to provide assistance to customers beginning with opportunity identification and project development through detailed design, construction, start up, and operations. Challenging environments Today a large number of the world’s petrochemical complexes are in the most extreme and challenging coastal and desert locations. Working under these technically complex and tough environmental conditions we have established a strong reputation for performance and safety in the petrochemical field. Our immense international project experience combines with local knowledge ensuring every stage of the project is optimally managed to improve profitability.
Project Rio de Janeiro Petrochemical Complex (COMPERJ) Customer Petrobras Project Location Itaborai, Brazil Phases COMPERJ will be the largest industrial undertaking in the history of Petrobras and Brazil. With a total cost of US$ 8.5 billion, it will be one of the largest petrochemical complexes in the world. Due for completion in 2013, COMPERJ will process 150,000 barrels per day of Marlin crude, which will increase Brazil’s heavy oil refining capacity and produce petrochemical products for internal and external markets. This complex will bring together a first-generation refining and petrochemical facility producing ethylene, propylene, benzene, and paraxylene. The second-generation units will produce styrene, ethylene glycol, polyethylene, polypropylene, and PTA and includes the supply of water, steam and electrical energy for the whole complex. WorleyParsons is providing proven mega project management and delivery know-how to yield optimum project execution to meet Petrobras’ goals and objectives. Our activities include; project integration services for the complex, licensing and basic design and frontend engineering design (FEED) for the Auxiliary Units, utilities and offsites, commissioning, and start-up. A unique approach includes the use of integrated workshops to define the key elements of site plan configuration, engineering systems for global implementation, procurement of key equipment and materials, constructability and logistics. WorleyParsons is providing early critical assessment to key areas, enabling Petrobras to obtain the data required to validate the aggressive schedule.
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11
mega petrochemical projects executed in the last ten years
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Plastics & Polymers Maximizing the economic benefit from polymers production can have a great impact on the financial return from a facility. WorleyParsons’ experience shows significant capability and know-how in developing world-class plastics and polymer plants for over 50 customers globally. Our plastics and polymers capability includes: • Polyethylene (PE) • Polypropylene (PP) • Polystyrene (PS) • Polyoxymethylene (POM) WPC • Polymethylmetacrylate (PMMA) WPC • Super Absorbent Polymer (SAP) WPC • Nylon
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Success in project delivery - large and small Every complex greenfield or brownfield polymer facility requires ongoing capital expenditure. The project execution methodology that delivers integrity and business improvements and life cycle return for customers is what differentiates WorleyParsons in many markets, enabling project teams to act swiftly and decisively to meet ongoing challenges, from small to mega projects. Full project development - from concept to completion Our project execution methodology delivers integrity and business improvements, and life cycle return for our customers and differentiates WorleyParsons in this market. For example, our breadth of experience encompasses feasibility studies, large capital projects, expansions, revamps, and major grass roots installations in plant types such as polyethylene (HDPE, LDPE, LLDPE); polypropylene (homopolymer, random and impact copolymer); polystyrene; poly-methyl methacrylate, and nylon.
Project The ACAI/NASA Project Customer BASF-YPC Company Limited (BYC); and BASF South America (BASF SA) Project Location Nanjing, China and Camacari, Brazil Phases In order to capitalize on emerging Super Absorbent Polymer (SAP) markets in China and Brazil, BASF SA has invested in a major capital venture of two SAP production facilities at two sites located in Nanjing, China and Camacari, Brazil. These complex plants will use advanced new technologies in acrylic acid processing, which is scheduled for production in 2014. Due to time constraints, BASF SA and BYC decided to capitalize on the synergies by cloning the two sets of plants, therefore maximizing efficiencies in design, schedule and resources. BASF SA and BYC chose WorleyParsons for the FEED, detail engineering, procurement and construction management (EPCM) of the two plants based on our significant presence in China and Brazil and the capability of our experienced team of specialists.
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6,000
KTA polymer capacity in projects delivered
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Inorganic Chemicals The Inorganics sector is diverse, however most sector players face similar challenges, as well as the ongoing challenge to manufacture at low cost. Our Chemicals Customers: • Albemarle • BASF • BOC Gases • Celanese • ChemaWEyaat • CSBP • Dow Chemicals • DuPont • Eastman Chemicals • Incitec Pivot • Ma’aden • Orica • PTT Ammonia • Ruwais Fertilizer Industries (FERTIL) • Sastech • Qenos
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Our team of specialists provide a wide range of technical and operational services to help our customers focus on profitable growth. We have executed over 80 plants and provide our customers with sustainable, long term solutions Environmental minds We have assembled a multidisciplinary team of specialists to assist our customers to reduce their carbon footprint. Our mission is to take a proactive approach to reduce emissions and improve energy consumption and resource use by embedding sustainability considerations into each stage of our EPCM services. Driving output At WorleyParsons we believe delivering performance improvements equips our customers to react with agility to opportunities and risks that allow them to develop a competitive advantage. This includes innovation, improved production techniques, supply chain re-engineering and low-cost sourcing, and identifying greater efficiencies in areas such as waste minimization, production processes and more effective controls. Our approach, balancing cost reduction with ongoing cost management, enables customers to review and streamline technical processes across their asset portfolio.
Project Project Trident Customer Orica Project Location Kooragang Island, Newcastle, Australia Phases Orica is planning an expansion of their ammonium nitrate (AN) production capacity located at Kooragang Island, Newcastle, Australia from 430,000 tpa to approximately 750,000 tpa. This involves a new nitric acid plant, ammonium nitrate solution plant and a new AN drying plant using Orica’s own technology. During the early stages of the project a number of technology suppliers were evaluated by WorleyParsons. Our technology neutral position meant that we could objectively evaluate all alternatives. The outcome was a more competitive bidding process resulting in a lower estimated CAPEX for the customer and the choice of technology supplier, which initially was not considered. WorleyParsons was then able to work with the chosen technology supplier to provide advice on Australian standards and modularization to ensure the overall success of the project. WorleyParsons’ scope included defining the basis of design, initial concepts, site layouts and initial cost estimates for the Outside Battery Limits (OSBL) and Inside Battery Limits (ISBL) scope along with advice on Australian standards for the ISBL FEL1&2 (Front End Loading) and AN drying plant FEL1&2. Subsequently WorleyParsons was awarded the FEL3 and detailed design for the AN drying plant. WorleyParsons modularization experts were utilized to create a modular design which is anticipated to provide significant cost savings to Orica whilst reducing on site HSE risks.
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Largest
technical grade ammonium nitrate facility in the world
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Fertilizers At WorleyParsons we have been adding value by providing innovative solutions to fertilizer companies globally. We have successfully delivered more than 30 phosphorus, nitrogen and potassium fertilizer projects around the world. Services include: • Program Management Consulting (PMC) • Engineering, Procurement and Construction Management (EPCM) • Front End Engineering Design (FEED) • Feasibility • Asset support
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We help our customers confront the industry’s most challenging issues and changes by developing effective solutions and strategies to help them unleash potential value in end markets. Distinctive technical capability At WorleyParsons, our people are not only technically strong, but also have strong industry experience and expertise. In our work with fertilizer companies, our phosphate and process experts apply deep technical, analytical, industry and business process skills into our solutions to help our customers bring together strategy and execution, manage complexity and risk and drive innovation. Effective Program Management Consulting (PMC) We support our customers all the way through the complex lifecycle of a fertilizer facility. Our knowledge has been gained from our role as PMC contractor and successfully delivering 76 mega projects, with a total installed cost of at least USD1 billion, in some of the world’s most challenging environments. We provide a holistic view to guide project practices throughout the project lifecycle, using our proven tools and methods for safety, design, procurement, commissioning, quality, cost, and scheduling.
Project Ma’aden Phosphate Development Customer Ma’aden Phosphate Company Project Location Saudi Arabia Phases The Ma’aden Phosphate Development located in Saudi Arabia is one of the world’s largest producers of di-ammonium phosphate, a fertilizer for use in grain and horticulture. This $4.5 billion (direct capital cost) phosphate project managed by WorleyParsons focuses on the economic development of the major phosphate resource rock located at Al Jalamid. The full project development involves the design and construction of a beneficiation plant and associated infrastructure located at Al Jalamid, a major fertilizer complex and port facilities at Ras Az Zawr, a new 1400 km rail link between Al Jalamid and Ras Az Zawr for processing and a power generation plant. The success of this world leading project is directly due to teamwork. WorleyParsons’ commitment to supporting Ma’aden in maintaining their schedule and creating a multi-national workforce focused on safety, quality and cost has been invaluable in assisting Ma’aden to achieve their business objectives.
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50m
hours worked without an LTI on the Ma’aden Phosphate project
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Specialty Chemicals At WorleyParsons, we help our customers grow their specialty chemicals business in new and existing markets. We do this by listening to our customers and using the knowledge gained from successfully delivering business solutions that meet their needs. Our specialty chemicals areas of expertise include: • Acetic acid • Acrylic acid • Silica • Carbon black • Pesticides • Esters • Polymer additives • Titanium dioxide
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Global excellence, cost efficiencies No matter the complexity of the project, our global procurement strategy enables our chemical customers to control costs while keeping up with evolving technologies. Our collaborations with large and small equipment suppliers keeps us well informed on current economic and market conditions allowing us to negotiate commercial agreements and pass cost efficiencies directly to our customers. Resourceful As a global company, our resources are plentiful, thanks to our investment in the transference of global knowledge, skills and technological innovation. But we also take a personal approach in our customer relationships and ensure that we have the right people to serve each customer. For example, if needed, we can locate professionals with a specific skill set and facilitate their deployment to the customer’s location anywhere in the world.
Project MATCH Project Customer Evonik-Degussa Specialty Chemicals Project Location Shanghai, China Phases Evonik Industries, whose chemicals business was formerly known as Degussa, has invested in a greenfield integrated methyl methacrylates and methacrylate specialties production plant in Shanghai, (known as MATCH). This US $350 million world-scale facility produces products to supply the optoelectronics, paint and adhesives, and automobile industries. WorleyParsons commenced early in the project as part of an integrated team to support the government approval process and develop a preliminary design package. Involvement continued through basic engineering and the provision of EPCM services for the process units and all related infrastructure and utilities. The use of state-of-the-art design tools and our extensive Chinese procurement capability enabled construction to commence in September 2007. The total site workforce peaked at 2,500 people before successful Mechanical Completion in August 2009. The MATCH project continues our long relationship with Evonik – Degussa, where safety is at the forefront of our performance goals.
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2,170 KTA cumulative product capacity
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Sustainability Changing commercial and ecological drivers are alerting operating environments for businesses worldwide. Today, our Chemicals customers face the challenges of increased regulation, mitigating risk and incorporating environmental, social and financial sustainability into their decision-making and project development. Our sustainability services include: • Developing sustainability policy and objectives • Sustainability management and reporting • Greenhouse gas and carbon management • Climate change adaption • Embedded EcoNomicsTM - integrating sustainability in project delivery • EcoNomicsTM assessments sustainable decision making
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By working closely with our customers we convert their sustainability goals into tangible business solutions - reducing energy use, eliminating waste, reducing emissions, increasing direct localized economic activity and improving social outcomes. This means our customers can efficiently and effectively optimize their operations. We support our customers by looking at the needs of their organizations first, from policy to projects, recognizing the need for appropriate policy objectives to drive sustainability throughout operations. Addressing the ‘how do we really make sustainability happen’ is where we make all the difference. EcoNomicsTM - Building sustainability into project design and delivery We have developed a unique framework which ensures sustainability objectives are identified and delivered right throughout all project phases - our EcoNomicsTM initiative. This approach establishes systematic processes which deliver a structured method to opportunity identification, assessment and implementation in line with the engineering process. This helps our customers manage risk and effectively respond to their rapidly changing business environment.
164m
tonnes per year of CO2 saved for the past five years
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Improve Improve is WorleyParsons’ service for brownfield operations, focused on improving our customers’ business outcomes. It is a tailored service to meet the needs of individual sites by sustaining assets and optimizing operational performance.
260+
alliance or long term contracts globally
Delivering more value Improve delivers value, year on year, for our long term customers. At WorleyParsons, we believe successful Improve contracts are based on strong long term relationships utilizing trust and teamwork. This enables everybody to focus on the critical issues that drive long term contract performance improvement, such as safety, optimal capital spend and efficient and effective use of resources. We deliver an estimated US $13 billion of total value to our customers annually. Improved business outcomes Using the knowledge accumulated from over 260 international alliances or long term contracts, we have developed a culture and a suite of unique tools, systems and delivery methodologies that can help us develop and manage portfolios, deliver projects in the most efficient and cost effective manner and then report and share outcomes across our teams and the customer’s enterprise. These tools lead the industry and are custom designed to easily integrate with our customers’ operating protocols. They establish our platform for continuous improvement in the relationship level whether at site or enterprise level.
Project Global EPCM Alliance Customer DuPont Project Location Canada, China, UK Phases WorleyParsons provides EPCM services for capital projects to support facilities in Canada, China and the United Kingdom, with discretionary opportunities in the United States for projects with an individual value greater than USD10 million, and provision to support work in Brazil. WorleyParsons also provides site based teams and support to DuPont’s manufacturing facilities. We deliver these services through our global network of offices and by working with DuPont in integrated teams either at manufacturing facilities or in DuPont’s regional centers. This alliance includes approximately 250 WorleyParsons personnel globally.
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Our Vision
WorleyParsons will be the preferred global provider of technical, project and operational support services to our customers, using the distinctive WorleyParsons’ culture to create value for them and prosperity for our people. Leadership
Agility
• Committed, empowered and rewarded people • EcoNomics™ – Delivering profitable sustainability • Integrity in all aspects of business • Energy and excitement • Minimum bureaucracy
• Smallest assignment to world-scale developments • Local capability with global leverage • Responsive to customer preferences • Optimum solutions customized to needs
Relationships
Performance
• Rapport with all stakeholders • Open and respectful • Collaborative approach to business
• Zero harm • Results for our customers and employees • Creating wealth for our shareholders • World-class resources, capability, and experience
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For further information about our global capability, email chemicals@worleyparsons.com
www.worleyparsons.com