Creating lasting Values - Pörner Group

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Creating lasting Values - Pörner Group

ProjectsShell byPörner +PartnerVienna (MichaelMazzucato).Sincethe first ShellAustria fillingstation wasbuilt by Pörner in Mauthausenin 1992, Shell Austria has beenamong the regular customers.The largest filling stationproject for Shell Austria guidedby Pörner + Partner recentlywas the construction of the firstunmanned truck filling stationin Loosdorf/Lower Austria.Apart from the usual timepressureaspecialchalle n g efor allpartiesinvolvedin this project was supervisionand data transfer.Initial filling and commissioningtook place in due timein mid February 2010. The officialopening ceremony withrepresentatives from politics,economy and numerous Shellemployees from Germany, Austriaand Switzerland was heldon March 5 th , 2010.The team headed by MichaelMazzucato comprises eng. ClaudiaDeutschmann-Zahor, eng.Thomas Fojtl and eng. ClemensLeimer and is in charge of morethan 100 filling stations in Austria.Apart from construction ofnew filling stations and largerrevamps this field of work alsoincludes technical and opticalrefurbishments, Austria-wideroll-outs (design modifications,introduction of new fuel qualities,installation of automatictank capacity measurementsetc.), soil decontaminations,complete closing-down as wellas takeover resp. handover offilling stations to other groupsof companies.The specialized Pörner +Partner team provides thecomplete service portfolio beginningwith layout includingproperty valuation, obtainingauthority approval, tenderingand price negotiations on behalfof the customer, local constructionsupervision including engineeringand site coordinationaccording to BauKG (FederalConstruction Works CoordinationLaw applicable in Austria)up to handover.In recent years this Shell teamwas more and more entrustedwith maintenance tasks. •2 ENGINEERING-TIMES Krefeld (Gerhard Bacher). this year, with commissioning+ + + Pörner Ingenieurgesellschaftearmarked for the end of 2011.mbH Grimma received In addition to the productionturn-key contract for setting plant, new formalin and methanolup a formalin plant in close cooperationtanks will also be installedwith licensor Dynea on an area of about 1,000 m 2 .ASA for LANXESS in Krefeld-Uerdingen + + +On March 18 th , 2010 GerhardBacher, GeneralManager of Pörner Grimma,and Lars R. Axelsen,Group Vice President ProcessTechnology of DyneaASA signed a contract forturn-key construction ofa 150,000 mtpy formaldehydeplant (32% concentration)with infrastructurefor LANXESS Germanyin Krefeld-Uerdingen/Germany.The total investment valueof the new plant includingprocess optimizationamounts to approx. EUR18 million. Constructionof the new plant is expected Pörner Grimma: Technologyto start in the third quarter of center for formalin/derivatesPörner Grimma is the PörnerGroup’s technologycenter for formalin and itsderivates (formalin, UFC, proved and optimized thisparaformaldehyde, hexaminepartnership is successfullyUF, MUF, MF, PF being continued.resins, novolacs and bacelites,Besides the turn-key supplyacetaldehyde, penta-and erection of the formalinerythritol, polyester and process plant with downstreamalkyd resins).thermal off-gas treatment withIn a more than 20 years’ heat recovery Pörner Grimma’scooperation with Dynea scope of work also includes in-Pörner grants 7 th license to IndiaThe basic engineering will beVienna (Gebhard Kracher).Pörner has been active on theIndian market for many years.Already the 7 th Biturox ® plantin India furnishes proof of thegood business relations withthe Asian country.New order from ESSARPörner Vienna has received anew order for a Biturox ® plantthis March. The customer isESSAR OIL Ltd. – one of theleading oil & gas companiesStiffnessViscosityHigh PI BitumenLow PI Bitumenlow temperature limitfor performancehigh temperature limitfor performancemaximum viscosity forsatisfactory compactionminimum viscosity forsatisfactory compactionLow PIHigh PI-40 0 60 150TEMPERATURE °CNEW TURN-KEY CONTRACT FOR PÖRNERPörner Grimma builds newformalin plant for LANXESSIn servicein India. Pörner has enjoyed along and successful partnershipwith the globally acting groupwith over 20 subsidiaries anda workforce of approx. 60.000employees.The new bitumen plant willbe built at Vadinara refinery onthe west coast of India. As wellas the license, the scope of servicesincludes the basic engineering,pilot tests with variousraw materials, commissioningand start-up.eleven projects have alreadybeen implemented together.With the construction of thelatest formalin plant basedon the Dynea Silver ® processpermanently being im-Contract signing in Grimma, (f.l.t.r.):G. Bacher (MD Pörner Grimma), L. Axelsen(Group Vice President, Dynea), Dr. M.Friederich (Engineering Manager BAC-TTMP-Plant, LANXESS), R. Schraysshuen(Administration & Sourcing - Head ofProcurement, LANXESS)More than 50% of bitumenproduction from Biturox ® plantsConstructiontemperature rangefor compaction(Low PI)Biturox ® Multigrade BitumenFatigue Cracking, FrettingRuttingtemperature rangefor compaction(High PI)© Pörner Ingenieurgesellschaft mbHBiturox ® improves thethermal susceptibilityof bitumen.The result: less ruttingand at the sametime less fatigue cracking,which enhancesthe street´s economiclife-time.completed after 5 months only,so that the finished plant can behanded over to the customer inexactly one year.IOCL Mathura commissionedIn the previous Indian projectPörner was awarded a contractfor a revamp of two reactors inthe Mathura refinery.For the customer, the IndianOil Corporation Ltd. (IOCL), itis already thesecond Biturox® plant aftera projectimplementedin the GujaratRefinery,Vadodara in1998.The revampof twoold reactorsof Russiandesign wasfrastructure measures such asthe installation of a methanoland formalin tank as well asmethanol unloading facilitiesand an extensive piping systemfor connecting the plant withthe existing infrastructure.LANXESS – a strongpartnerWith the new formalinplant the specialty chemicalsgroup LANXESS willno longer be dependent onpurchasing this feedstockrequired to produce trimethylolpropane(TMP).TMP is e. g. used for numerousproducts in thefurniture, constructionand automotive industries.“We will have significantcost advantages because ofzero transportationcosts and synergy effectsas to energy efficiency”,explains WernerBreuers, boardmember of LANXESSAG.LANXESS is a leadingspecialty chemicalsgroup that hasabout 14,600 employees in 23countries currently. The companymaintains 43 manufacturingbases all over the world.LANXESS’ core business coversdevelopment, productionand sales of plastics, rubber,intermediate products and specialchemicals.•engineered and the key equipmentdelivered by Pörner Vienna.Commissioning took placein October 2009 under supervisionof Pörner process engineers.The plant was handedover to the customer at the endof the year.With that more than 50% ofbitumen made in India is producedin plants licensed byPörner.•G. Kracher duringcommissioning inMathura


Series: The Perfect Project6 ENGINEERING-TIMES sions etc.) have an essentialOptimal Project PreparationVienna, Leipzig (Gerhard Vlcek,Lutz Hoffmann, Lars Reinhold).In plant engineering investmentprojects where alwayshigh amounts of money haveto be approved, factors such asrisk analysis, financing and thequestion of the most efficienttechnology play an importantrole. Just in economically insecuretimes most accurate factsabout profitability of the projectare essential to make a decisionagainst or in favour of a project.Finally, a project is only perfectwhen the return on investmentis optimized in terms ofinvestment and operating costsas well asexpectedturnover.The plantdoes notonly haveto be engineeredperfectly,c o m -pleted ontime and successfully be commissioned,it also has to be operatedefficiently as to technicaland economic criteria andhas to meet or even surpass thedefined quantities and qualitycriteria.Why is project developmentso important?If project development is understoodas all economic andtechnical planning and calculationsprior to the actual startof the project, so it provides essentialsupport to make entrepreneurialdecisions on investmentprojects.In this important decisionmakingprocess Pörner Groupprovides its customers withcomprehensive know-how asto:• concept preparation• technology providing /selection• (bankable) feasibilitystudies• financing support• environmental impactassessment• safety analysis• expert opinionsFive questionsTo put it simply – in the courseof project development fivequestions have to be answeredand fixed in writing:WHAT – WHO – HOW –WHEN – WHERESimple questions, but occasionallyhard to answer. The simplestand fastest answers cantheoretically be given to thequestions WHAT and WHO:customers usually know whatthey want to produce, revampor build up, and the possibleresponsible promoter resp. purchaseris also known at thatpoint of time.To answer the questionsHOW, WHEN and WHERE ismore difficult. When it comesto large projects the questionscan normally not be draftedsimply and clearly since thereare often interactions and dependencies.Sometimes the plant locationcan be decisive for the technicalconcept of a plant: existinginfrastructures (e.g. railway,ship) or local conditions (e.g.limit values for noise, emis-GALP Bitumen WorkshopLisbon (Lydia Barth). With itsBiturox ® process Pörner is theworld market leader in bitumenoxidation plants.In the last 10 years alone 16licenses were granted and bitumenplants built up mainly inEurope. Numerous tests withmost diverse feeds were carriedout in Pörner-owned pilot plantsin the Schwechat laboratory.In doing so Pörner has gatheredspecific know-how thatour customers now can benefitfrom. For this reason Pörner ismore and more entrusted withcompiling studies about the bitumensubject.Contract award for studyIn January 2010 Pörner receivedan order to prepare anoptimization study related to thebitumen production in the tworefineries in Sines and Porto,of the Portuguese oil companyBitumen workshop atGALP in Lisboninfluence on the plant conceptas well as climatic conditions.In this respect cost-wise effectsof WHERE and WHEN shouldnot be neglected at all.HOW - the most difficultquestionIn industrial plant engineeringthe designed plant capacity andthe selected technology havethe prime influence on costs.For this reason the questionof HOW is the most importantone both from the economicand technical point of view wellbefore the GO phase of a projectstarts.With its competence in processtechnology Pörner engineerssupport their customersin investigating, selecting andproviding the suitable technology.Therefore, Pörner Group hasbeen working closely with internationallyrenowned licensorsand technology-providers formany years in order to developand implement plant conceptsbased on the selected process.Developing new technologies,implementing special technologiesand designing ‚open art’technologies are in the center ofcombined efforts.Know what is feasibleTechnology selection is oftenpart of a project study – alsocalled feasibility study. However,it is rather a check of possibilitiesthat is often a MUST inrespect to financing by a bank.A feasibility study clarifiesorganizational opportunitiesand economic feasibility (e.g. budget, financing), but alsoGALP. Part of the scope of serviceswas a bitumen workshopfor all GALP specialists and employeesinvolved in the bitumenissue.Bitumen workshopat GALPThe workshop took place in theGALP headquarters in Lisbonon February 23 rd /24 th .Under the headline ‚How toproduce quality bitumen economically’the lectures weredivided into three sections: bitumenquality (bitumen chemistryand standards), process engineering(‘how to make...’) andprofitability (commercial benefitsof more, better and costeffectiveproducts).The workshop was precededby kick-off meetings in bothrefineries: thus, the technicalbasis for the requested optimizationwas well-defined. As aresult, the workshop becamea very lively discussion amongBankableFeasibility StudyWhen elaborating a feasibilitystudy the Pörner Group offersto prepare a bankable feasibilitystudy. This includesa detailed investmentand operating costestimate based on thebasic engineering.In order to compile such aprofitability calculation efficientlyand in a tamper-proof mannerPörner Group makes use of theCOMFAR III program. COMFARis a calculation program especiallydeveloped by UNIDO (partof UNO with headquarters in Vienna)to carry out profitabilitycalculations. COMFAR allowsto calculate short- and longtermfinancial developments ofa project where input data andtechnical feasibility and theavailability of resources (rawmaterials, technology, areas,employees, technical aids etc.).It can include pilot plant testsand computer simulations aswell.Michal Blazej andAndreas Pörnerapprox. 20 participants andPörner experts: the talks did notconfine to theory, but were immediatelycompared with ownexperiences gained by GALP’slaboratory, production and marketingexperts.A possible changeover tolighter crude oils and targetedquality improvement (e. g. PENindex) were explained and discussedin detail in order to meetnew standards and open up newmarkets.The discussion with all participantsscheduled for the secondafternoon lasted until latenight: a visual proof of the GALPteam’s commitment and reassurementfor Pörner that theworkshop was of great value toour Portuguese customer. •Tamper-proof profitabilitycalculationwith COMFAR IIIassumptions made are transparent.Because of the tamperprooffeature, bankable feasibilitystudiespreparedwith COM-FAR areacceptedby interna t i o n a ldevelop m e n tb a n k s( W o r l dB a n k ,IFC, ADB,IDB…).An importantstep towards financing,where Pörner Group canbe of assistance.•UNO City in ViennaWith a project study the riskof achieving the objective shallbe checked resp. defined, if it isnot sure whether it is possibleat all. By a feasibility study itcan be found out what expenses(time- and money-wise) are requiredto realize a project. Forthis the following investigationshave to be made:• market analysis• analysis / comparison oftechnologies• analysis / comparison oflocations• analysis of competitors(where necessary)• risk analysis (technology,time, expenses, legal frameworkconditions, subsoiletc.)• profitability calculations(e.g. return on investment)Stop or GoIf the result of the study is negativeor inefficient or too riskyunder given preconditions,the project has to be rejectedor completely changed. Aftercompiling a feasibility study adecision on stop or go has to bemade in any case.To sum up, project developmentplays a decisive role ina perfect project. With wellfoundedand as comprehensiveas possible analysis of mostdiverse influencing factors aplant engineering project cansuccessfully be implemented inmost cases.•

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