freshhh2012 MOiL Tycoon

Game Rules
!!Note: the changes in the game rules are marked as follows:
Minimal bottom hole pressure at

About the game

The game is a turn-based strategic game, aiming to imitate reality as much as possible. However it still contains several simplifications to make the game easier to understand and more entertaining to play.

Game concept

You are the managers of a well-established oil company with a diversified upstream and downstream portfolio continuously seeking new upstream opportunities to replace the reserves and the production, as well as to improve the efficiency of your refineries. Freshhhfield had decided to open its oil industry to international players recently, due to a lack of funds for putting into production the sizeable discoveries made by the National Oil Company of Freshhhfield. Several companies entered the First International Bidround of Freshhhfield which resulted in a significant increase of production and oil export levels of the country. Your company owns four oil fields in Freshhhfield. Thanks to the success of the international bid round, Freshhhfields two neighbouring countries, Freshhhia and Freshhhrock have also opened up and the three countries formed the Oil Producer Fresshian Countries OPFC Area. Thanks to your long-lasting successful international track record and your presence in Freshhhfield you are one of the few companies invited to operate in the OPFC Area. The upstream industry has a long history in Freshhhia and Freshhhrock as well, however most discovered fields could not be developed due to the lack of funds in these closed economies in recent decades. The primary objective of OPFC countries is to find operators who commit themselves to efficiently developing and producing the already discovered hydrocarbon fields. Therefore no exploration licenses will be granted, and you can only bid for discovered fields. You are delegated exclusively to the management of the OPFC Area portfolio, and you dont have to deal with other assets of the company. Nevertheless you have access only to the free funds of your own portfolio to acquire new opportunities here. Your aim is to prove that you are the best managers by maximizing the cash generation of your companys Freshhhian upstream portfolio by creating value added with both upstream and downstream operations.

You start the upstream game with 500 million F$ (Freshhh Dollar) of cash at hand. You will also receive 5500 million F$ for downstream operations.

Timing

Contestants are going to play for 18 turns. 1 turn in the game means 24 hours in the real world, so in every 24 hours, there is going to be a turn change. (GMT 12:00 next round financial accounting and the effects of decision-making only show when a turn change occurs)

Financing

You start the game with a separate Upstream and Downstream budget with 500 million F$ in Upstream and 5500 million F$ for Downstream. You have a revolving credit of 1500 million F$ total at 10% interest rate. You can use this credit facility to finance up to 60% of your investments (Downstream and Upstream too). In the meantime you cannot use the credit to acquire new fields. If you exceed the 60% limit on any of your investments, the penalty interest will be 30%.

UPSTREAM
Playing the game

In each turn you will be offered the chance to acquire oil fields in the OPFC Area (5 fields per turn until turn 10, 6 fields in turn eleven and 0 fields thereafter). Each license will be offered only once. Specific geological, fiscal and economic data and the price of the fields will also be rendered. With the help of this information you will have to evaluate the fields and purchase them if you have sufficient amount of funds and of course the opportunity is prospective enough. Your funds are scarce so dont waste them on low return projects. If the IRR of a project is just a few percents, it might be better to wait for more suitable opportunities. After the purchase your task will be to work out and fulfil a field development program on the field.

Your performance and the final scoring is based on the cash generated your companys Freshhhian portfolio. We will also take into consideration and evaluate the effects of your decisions made in the final turn. (By running a 19th turn automatically without the opportunity to make any decisions right at the end of the game.) You can see country specific information or elect the lincenses in the Locator. By selecting an active license area a list of input data will appear (for details see Inputs section) and you can also acquire or go to the selected field. When you successfully sign an agreement, you will be navigated to another screen where the map of the license area will appear. Here you will find 4 panels/ buttons: Field details shows the wells and facilities in operation and under construction and the fields production performance Financial data indicates the main financial results relating to the given license area Development panel contains facilities that can be constructed. For detailed information about building, please see section Field Development, facilities and costs. Abandon field button shall be used if the player wants to stop the operation of a field.

Selling the produced hydrocarbons

Crude oil The oil quantity that leaves the license area is sold on the average international market price at the end of the year. Note that there can be several bottlenecks of oil sales. (See the facilities section for details.) Natural gas The associated natural gas is used for power generation, or transferred to the government for free, according to the license agreements in force in the OPFC area. (This is done automatically; the teams do not have to deal with gas at all.)

Fiscal regime

If the teams want to plan their revenues precisely, they have to model the fiscal regime of the license agreements as well. Each country has its own tax regime but they are quite similar. The OPFC 3

countries use simple royalty system. According to the regulations a single tax is levied on the oil revenue of the company. For the tax rates of the countries please see the table below. Tax rates Freshhhfield 70% Freshhhia 75%

Freshhhrock 80%

Inputs & miscellaneous rules

The following data will be provided for each field.

Field data Depth API Rsi Area Average thickness Porosity Heff/H Initial water saturation Permeability Distance from main road Distance from main train line Distance from main pipeline [ft] reservoir depth API gravity [scf/bbl] Gas-Oil Ratio [acre] [ft] [%] 1/1 [%] [md] [miles] Area of the field Average thickness of the reservoir Porosity of the reservoir rock The ratio of effective and average thickness Initial water saturation in the reservoir Permeability of the reservoir rock In case a CPU is built, its distance from the closest main road In case a CPU is built, its distance from the closest main rail line In case a CPU is built, its distance from the closest main hydrocarbon route.

[miles]

[miles]

Furthermore, information on the country in which the field is located, will also be granted. These data are constant throughout the game. These are the following:

Country data Average temperature Geothermal gradient OPEX parameter CAPEX parameter Government take The % of the generated oil revenue withdrawn by the government [F ] [F /1000 ft] average atmospheric temperature

average geothermal gradient OPEX and CAPEX levels are somewhat different in the countries you operate

There are some technical parameters which are constant regardless of the country or field. These are:

Constants Atmospheric pressure Methane density Well diameter 14.7 psia

0.037463 pound / cubic ft 0.29 ft the diameter of the well sections that cross the reservoir

Oil price varies throughout the game. In the first period the price is F$ (Freshhh Dollar) 100 /bbl.

Evaluation of fields production curve

Before purchasing a development concession you will need to evaluate it. To do this, you have to calculate the oil in place, the recoverable reserves and finally the production profile while also considering the necessary investment, operating costs and taxes. The recoverable reserve size (i.e. the recovery ratio) and the production profile are dependent on your field development scheme. (Please see next section for detailed information on field development.) Note that the fields are developed with pressure maintenance technology and ESPs (electronic submersible pumps) are used at each production wells. With the above specified data set and with the use of the Vasquez and Beggs (1980) formula, you can calculate - the Bubble point pressure, the Oil formation volume factor, and the Original reserve for undersaturated reservoir. 5

Following that, OOIP Original Oil In Place can be calculated During the Recoverable Reserve calculation, use Beggs and Robinson (1975) for the oil viscosity calculation McCain (1991) for the water viscosity calculation. The water is assumed to be freshhh water without any salt content. For estimation of the recovery factor with pressure maintenance technology please use the correlation issued in API Bulletin D14 (1967) The production is separated into two phases, waterless production and production with water. The total liquid (water+oil) production level of a field with a given well network is constant in the entire life of a field (without taking into consideration the bottlenecks of the surface infrastructure) but watercut of the production changes in time. For the calculation of the production profile you may use the following formulas:

For waterless production portion (from sensitivity calculation made by numerical simulation) Wlp= waterless (till 1% of water contain) production portion of the total production Wlp=0.6047-0.035*log(o/w)+0.02861*log(Wd)-0.0342*log(h)+0.06*(heff/h)-0.0067*log(k) where; (Wd) Well distance interval = 2000 < distance between the injectors and producers < 10000 [ft] Reservoir total thickness interval (h) = 40 < thickness < 300 [ft] Permeability interval = 1 < k < 1000 [mD] Over (or below) the limits the maximal (minimal) limit value has to be used

Distance between injectors and producers = 2*(A/(n+m)/3.14)^0.5 where: A: field area [sq ft] n: number of producers m: number of injectors 6

ROOIP in the waterless production phase =ROOIP*Wlp* Sp, where Sp= Scheme parameter, a correction factor depending on the injection well pattern: At five point system (producer -injector ratio = 1) Sp=1 At seven or four point system (producer -injector ratio = 2) Sp=0.9 At nine point system (producer -injector ratio = 3) Sp=0.8 Sp can be calculated directly from the final producer-injector rate for a middle point

When the produced oil amount in the waterless production phase exceeds ROOIP*Wlp* Sp, the waterless phase alters to production with water phase. In production with water phase For Field level Water Oil Ratio prediction use Timmermann (1971) formula, where; Np= cumulative oil production [bbl], its domain: ROOIPWlp > Np > ROOIP a, b = reservoir specific constants, can be determined from the first and last point of the curve 1st point (starting of the water production) WC=1%, Np=ROOIPWlp 2nd point (end of potential production) WC=99%, Np= ROOIP

For well level estimations you may use the following equations Average producer productivity equation:

where:

qf = qo+qw [bbl/d] re=drainage radius [ft] rw= wellbore radius [ft]

re = (A/n/3.14)^0.5 A: field area [sq ft] n: number of producers

Estimation of the average injector final productivity:

where iw [bbl/d] Kw= average water permeability (assumed to be equal to k) rei = middle distances between the injectors and producers rei = (A/(n+m)/3.14)^0.5 where: A: field area [sq ft] n: number of producers m: number of injectors

As the game itself, the model for the estimation of the production of a field should also be built using 1 year long periods.

Field Development, facilities and costs

To bring up the precious oil from the depths of the earth, you will need to develop the field. For this purpose, producer and injector wells are needed as well as a well-designed surface facility. The design of the transportation capability is also your task. For a well-functioning field development program you need to focus on the produced amount, the capacities of the equipment (bottleneck effect) and the timing of your development. Both the production and injection capacity, as well as the surface processing or transportation capacity can be the bottleneck in the system. Also, according to the rules of OPFC, the daily oil production of a field cannot be greater than one third of its storage capacity. It is important to optimise the number of wells and capacity of the surface infrastructure to make the operation of the field as efficient as possible. Before starting the field development you have to take into account thatThe granted concession rights are valid for 20 years or turns.All fields need to be developed with pressure maintenance technology.For security reasons the maximal drawdown pressure at water injector wells is 1500 psia. Minimal bottom hole pressure at producer wells is 50% of reservoir pressure. Pressure build-up follows hydrostatic tendency. g is 10 m/s2. In the Development panel you will find the facilities that can be constructed (Producer well, Injector well, Oil processing train, Storage tanker, Road, Rail and Pipeline transportation units). By clicking on Investment button, you can see the CAPEX of the units to be construced. You can select the number of units (in case of wells), or the capacity (in case of other facilities). When you have set the desired number or capacity of all the facilities, you may select Accept. Keep in mind that there are certain limitations for the construction of production facilities. Note that in one turn you are only able to access the build panel once. That means that you have one opportunity in each turn to decide what facilities are to be constructed. Limits for players' inputs Maximum unit/ capacity built in period Production wells+Injector wells Oil processing train Storage tanker Export route - road piece bbl/d bbl bbl/d 10 50,000 150,000 50,000 Step/interval on the slider 1 1,000 1,000 1,000 Maximum pieces/ capacity built per concession N/A 4 trains* 6 tanks* 50,000

Export route - rail Export route - pipeline

bbl/d bbl/d

100,000 500,000

1,000 1,000

100,000 500,000

* Note: The number of units is maximised not the capacity. It can happen that the revenues of a field will not cover the OPEX and the taxes payable for the given field. In this case you can abandon the field at zero charge in each period. However, you cannot abandon a field if there are ongoing construction works within its perimeters. Below you will find a summary of the different equipment and facilities that could be developed and the cost-functions of the CAPEX and OPEX related to them. CAPEX is charged when the construction order is given (except for Oil Processing train). When the Processing train is being constructed the first part of the CAPEX is charged on the spot while the remaining parts are charged at the beginning of the following turns.Facilities start the operation in the turn following the construction except for the Processing train that is in operation from the 3 following the start of construction. Production wells are the elemental tools of oil mining. CAPEX of one unit depends on the depth to be drilled and geological factors. The construction costs contain the installation of ESP (Electrical Submersible Pump), pipelines connecting to the CPU (Central Processing Station) and other well site infrastructure. As pressure maintenance technology is used for field development, injector wells must also be drilled Injector wells are fed by the water of nearby rivers and lakes. Significant part of operational costs of wells connected to the amount of liquid produced, however the regular maintenance of wells requires notable financials as well. Capital and operational costs for producer and injector wells for can be calculated as follows:. Production well CAPEX - fix CAPEX - variable OPEX - fix OPEX - variable Production or injector wells drilled in period [#] * F$ 5 mln/well Production or injector wells drilled in period [#] * F$ 0.2 mln/1000 ft * Reservoir depth [1000feet]^1.5 Production or injector wells in operation [#] * F$ 0.25 mln/well/year Produced or injected liquid amount [MMbbl/year]^0.8 * F$ 0.3 mln/MMbbl
rd

year

Oil processing train or CPU is the heart of each oil field. Their main task is to transform the produced raw oil into a transportable and marketable quality product. The construction of an oil processing train takes 3 years. CAPEX emerges as follows: in the first year 30%, in the second year 50%, in the third year 20% of total cost. As evident as it is the construction cost depends on the capacity of the unit, with significant initial investment. The OPEX of the unit is also related to the maximal capacity. One processing train can be built in each period (until reaching 4 trains) of which the minimal capacity is 1,000 bbl/day while the maximal capacity is 50,000 bbl/day.

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Oil processing train CAPEX - fix CAPEX - variable OPEX - fix OPEX - variable F$ 20 mln Processing train capacity built in period [Mbbl/d]^0.9 * F$ 8 mln/(Mbbl/d) Processing trains in opearation [#] * F$ 0.5 mln/train/year Processing train capacity [MMbbl/year] ^0.8 * F$ 1.8 mln/MMbbl

Storage tankers are required for temporary oil storage, as in some cases the transportation is not possible immediately. CAPEX of these facilities are proportional to the size and capacity of the unit. However the operational costs are unit based. One tanker can be built in each period (until reaching 6 tanker units) of which the minimal capacity is 1,000 bbl/day while the maximal capacity is 150,000 bbl/day. Storage tanker CAPEX - fix F$ 1 mln

CAPEX - variable Storage capacity constructed in period [Mbbl]^0.9 * F$ 0.5 mln/Mbbl OPEX - fix OPEX - variable Storage tankers in operation [#] * F$ 0.1 mln/#/year N/A

Players may choose between three different means of transportation. One transportation system can be built in each period from all types of transportation infrastructures. For road transportation a road connecting to the main system must be built together with truck filling heads. Road CAPEX must be paid in the first year road is constructed and only have to be paid. Whereas filling station CAPEX must be paid each time additional road transport capacity is constructed. OPEX of road has fix part due after a road is constructed and a variable part depending on the length of the road. Fix filling station OPEX must be paid based on the number of filling stations in operation. The external transportation cost in case of road transport is 7 F$/bbl (in excess of the CAPEX and OPEX of the facilities). One road transportation unit can be built in each period (until reaching the total road transportation capacity of 50,000 bbl/d) of which the minimal capacity is 1,000 bbl/day while the maximal capacity is 50,000 bbl/day.

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Road CAPEX fix F$ 1 mln

CAPEX - variable Road lenght [mile] * F$ 0.5 mln/mile OPEX fix OPEX - variable F$ 0.1 mln/year Road lenght [mile] * F$ 0.1 mln/mile/year

Truck filling station CAPEX fix CAPEX - variable OPEX fix OPEX - variable F$ 1 mln Truck filling capacity built in period [Mbbl/d]^0.8 * F$ 0.5 mln/(Mbbl/d) Truck filling stations in operation [#] * F$ 1 mln/#/year N/A

For transportation with train a pipeline to and a filling station at the nearest rail line must be constructed. Pipeline CAPEX has a notable large fix part and a variable part dependent of the length and the capacity of the pipe. CAPEX of filling station follows the same logic, self-evidently without taking into consideration the distance. Note that each time a new pipeline is constructed a new filling station must also be built. Fix OPEX of both units is based on the number of facilities built while variable OPEX of the pipeline depends on its capacity. The external transportation cost in case of rail transport is 5 F$/bbl (in excess of the CAPEX and OPEX of the facilities). One rail transportation unit can be built in each period (until reaching the total rail transportation capacity of 100,000 bbl/d) of which the minimal capacity is 1,000 bbl/day while the maximal capacity is 100,000 bbl/day.

Pipeline to rail filling station CAPEX - fix CAPEX variable OPEX fix OPEX - variable F$ 10 mln Pipeline capacity built in period [Mbbl/d]^0.5 * F$ 0.16 mln/(Mbbl/d) * Pipeline lenght [mile] * CAPEX variable Length parameter F$ 1 mln/mile Pipelines to filling stations in operation [#] * F$ 0.1 mln/#/year Pipeline capacity in operation [MMbbl/year] * Pipeline lenght [mile] * F$ 0.002 mln/MMbbl

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Rail filling station CAPEX fix CAPEX - variable OPEX fix F$ 5 mln Rail filling capacity built in period [Mbbl/d]^0.8 * F$ 2 mln/(Mbbl/d) Rail filling stations in operation [#] * F$ 2 mln/#/year

The third mean of transporting the crude oil to the international market is using an pipeline. In this case a pipeline to the nearest international transportation pipeline and a connection point must also be constructed. If pipeline capacity has to be increased, a new pipeline and a separate connection point has to be built. The CAPEX and OPEX functions of these facilities are quite similar to that of the railway units, however they have significantly higher initial costs. Meanwhile the external transportation cost in case of pipeline transport is 3 F$/bbl (in excess of the CAPEX and OPEX of the facilities). One pipeline transportation unit can be built in each period (until reaching the total road transportation capacity of 500,000 bbl/d) of which the minimal capacity is 1,000 bbl/day while the maximal capacity is 500,000 bbl/day.

Pipeline CAPEX - fix CAPEX variable OPEX - fix OPEX variable F$ 10 mln] Pipeline capacity built in period [Mbbl/d]^0.5 * USD 0.16 mln/(Mbbl/d) * Pipeline lenght [mile] * USD 1 mln/mile Pipelines in operation [#] * F$ 0.1 mln/#/year Pipeline capacity in operation [MMbbl/year] * Pipeline lenght [mile] * F$ 0.002 mln/MMbbl

Connection point CAPEX - fix CAPEX - variable OPEX - fix OPEX - variable F$ 20 mln Pipeline capacity [Mbbl/d] * F$ 3 mln/(Mbbl/d) Connection points in operation [#] * F$ 0.5 mln/#/year N/A

OPEX is incurred from the year the facility is in operation. OPEX is charged at the end of each turn. Parts of OPEX that not depend on the actual throughput of a unit are paid for all the commissioned infrastructure irrespective of their utilisation. It is important to note that: All costs are multiplied by a Country factor representing the price differences of different countries.

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Construction of facilities takes 1 year (except for Oil processing trains). The operation begins in the year following the construction year. Facilities operate 300 days a year, taking into consideration the time spent on repair, adjustment and maintenance. In case more than one means of transportation is available, oil is transported via the cheapest way. If the capacity is not enough the rest of the production is transported via other existing means.

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REFINERY

Game concept

A regional company sold its refinery construction. Your company has bought it, and it is your task to make it as profitable as possible. Gasoline and diesel product lines have already been built. The refinery will be operational from the start. Units available from the start: Crude Distillation Unit (CDU) Light Naphtha Hydrotreater Heavy Naphtha Hydrotreater Light Naphtha Isomerisation Unit CCR Reformer Unit Gasoil Hydrotreater The refinery will use crude bought from the market. The utilization rate can be set by adjusting the imported crude volume. Due to the limitations of technical processes, the annual refinery (CDU) utilization rate can not be less than 60%. As a simplification, this restriction does not apply for other refinery units. The minimum imported crude volume is always set automatically to match the minimum utilization rate. Some units have a maximum capacity specified. For the other plants, where it is not specified, there is no maximum throughput limit. The company will be able to convert the products into money at market prices. During the game, you have to make several decisions to operate and expand your refinery in an optimal way. The goal is to achieve maximum amount of money at the end of the defined period. The aim of the programmers was to create a game as realistic as possible, but it still contains several simplifications to make the game easier to understand and more entertaining to play. Here you can find a short term prognosis about the changes in refinery product prices (as the game progresses more data will be avaiable and changes will be indicated in the game rules)

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UNIT\TURN
Crude oil LPG Petchem Naphtha Kerosene Diesel Petchem & Heating Oil Light Fuel Oil Heavy Fuel Oil Bitumen Propylene Gasoline Base Gasoline Coke Sulphur F$/bbl F$/t F$/t F$/t F$/t F$/t F$/t F$/t F$/t F$/t F$/t F$/t F$/t F$/t

2012
99,852 837,541 909,460 1064,829 892,814 903,040 705,034 604,290 689,467 1274,326 990,169 912,607 285,714 71,429

2013
105,729 960,714 922,363 1029,971 1021,531 804,163 775,513 630,074 711,050 1305,701 1071,956 1005,897 285,714 71,429

2014
96,598 870,170 819,756 1007,491 959,270 754,013 573,474 504,886 672,117 1439,471 965,497 817,573 285,714 71,429

Playing the game

Each turn you have to make different decisions to optimize the efficiency of your refinery. There will be operational decisions. You can: Alter the path of different refinery streams by splitters Choose catalyst for HDS/MHC Unit Along the way, you can construct new facilities to keep up the competitiveness of your company and to fulfill the environmental regulations and product qualities. Not all technologies are available from the start. You can see your opportunities in the following table:

from 2012 HDS-MHC HDS-MHC Revamp DCU HPP FCC Claus Unit BBU available not available not available not available avaiable not available not available

from 2014 available available not available not available avaiable not available not available

from 2016 available available available not available avaiable not available available

from 2018 available available available available avaiable available available

Plant availability for construction

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Utilities

Fuel: the energy consumed in the process to heat up the materials to the required temperature. Some units produce fuel gas, but that is not sufficient for the refinery. Excess fuel is bought from the market as natural gas. Natural gas is also the feed of the Hydrogen Plant. The heating value is the same for the produced fuel gas from all refinery units and the natural gas: 50 GJ/t. If more fuel is produced in the refinery units, than consumed, the excess fuel gas is burnt on the refinery flares. Electricity: mainly intended to propel the pumps and move the feed and products, but used also for light and for supplying control systems. Cooling water: used in cooling processes for condensation and temperature control.

Steam: used for technological processes, heating and stripping. Some units produce more steam, than the amount necessary for operation. This is indicated with a negative value in steam consumption. If a unit produces steam then the excess steam is redirected to other units for usage but it can not be sold on the market.. If the amount of produced steam is not sufficient, the necessary amount is bought from the market. Hydrogen: Hydrogen is used in hydrotreater and isomerisation units. The price of the hydrogen varies in time. Hydrogen can be produced or bought from the market. In the first part of the game external hydrogen is purchased for 5000 F$/t, but starting from 2020 the hydrogen price increases dramatically to 20000 F$/t (due to the availability from a different supplier). In case of more hydrogen is produced in Reformer unit, than needed for refinery processes, the excess of hydrogen is burnt on the refinery flares. Catalyst: As a simplification, catalyst expenses are calculated as utility, except the HDS/MHC unit, in which it is your task to change the catalyst every two years. Catalyst price is specified for each unit. UTILITY (UOM) Fuel (F$/GJ) Electricity (F$/MWh) Cooling water (F$/1000 m ) Steam (F$/GJ)
3

Price 12.4 106 112 10.4

Utility prices

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For all refinery units utilities are calculated proportional to the feed. Consumed hydrogen is not calculated in the feed, but it appears in the product. That is why hydrogen consuming units have an overall yield over 100%.

PROCESSES IN THE REFINERY

Crude Distillation Unit (CDU)

The first step in a refinery is the distillation of crude into different fractions. Lighter compounds are separated in the predistillation and main (atmospheric) distillation columns. Heavy compounds have to be distilled in a vacuum distillation column. The products of CDU are further processed in different refinery units. Capacity of the CDU is 10000 kt/year. We would like to lay emphasis on the fact that Fuelgas is used by the refinery for heating, and it does not show in the final product summary (the final balance may lack a few kt-s of product).

Crude properties API gravity ( ) 31.32

Sulphur content (%) 1.45 Watson factor 12

For the conversion from barrels to tons the following equation is used:

Barrels of crude oil per metric ton =

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Product Fuelgas LPG Light naphtha Medium naphtha Heavy naphtha Kerosene Light atmospheric gasoil Heavy atmospheric gasoil Light vacuum gasoil Heavy vacuum gasoil Slop wax Vacuum residue Losses

Yield (wt%) Product destination 0.02 1.16 2.92 6.52 7.30 7.60 14.53 7.30 7.81 26.04 3.00 15.30 0.50 Products of the Crude Distillation Unit Used for heating For sale Light Naphtha Hydrotreating Heavy Naphtha Hydrotreating Heavy Naphtha Hydrotreating For sale Gasoil Hydrotreating or for sale as Petchem and Heating Oil Gasoil Hydrotreating or for sale as Petchem and Heating Oil Gasoil Hydrotreating or for sale as Petchem and Heating Oil HDS/MHC, or for sale as Light Fuel Oil Delayed Coker, Bitumen Plant, or for sale as Heavy Fuel Oil Delayed Coker, Bitumen Plant, or for sale as Heavy Fuel Oil

OPEX
Utility (UOM) Fuel (GJ/kt) Electricity (MWh/kt) Cooling water (m /t) Steam (GJ/kt)
3

Consumption 650 7.36 3.3 -23

Utility consumption of the Crude Distillation Unit

Light Naphtha Hydrotreater (LN HDS)

The crudes sulphur content appears in its products in different quantities. Sulphur content has to be removed to fulfill environmental and quality regulations. Sulphur is removed by a catalytic process called hydrotreating or hydrodesulphurization.

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Product Fuelgas LPG Light Naphtha H2S Losses

Yield (wt%)Product destination 0.80 3.00 96.13 0.07 0.20 Products of the Light Naphtha Hydrotreater Used for heating For sale Light Naphtha Isomerisation Unit, or for sale as Petchem Naphtha Burnt or to Claus Unit

OPEX
Utility (UOM) Fuel (GJ/kt) Electricity (MWh/kt) Cooling water (m /t) Catalyst (F$/kt) Hydrogen (wt% of feed)
3

Consumption 500 6 12 250 0.2

Utility consumption of the Light Naphtha Hydrotreater

Heavy Naphtha Hydrotreater (HN HDS)

It is very similar to the LN HDS. Since heavy naphtha contains slightly more sulphur, desulphurization requires higher temperature and/or pressure and more hydrogen. Product Fuelgas Heavy Naphtha H2S Losses Yield (wt%) Product destination 0.40 99.55 0.15 0.20 Products of the Heavy Naphtha Hydrotreater Used for heating CCR Reformer, or for sale as Petchem Naphtha Burnt or to Claus Unit

OPEX
Utility (UOM) Fuel (GJ/kt) Electricity (MWh/kt) Cooling water (m /t) Catalyst (F$/kt) Hydrogen (wt% of feed)
3

Consumption 300 6 8 200 0.3

Utility consumption of the Heavy Naphtha Hydrotreater 20

Light Naphtha Isomerisation Unit (LNI)

Desulphurized naphtha is not good enough for motor gasoline (mogas). This fuel cut contains mostly pentanes and hexanes. Research octane number (RON) of light naphtha is around 70. Isomerization of this constituent can improve its octane number, reaching a good MON without olefinic and aromatics content. Product Yield (wt%) Product destination Fuelgas Isomerate Residue Losses 2.9 83.00 15.00 0.10 Used for heating Gasoline Blending or Base Gasoline For sale as Petchem Naphtha

Products of the Light Naphtha Isomerisation Unit

OPEX
Utility (UOM) Fuel (GJ/kt) Electricity (MWh/kt) Cooling water (m /t) Catalyst (F$/kt) Hydrogen (wt% of feed)
3

Consumption 3000 40 25 500 1

Utility consumption of the Light Naphtha Isomerisation Unit

CCR Reformer

Catalytic reforming is a chemical process used to convert petroleum refinery naphthas, typically having low octane ratings, into high-octane liquid products called reformates which are components of highoctane motor gasoline. Basically, the process re-arranges or re-structures the hydrocarbon molecules in the naphtha feedstock into aromatic components as well as breaking some of the molecules into

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smaller molecules. The overall effect is that the product reformate contains hydrocarbons with more complex molecular shapes having higher octane values than the hydrocarbons in the naphtha feedstock. In so doing, the process separates hydrogen atoms from the hydrocarbon molecules and produces very significant amounts of byproduct hydrogen gas for use in a number of the other processes involved in a modern petroleum refinery.

Product Fuelgas LPG Reformate Hydrogen Losses

Yield (wt%) Product destination 4.30 4.40 88.00 3.10 0.20 Products of the CCR Reformer Used for heating For sale Gasoline Blending or Base Gasoline Used for hydrotreating processes and isomerisation

OPEX
Utility (UOM) Fuel (GJ/kt) Electricity (MWh/kt) Cooling water (m /t) Catalyst (F$/kt)
3

Consumption 3000 95 14 500

Utility consumption of the CCR Reformer

Gasoil Hydrotreater
Sulphur content of diesel is also regulated very strictly. To produce marketable diesel fuel, a gasoil hydrotreater is necessary to remove sulphur content. Product Yield (wt%) Product destination Fuelgas LPG Naphtha Diesel H2S Losses 1.0 0.5 3.7 94.45 0.9 0.2 Products of the Gasoil Hydrotreater Used for heating For sale For sale as Petchem Naphtha For sale Burnt or to Claus Unit

OPEX

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Utility (UOM) Fuel (GJ/kt) Electricity (MWh/kt) Cooling water (m /t) Catalyst (F$/kt) Hydrogen (wt% of feed)
3

Consumption 300 15 5 300 0.75

Utility consumption of the Gasoil Hydrotreater

Hydrodesulphurization / Mild Hydrocracker Unit (HDS/MHC)

The aim of an HDS Unit is to pretreat the feed of the FCC Unit. It is similar to hydrotreating, but operates on higher pressure and temperature. With the proper selection on HDS/MHC catalyst moderate flexibility can be achieved in the refinerys product slate. Two catalyst packages are available to choose from: HDS catalyst: Removes significant amount of sulphur with low hydrocarbon conversion. HDS/MHC catalyst: Removes significant amount of sulphur and converts a larger amount of heavy components into more valuable light hydrocarbons, mainly gasoil. Building the HDS unit: each team must set capacities before building the HDS unit! After the capacities are set , HDS can be built, before that the game does not allow the plant to be constructed. HDS-MHC Unit is built along with the FCC Unit!!

Product Fuelgas LPG Naphtha HDS Gasoil HDS Raffinate H2S Losses

Yield in HDS Model (wt%) 0.5 0.4 1.5 12.3 84.0 1.7 0.6

Yield in HDS/MHC mode (wt%) 0.7 0.6 5.4 21.0 71.2 1.7 0.6

Product destination Used for heating For sale For sale as Petchem Naphtha For sale as Diesel To FCC Unit, or for sale as Light Fuel Oil Burnt or to Claus Unit

Products of the HDS/MHC Unit

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OPEX & CAPEX

Utility (UOM) Fuel (GJ/kt) Electricity (MWh/kt) Cooling water (m /t) Steam (GJ/kt) HDS Catalyst (MMF$/charge)* HDS-MHC Catalyst (MMF$/charge)* Hydrogen (wt% of feed)
3

Consumption 300 36 4,5 250 3.6 6 1.0 (1.2 in MHC mode)

Utility consumption of the HDS/MHC Unit

*Both catalyst types lifetime is 2 years, after this period the catalyst has to be changed, otherwise the unit stops operating. Catalysts have to be ordered a year prior to the change! The construction cost of the newly built HDS/MHC unit involves a HDS catalyst, with which the unit can start its operation in the first 2 years. You do not have to wait 2 years if you would like to change the catalyst, you can do that each year but of course ordering has to be done one year prior to change too. Total Investment Cost: Before constructing the unit, you can choose among three maximum capacities. If necessary, the unit can be revamped to higher capacity later in the game. Until the revamp is complete, the unit operates at the original, lower capacity. Capacity (kt/year) 2000 2600 3300 Revamp from 2000 to 2600 Revamp from 2600 to 3300 Revamp from 2000 to 3300 CAPEX (MMF$) 200 230 270 60 80 140

Construction time: Cost distribution:

2 years 1st year: 2nd year 60% 40%

Revamp of HDS/MHC unit takes one year, revamp cost is fully charged in the year of ordering.

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Fluid Catalytic Cracking Unit (FCC)

Fluid catalytic cracking (FCC) is a conversion process used in refineries. It is widely used to convert the high molecular weight hydrocarbon fractions of crude oils to more valuable gasoline, olefinic gases and other products.

The FCC process vaporizes and breaks the long-chain molecules of the high-boiling hydrocarbon liquids into much shorter molecules by contacting the feedstock, at high temperature and moderate pressure, with a fluidized powdered catalyst. In effect, refineries use fluid catalytic cracking to correct the imbalance between the market demand for gasoline and the excess of heavy, high boiling range products resulting from the distillation of crude oil. FCC Unit is built along with the HDS-MHC Unit!! Product Fuelgas Propylene LPG FCC Gasoline LCO HCO MCB Losses Yield (wt%) Product destination 3.8 4.5 16.4 50.3 12.7 3.0 4.5 4.8 Products of the FCC Unit Used for heating For sale For sale Gasoline Blending or Base Gasoline For sale as Petchem and Heating Oil For sale as Light Fuel Oil For sale as Heavy Fuel Oil

OPEX & CAPEX

Utility (UOM) Fuel (GJ/kt) Electricity (MWh/kt) Cooling water (m /t) Steam (GJ/kt) Catalyst (F$/kt)
3

Consumption 160 50 25 -250 200

Utility consumption of the FCC Unit Total Investment Cost: 380 MMF$ Construction time: Cost distribution: 2 years 1st year: 2nd year 60% 40% 25

Delayed Coker Unit (DCU)

Delayed coking is a thermal process in which the vacuum residue from crude distillation is converted into lighter components and coke. The feed is heated in a furnace then confined in a reaction zone or coke drum under proper operating conditions of temperature and pressure until the unvaporized portion of the furnace effluent is converted to vapor and coke. Vapor is fractionated into different products. Product Fuelgas Propylene LPG Naphtha* DC Gasoil* Heavy Coker Gasoil (HCGO)* Coke Losses Yield (wt%) Product destination 4.0 2.0 2.5 11.0 19.5 36.5 24.0 0.5 Products of the DCU Unit *The marked streams can not leave the refinery without further treatment, therefore the DC Unit is not operable without the HDS-MHC Unit. Used for heating For sale For sale Heavy Naphtha Hydrotreating Gasoil Hydrotreating HDS/MHC For sale

OPEX & CAPEX

Utility (UOM) Fuel (GJ/kt) Electricity (MWh/kt) Cooling water (m /t) Steam (GJ/kt)
3

Consumption 1200 25 0.5 450

Utility consumption of the DCU Unit

Total Investment Cost: 550 MMF$ Construction time: Cost distribution: 4 years 1st year: 2nd year 3rd year 4th year 30% 30% 20% 20% 26

Bitumen Blowing Unit (BBU)

Asphaltic bitumen, normally called "bitumen" is obtained by vacuum distillation or vacuum flashing of an atmospheric residue. This is straight run" bitumen. The physical properties of asphalts may further be modified by 'air blowing'. This is an oxidation process which involves the blowing of air through the asphalts, either on a batch or a continuous basis. Maximum capacity of the BBU Unit is 400 kt/year. Product Yield (wt%) Product destination Bitumen Losses 98.0 2.0 Products of the BBU Unit For sale

OPEX & CAPEX

Utility (UOM) Fuel (GJ/kt) Electricity (MWh/kt) Cooling water (m /t) Steam (GJ/kt)
3

Consumption 100 20 2 200

Utility consumption of the BBU Unit Total Investment Cost: 50 MMF$ Construction time: Cost distribution: 2 years 1st year: 2nd year 60% 40%

Hydrogen Production Plant (HPP)

Hydrogen is required in refineries for hydrotreating processes, to remove sulfur, nitrogen and other impurities from hydrotreater feed. A limited quantity of hydrogen is produced in the catalytic reforming of naphthas, but generally the quantity is insufficient to meet the requirements of the refinery. Hydrogen is produced by the steam reforming of natural gas, which is bought from the market or consumed from the refinery fuel gas pool (simplification). The throughput of HPP is always determined by the demand of hydrotreaters. If maximum capacity is reached, excess hydrogen is automatically bought from the market.

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Product Yield (wt%) Product destination Hydrogen Losses 23.8 76.2 Products of the HPP Unit Used for hydrotreating processes and isomerisation

OPEX & CAPEX

Utility (UOM) Fuel (GJ/kt)* Electricity (MWh/kt) Cooling water (m /t) Steam (GJ/kt) Catalyst (F$/kt)
3

Consumption 6000 60 10 -1800 780

Utility consumption of the HPP Unit *Specific fuel consumption does not contain the feed natural gas of HPP.

Total Investment Cost: Before constructing the unit, you can choose between different maximum capacities. You can see your options in the table below. After your initial choice, there is no possibility to expand capacity, so choose carefully. Feed capacity (kt/year) CAPEX (MMF$) 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 36 63 86 108 129 149 168 187 205 225 240 260 275 290 305 325

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340 360 380 400 Construction time: Cost distribution: 2 years 1st year: 2nd year 60% 40%

340 355 370 385

Claus Unit
Most crude oil contains varying amounts of sulfur. Hydrotreating various distillates from these crudes generate hydrogen sulfide (H2S), which is converted to elemental sulfur in the Claus Unit to minimize atmospheric pollution. In the absence of sulfur recovery, the only option would be to burn this gas in refinery furnaces, releasing huge amounts of sulfur dioxide into the atmosphere. A new government law will come into force in 2020 imposing a serious penalty on H2S burning: 30000 F$/t. The throughput of the Claus Unit is always determined by the H2S production of the hydrotreaters. Product Yield (wt%) Product destination Sulphur Losses 84.8 15.2 Products of the Claus Unit For sale

OPEX & CAPEX

Utility (UOM) Fuel (GJ/kt) Electricity (MWh/kt) Cooling water (m /t) Steam (GJ/kt) Catalyst (F$/kt)
3

Consumption 810 100 40 -3500 1200

Utility consumption of the Claus Unit Total Investment Cost: Before constructing the unit, you can choose between different maximum capacities. You can see your options in the table below. After your initial choice, there is no possibility to expand capacity, so choose carefully.

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Feed capacity (kt/year) CAPEX (MMF$) 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 51 69 82 92 102 110 117 124 130 136 142 147 152 157 162 166 170 175 180 185

Construction time: Cost distribution:

2 years 1st year: 2nd year 60% 40%

Gasoline Blending

Motor gasoline has to be blended from different streams to fulfill the environmental and quality regulations. It is your task to blend marketable gasoline by setting up the splitters correctly. Excess amount of blending components will be sold as Base Gasoline for a lower price. If the blended gasoline does not meet the requirements, it will also be sold as Base Gasoline. Gasoline Blending is not possible until all the components are available.

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SPG (kg/dm3) RON MON RVP(kPa) Olefin (%) Aromatics (%) FCC Gasoline Reformate Isomerate 0.75 0.83 0.68 93.5 103 90 82.5 92 85 56 30 80 27 0 1 26 81 0

Gasoline blending components and their properties

Property SPG (kg/dm3) RON MON RVP (kPa) Olefin (%) Aromatics (%)

Minimum spec. Maximum spec. 0.73 95 85 45 60 18 35 0.77

Requirements for motor gasoline The properties of blended gasolines are calculated from the weighted average of the blending component properties. The calculation is volume based (in V/V%). Refinery splitters related to Gasoline blending can be adjusted with 0.1% units with the help of little +/- signs next to the splitter for finetuning the gasoline recipes to satisfy the strict specifications. Example for calculation: 70%(V/V) FCC naphtha + 15%(V/V) Reformate + 15%(V/V) Isomerate RON = 0.7 * 93.5 + 0.15 * 103 + 0.15 * 90 = 94.4

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Final Scoring

40 teams are going to get to the creative round. Ten teams who scored best in the Upstream part of the game, ten teams with the best scores in the Downstream part, and twenty teams with the best overall score (apart from the teams already qualified with the US or DS parts). We will also take into consideration and evaluate the effects of your decisions made in the final turn. (By running a 19th turn automatically without the opportunity to make any decisions right at the end of the game.) After that we rank the teams according to how much cash they have on their account and the remaining unpaid credit is substracted from the final result. Then we rank the teams of US, DS and overall preformance.

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