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Logistic brochure (pdf, 3.3 MB) - Mol

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To our readers<br />

Through this publication, we should like to acquaint you with the activities of the MOL Group <strong>Logistic</strong>s<br />

Unit, its equipment and its operations. We would also like to review the market demands the current<br />

system was established to meet, along with important developments it has had to respond to.<br />

The key competitive factors in the area of <strong>Logistic</strong>s are focus on the customer, cost-effectiveness<br />

and optimal execution of distribution and storage functions. One of the organisation’s top priorities is to<br />

maintain the quality of refinery products throughout the logistics process, up to and including the<br />

customer storage tank, or the customer vehicle fuel tank at our filling stations.<br />

One of the decisive results of change over the last decade has been that competition in the oil industry<br />

has now focused on the supply chains of integrated oil companies, rather than on products, salesmen,<br />

or refineries. Fast response to market change, focus on the customer and optimal orchestration of the<br />

crude oil supply-refining-distribution-marketing sequence, have become crucial competitive factors.<br />

The MOL Group <strong>Logistic</strong>s Unit – similar to other organisations – is characterised by the constant need<br />

to improve. As a result of comprehensive technical upgrades during the early 90’s, our storage depots<br />

are now fully in compliance with stringent EU environmental specifications, in every respect. In addition,<br />

the modernisation and automation of our loading systems and tanker lorry fleet have also been carried<br />

out. The successful functioning of our logistics processes is supported by a state-of-the-art information<br />

system, which on one hand delivers more accurate planning and execution of such processes, and on the<br />

other, has increased the security of our assets.<br />

From 2001 onwards, this approach was gradually and successfully introduced along the entire MOL<br />

Refining & Marketing Division (RMD) supply chain, together with associated execution of decision-making<br />

and implementation tasks. The MOL <strong>Logistic</strong>s Unit now operates as an integral part of that supply<br />

chain. Its valuable contribution can be gauged principally by the healthy state of RMD profitability today.<br />

As MOL Group operations expanded across national borders, so the <strong>Logistic</strong>s Unit itself, and its<br />

operations, also become regional in nature. The integrated <strong>Logistic</strong>s Unit now supplies 871 filling stations<br />

and about 14 thousand business customers, via a 2,530 km long pipeline network and a total 41<br />

depots, owned or leased, in 6 countries. The amount of products moved annually totals 25 million tons.<br />

The <strong>Logistic</strong>s Unit, through reliable fulfilment of business customer contracts, the accuracy of customer<br />

services, and its general high standards, plays a leading role in ensuring customer satisfaction with MOL<br />

Group services. Moreover, the <strong>Logistic</strong>s Unit, supported by the thorough and precise activities of its<br />

experts, the upgrades implemented across the area, and not forgetting its very innovative mentality, has<br />

contributed significantly to the fact that MOL Group has recently strengthened its market shares in an<br />

environment of ever-increasing regional competition.<br />

3<br />

Ferenc HORVÁTH<br />

Managing Director<br />

Refining & Marketing<br />

MOL Group


Crude oil logistics<br />

in Hungary during<br />

the pre-pipeline era<br />

The development of crude oil transportation<br />

means and methods is closely related<br />

to the development of the oil industry.<br />

Over the decades, the demand for various<br />

types of hydrocarbon derivative changed<br />

continually.<br />

New products appeared the distribution of<br />

which required new methods. The geographical<br />

position of the country and historic, economic<br />

and eco-political factors also played<br />

an important role in the development of<br />

hydrocarbon transportation systems.<br />

The beginnings (1865 to 1918)<br />

Crude oil transportation<br />

in tanks by rail<br />

The beginning of<br />

this era saw the<br />

general use of<br />

kerosene, the first<br />

product produced<br />

by processing crude<br />

oil. Used primarily<br />

for illumination,<br />

this product, of<br />

foreign origin, was initially delivered to customers<br />

in containers. From 1865 onwards, small<br />

kerosene refineries were established in Hungary,<br />

which processed crude oil from Romania, Galicia<br />

and later of domestic origin. Most of the finished<br />

product was distributed to consumers in barrels,<br />

with a smaller amount by rail tanker car.<br />

At the turn of the century, oil processing units<br />

were established which could already be considered<br />

large-scale plants. Crude oil arrived at<br />

Bratislava and Budapest primarily by Danube<br />

barge, and Fiume by sea. Galician crude oil was<br />

delivered to refineries by rail tanker car. After the<br />

turn of century, refineries of greater capacity<br />

were built. In addition to kerosene – with the start<br />

of motor-car travel - petrol and diesel appeared.<br />

Since demand did not require improvements in<br />

the distribution process, associated logistics did<br />

not follow the development in the crude oil industry.<br />

Crude oil could be economically transported<br />

simply by water and rail tanker car, the same also<br />

being true for finished products.<br />

4<br />

Between the two world wars (1918 to 1939)<br />

Loading a barrel<br />

with crude oil<br />

Following the<br />

World War I peace<br />

treaties, the majority<br />

of large plants and<br />

crude oil fields were<br />

located in territories<br />

disannexed from<br />

Hungary. Only two<br />

medium-sized refineries<br />

and four smaller<br />

plants were left within<br />

the new national borders.<br />

The Csepel and<br />

Almásfûzítô refineries, both located on the<br />

Danube, were supplied with crude oil by barge,<br />

and the smaller units by rail tank car. Although<br />

feedstock was only available from foreign<br />

sources, the number and capacity of refineries<br />

increased continuously. Some changes were<br />

brought about by the appearance of the first<br />

tanker lorry in Hungary, but the proportion of<br />

transportation by tanker lorry remained low, due<br />

both to the out-of-date road network, and the<br />

low number of road vehicles. The lion’s share of<br />

transportation was by rail tanker car or container.<br />

Transportation by tanker lorry in the pre-pipeline era


The place and role of<br />

<strong>Logistic</strong>s in MOL Group<br />

In MOL Group, the predecessor of<br />

today’s <strong>Logistic</strong>s Unit was the Mineral<br />

Oil Marketing Company (Ásványolajforgalmi<br />

Plc.), established in 1948.<br />

Called ÁFOR after 1957, the company<br />

was a member of the National Crude Oil<br />

& Gas Trust (Országos Kôolaj- és Gázipari<br />

Tröszt - OKGT), for three and a half<br />

decades.<br />

MOL was established in October 1991.<br />

Following organisational changes, crude oil and<br />

product storage and distribution activities were<br />

performed by the Product Storage & Distribution<br />

organisation (TTSz), reporting to the Marketing<br />

& Sales Directorate.<br />

In 1996, after core processes had been<br />

audited, a significant re-organisation took<br />

place; as the result of an efficiency improvement<br />

project, (CPR - Core Process Redesign),<br />

an independent logistics organisation<br />

was created. In 2001, the <strong>Logistic</strong>s Unit<br />

became an integral part of the new Refining<br />

& Marketing Division (RMD).<br />

Crude oil<br />

Supply<br />

The <strong>Logistic</strong>s Unit’s place in the supply chain<br />

Refining<br />

& Marketing<br />

Refining <strong>Logistic</strong>s Commercial<br />

Supply Chain Management (SCM)<br />

5<br />

Co-ordinated by Supply Chain<br />

Management (SCM), the <strong>Logistic</strong>s Unit carries<br />

out its tasks in conjunction with two<br />

other important organisations - Refining and<br />

Marketing. On 1st January 2004, the integrated<br />

<strong>Logistic</strong>s Unit, which includes similar<br />

functions at Slovnaft, was established.<br />

<strong>Logistic</strong>s Unit responsibilities are to manage<br />

MOL feedstock supplies, to perform<br />

stock management tasks, to store and distribute<br />

self-produced or imported hydrocarbons,<br />

and to provide logistics support to<br />

trading and regional sales activities.<br />

Additionally, the <strong>Logistic</strong>s Unit carries out<br />

the organisation and management of effective<br />

and quality-focused customer services<br />

in compliance with sales contract commitments,<br />

as well as the general operation of<br />

logistics systems in a cost and capacity-efficient<br />

manner.<br />

DS<br />

Technology


At the time the <strong>Logistic</strong>s Unit was established,<br />

more than two thousand people were employed in<br />

the organisation. However, as a result of organisational<br />

changes, depot closedowns, and general<br />

efficiency improvements, headcount has fallen<br />

significantly. In the 1990s, MOL outsourced road<br />

transportation and maintenance to MOLTRANS<br />

Ltd. and Pentaszerviz Ltd., respectively. Due to<br />

re-organisation, Functional Units (such as IT,<br />

Planning & Controlling, Human Resources) were<br />

also removed from the <strong>Logistic</strong>s Unit.<br />

Rail<br />

Distribution<br />

Product Pipeline<br />

Transportation<br />

Integrated<br />

<strong>Logistic</strong>s<br />

Dispatcher<br />

Services<br />

Primary<br />

Distribution<br />

Barge<br />

Loading<br />

Crude Oil<br />

Pipeline Supply<br />

Surveying, Route<br />

Supervision and<br />

Government<br />

Authority<br />

Relations<br />

President and GCEO<br />

Terminal<br />

Operation<br />

Depots<br />

Maintenance<br />

The place of the <strong>Logistic</strong>s Unit in MOL’s organisation<br />

6<br />

In 2002 – to emphasize the quality-maintenance<br />

role of the <strong>Logistic</strong>s Unit – the Quality<br />

Control Unit was attached to it. In 2004, the number<br />

of employees in the <strong>Logistic</strong>s Unit increased<br />

significantly due to the integration of Slovnaft.<br />

Today, the headcount amounts to some 1,300<br />

people.<br />

Since 1996, <strong>Logistic</strong>s has implemented a<br />

Standard ISO 9001 certified Quality Assurance<br />

System that covers all the Unit’s activities and<br />

depots.<br />

GCEO<br />

Refining and<br />

Marketing<br />

<strong>Logistic</strong>s<br />

Forwarding<br />

Central<br />

Freightage<br />

<strong>Logistic</strong>s<br />

Quality<br />

Control<br />

State<br />

Reserves<br />

(Slovakia)


The development of<br />

pipeline systems<br />

Significant changes occurred in the<br />

Hungarian oil industry from the mid-1930’s<br />

onwards. These also had an impact on logistics<br />

activities. As part of preparations for war, capital<br />

invested in the oil industry increased and<br />

new refineries were constructed. Hungarian<br />

hydrocarbon exploration was also successful;<br />

significant amounts of crude oil and natural gas<br />

were discovered in Zala County. With increased<br />

production, additional efficient crude oil<br />

pipelines were constructed and crude oil<br />

imports ceased in 1939.<br />

A crude oil pipeline<br />

Between 1939 and 1942, more than 300 kms<br />

of crude oil pipeline were laid between the Zala<br />

County production fields and Almásfüzítô,<br />

Pét and later, Szôny. The Csepel refinery was<br />

supplied by the Lovászi-Bázakerettye-Újudvar-<br />

Budapest crude oil pipeline, with a branch-line<br />

constructed to supply Szôny and Pét. The construction<br />

of such pipelines, together with a 100<br />

km long natural gas and an almost 100 km long<br />

product pipeline line, constituted a fundamental<br />

change in the distribution area.<br />

During World War II, the railway tanker car,<br />

tanker barge and road tanker lorry fleets were virtually<br />

completely destroyed. Vehicle replacement<br />

ran into difficulties since their domestic manufacture<br />

had been discontinued after the war.<br />

In 1951, a new crude oil field was discovered<br />

in the Nagylengyel region of Zala County. The<br />

following year, Zala Asphalt Company, (the<br />

name was later changed to Zala Crude Oil<br />

Company) was established to process crude oil<br />

produced there. By the time production started,<br />

the Nagylengyel-Zalaegerszeg crude oil pipeline<br />

was already in service, and the new refinery<br />

received feedstock for processing through it.<br />

7<br />

While domestic crude oil production<br />

increased relatively slowly in the 1950s and<br />

1960s, consumption doubled every 7 to 10 years.<br />

By the end of the 1950s, Hungary was more and<br />

more obliged to import. Imports were facilitated<br />

by long-term contracts concluded with the<br />

Soviet Union.<br />

Initially, imported crude oil was shipped by<br />

rail. With sharp increases in demand, rail transport<br />

ran into increasing difficulties – a situation<br />

also experienced by other Central-European<br />

socialist countries. On the recommendation of<br />

the Soviet Union, the issue of a more economic<br />

way of transporting crude oil by pipeline was put<br />

on the agenda. Under COMCON, an agreement<br />

was soon made to construct the Friendship<br />

crude oil pipeline system, which would connect<br />

oil fields along the River Volga with Poland, East<br />

Germany, Czechoslovakia and Hungary.<br />

A Friendship crude oil pipeline receiving station in Hungary<br />

The construction of Friendship I, the section<br />

of the pipeline going through Czechoslovakia to<br />

Hungary, with a capacity of 3.5 million tons per<br />

year, started in 1961, and the section to<br />

Kápolnásnyék was commissioned as early as<br />

the following year (crude oil being further<br />

transported to Szôny via a pipeline constructed<br />

during WW2). The first shipment arrived in<br />

September 1962. The branch line to Százhalombatta<br />

was completed in 1965, so the<br />

imported crude oil could be delivered to the<br />

Duna Crude Oil Company, commissioned in the<br />

same year. A pipeline was also built to link up oil<br />

fields discovered in the meantime, in the Great<br />

Hungarian Plain; the 160 km long Algyô-<br />

Százhalombatta pipeline, with a capacity of 2<br />

million tons per year, was completed in 1970.


As the country’s crude oil consumption and<br />

imports increased year by year – and the industry<br />

policy of the time forecasted further dynamic<br />

increases – it became obvious in the second half<br />

of the ‘60s that the Friendship I pipeline and rail<br />

transportation would not be able to meet<br />

increasing demand. So plans were set in motion<br />

to construct a pipeline of higher capacity, which,<br />

in addition to the Százhalombatta refinery,<br />

would also be able to supply Soviet feedstock to<br />

the planned refinery at Tiszaújváros, (then<br />

Leninváros). The pipeline Friendship II agreement<br />

was signed in Moscow in 1969. The branch<br />

line of the main pipeline in the Ungvár region,<br />

entering Hungary at Tiszaszentmárton, was<br />

completed in 1972, with a maximum annually<br />

capacity of 7.9 million tons.<br />

Industry forecasts predicted an unbroken rise<br />

in crude oil consumption – to reach 20 million<br />

tons annually by 2000 – the provision of which<br />

would require new sources of supply and the<br />

construction of a new pipeline. Pursuant to the<br />

Adriatic Crude Oil Pipeline Convention, signed<br />

in 1974, a pipeline with an annual capacity of 10<br />

million tons, starting out from Omisalj in<br />

Croatia, was to be constructed by 1978, and be<br />

connected to the Friendship pipeline system.<br />

The pipeline would enter Hungarian territory<br />

in the Berzence region, and end at Százhalombatta.<br />

GERMANY<br />

CZECH REPUBLIC<br />

AUSTRIA<br />

POLAND<br />

SLOVENIA<br />

ITALY CROATIA<br />

Adria<br />

BOSNIA AND<br />

HERCEGOVINA<br />

SLOVAKIA<br />

Százhalombatta<br />

HUNGARY<br />

SERBIA-<br />

MONTENEGRO<br />

BELARUS<br />

ROMANIA<br />

Friendship<br />

MOLDOVA<br />

BULGARIA<br />

UKRAINE<br />

RUSSIA<br />

The Friendship and Adria crude oil pipeline systems<br />

8<br />

12000<br />

10000<br />

8000<br />

6000<br />

4000<br />

2000<br />

0<br />

Domestic production<br />

Other import<br />

Soviet / Russian import<br />

Developments in domestic crude oil production and<br />

imports<br />

Initially, the Adria pipleine supplied Hungary<br />

with Iraqi and Iranian crude oil, however, due to<br />

high transit charges, Soviet (then Russian)<br />

imports could not be replaced. Supplies were<br />

also delivered via both the Adria and Friendship<br />

I pipelines. During the time of the Yugoslav<br />

wars, pipeline operations were stopped, and<br />

deliveries have been irregular, ever since.<br />

By 1978, the current 850 km long crude oil<br />

pipeline system had been developed, with a<br />

capacity more than sufficient to secure the<br />

country’s current crude oil needs. (The increase<br />

in demand forecasted in the decades before, has<br />

not transpired.)<br />

Since 1992, crude oil comes almost exclusively<br />

via the Friendship II pipeline, however, to<br />

ensure supplies, the Friendship I and Adria<br />

pipelines also play important roles. A significant<br />

advantage of the Adria pipeline is that, as a<br />

potential competitor, it strengthens MOL’s<br />

bargaining positions with Russian suppliers. In<br />

addition, this pipeline represents a potential<br />

means of transiting Russian crude oil to the<br />

Adriatic Sea, from where it can be transported<br />

by tanker as far as North America.


During the second third of the 20th century, the proportion<br />

of hydrocarbons in world energy supplies<br />

increased strongly. Today, huge amounts of crude oil,<br />

more than 10 million tons daily, “hits the road” from the<br />

producer to the consumer. Due to geological and topographical<br />

conditions, the large producing and consuming<br />

countries are a long way away from each other.<br />

Such great distances have raised the importance of<br />

transportation’s role, and the selection of optimal transportation<br />

means has become crucially important.<br />

Major international crude oil transport routes<br />

It is vitally necessary to minimise crude oil product<br />

distribution costs. Although such products are transported<br />

shorter distances, typically, narrow margins<br />

cannot bear high logistics costs.<br />

Rail and road transportation are justified primarily<br />

for the distribution of smaller quantities, over shorter<br />

distances. Their investment costs – provided their<br />

services are available – are relatively low, but operating<br />

costs are relatively high.<br />

a VLCC (very large crude carrier)<br />

Due to the favourable economics of transportation<br />

by water, the largest share of intercontinental crude<br />

oil shipments is forwarded by sea. Such transportation<br />

is served by about 3,500 oil tankers.<br />

9<br />

The history of crude oil transport by sea dates<br />

back ca. 100 years, during which the average size of<br />

vessel increased on an on-going basis, while transportation<br />

costs decreased. Today, more than 400<br />

vessels are in the so-called VLCC (very large crude<br />

carrier) category, each capable of transporting<br />

between 160 and 320 thousand tons of crude oil.<br />

Even larger tankers, ULCCs (ultra large crude carriers)<br />

have also appeared. The only real disadvantage<br />

of transportation by water is that it is geographically<br />

limited. The best way to distribute crude oil across<br />

continents is by pipeline.<br />

The main advantages of pipeline distribution are<br />

continuity of transportation, adaptability to geographical<br />

conditions, and safety. In addition to the environmental<br />

and economic aspects, it is also important to<br />

remember that pipeline distribution losses are the<br />

lowest.<br />

Although the amount of iron used in pipeline construction<br />

approaches that necessary for a railway of<br />

the same length, maintenance and operating costs<br />

are only a fraction of those of railways, primarily due<br />

to the low energy and physical labour used. However,<br />

the main disadvantage is high capital cost.<br />

4<br />

3<br />

3<br />

specific cost<br />

2<br />

2<br />

1<br />

1<br />

0<br />

50 km 100 km 150 km 200 km<br />

Proportion of costs by distribution method,<br />

by various distances<br />

road<br />

rail<br />

barge<br />

pipeline<br />

The diameter of crude oil pipelines is typically<br />

between 4 and 12 inches, but for example, the<br />

Trans-Alaska pipeline is 24 inches in diameter. Most<br />

product lines are typically smaller. The United States<br />

of America has the most extensive pipeline system.<br />

Including product pipelines, it is approximately<br />

200,000 miles long (320,000 kilometres). The ex-<br />

Soviet member states also have a significant pipeline<br />

network, which plays an important role in the supply<br />

of crude oil to Europe.


The planning of crude oil supply<br />

The scheduling of crude oil supplies is prepared<br />

through by plannning a Duna Refinery<br />

Distillation Unit monthly processing programme.<br />

When defining daily schedules, Fényeslitke and<br />

Százhalombatta storage yard capacity must be<br />

factored in along with adequate stock levels and<br />

possible transit shipments. Additionally, smooth<br />

transit flow through pipeline network must be<br />

aimed at when making supply plans.<br />

The reception and metering of crude oil arrivals<br />

via the Friendship II pipeline takes place at<br />

Fényeslitke, near the Ukrainian boarder, in the<br />

presence of representatives of MOL and<br />

Transnieft, the operator of the pipeline in Russia.<br />

Assessment of crude oil quality is made at an<br />

accredited laboratory. To ensure continuity in<br />

reception and delivery, crude oil flows into one of<br />

four 20,000 m 3 storage tanks - one receiving product,<br />

one discharging product, one settling product,<br />

and one either storing crude oil, or being out<br />

of service.<br />

Fényeslitke-Százhalombatta pipeline section<br />

capacity – depending on the number of transport<br />

pumps in action – is 600 to 1080 m 3 per hour. Crude<br />

oil arrives at the Százhalombatta refinery where it<br />

flows into storage tanks via a metering loop.<br />

Not every crude oil product can be transported<br />

via pipeline. Basically product viscosity<br />

and product components, or the effects of<br />

their chemical properties on pipeline materials<br />

define their suitability for transportation.<br />

Heating oil is only suitable to a limited<br />

degree, and bitumen is not at all suitable for<br />

pipeline distribution.<br />

Due to its potential for high corrosion,<br />

pipeline wall thickness must be checked<br />

more frequently than normal when chemical<br />

naphtha is transported. To perform this task,<br />

so-called intelligent “pipe pigging” is used.<br />

10<br />

Product lines<br />

kt<br />

12000<br />

10000<br />

8000<br />

6000<br />

4000<br />

2000<br />

0<br />

Gasoline Gas- and heating oil Fuel Oil<br />

Development of major crude oil product consumption<br />

in Hungary<br />

In Hungary, motor car travel developed at a<br />

high rate between 1966 and 1975, while significant<br />

modernisation in agriculture was also taking<br />

place. These developments resulted in a significant<br />

increase in demand for oil products. The<br />

crude oil product marketing network had to be<br />

updated accordingly, which was the responsibility<br />

of Ásványolajforgalmi Plc. (Mineral Oil<br />

Marketing Company, called ÁFOR after 1957),<br />

established in 1948. In the early ‘60s, this company<br />

carried out the marketing of products by<br />

operating many hundreds of low capacity (50 to<br />

100 m 3 ) depots. At that time, almost all the larger<br />

railway stations had oil product storage farms<br />

on site, supplied by rail tanker car.<br />

The first product pipeline between Szajol and<br />

Százhalombatta was commissioned in 1965. The<br />

company built an over 1200 km long product<br />

pipeline network, mostly in the 70s, connected<br />

to 20 modern distribution depots, many of the<br />

smaller ones being closed down. In 60 to 400 m 3<br />

per hour capacity pipelines, typically 6, 8 and 12<br />

inches in diameter, eleven high capacity distribution<br />

starting pumps ensured the transmission<br />

of crude oil products. This product network was<br />

designed to interconnect with refineries, starting<br />

from Százhalombatta, and allowing product<br />

transmission among various refinery sites.


Pipeline transmission system<br />

The Százhalombatta and Tiszaújváros refineries<br />

are connected by two two-way pipelines via<br />

Szajol. Their approximate capacity of 2.5 million<br />

tons per year makes it possible to transmit<br />

petrol components and diesel feedstock from<br />

Százhalombatta to Tiszaújváros in addition to<br />

suppling feedstock to TVK Plc. Two further<br />

pipelines operate between Százhalombatta and<br />

Komárom, offering the excellent option of loading<br />

goods for export onto barges for further<br />

transportation by water. Up until 1984, when<br />

crude oil processing stopped at Komárom, one<br />

pipeline supplied oil to the Komárom Crude<br />

Oil Company.<br />

Several power plants, as well as TVK Plc. and<br />

Ferihegy Airport, are directly connected to the<br />

MOL Group product pipeline system. High<br />

importance is attached to the Eastern pipeline<br />

(formerly known as Solidarity) which connects<br />

to the Ukrainian and Russian product pipeline<br />

systems, through which diesel oil with 0.2 %<br />

sulphur content is received by the Tisza Refinery<br />

for desulphurisation.<br />

The product pipeline system delivers engine<br />

petrol and diesel to eight logistics depots<br />

(Csepel, Szajol, Komárom, Pécs, Székesfehérvár,<br />

Ebes, Dombóvár, and Füzesabony).<br />

Only the Algyô depot is supplied by rail. (The<br />

largest share of transport from depots is by<br />

road, but deliveries – primarily for export – are<br />

also performed by barge and rail.)<br />

11<br />

Operation of product pipelines<br />

Over the last few decades, the quantity of product<br />

distributed by the pipeline system has increased significantly,<br />

and the product range has been greatly<br />

expanded. Today, the volume of weekly deliveries<br />

amounts to 200 to 240 thousand tons, and dozens of<br />

product types (engine petrols, diesel fuels, chemical<br />

feedstocks, power plant fuel oil, JET-A1 aircraft fuel<br />

and semi-finished products) are distributed by<br />

pipeline.<br />

For efficient pipeline distribution, a 3-4 day programme<br />

is prepared twice a week, that comprises<br />

sales requirements, materials in the pipelines, depot<br />

turnovers and stock levels, forecasted refinery output,<br />

various means of transport (road, rail, barge),<br />

purchase orders from customers who receive goods<br />

via pipeline (e.g. MALÉV and TVK), and the availability<br />

of support facilities. After discussion and agreement,<br />

the Central Dispatcher Service is given the<br />

programme to implement.<br />

Distribution by pipeline may only take place if conditions<br />

for safe distribution are in place at both sending<br />

and receiving points, and along the pipeline, and if<br />

the product to be distributed is available in adequate<br />

quantity and quality. Subsequent deliveries of crude<br />

oil products by pipeline is made using the so-called<br />

”plug” transportation method. To permit the separation<br />

of products of different quality – in addition to<br />

maintaining their quality – the exact location of 30 to<br />

40 “product plugs” must be simultaneously monitored<br />

within the pipeline network.<br />

The separation and metering of in-coming product<br />

grades takes place in depot receiving stations.<br />

Separation is mainly performed by measuring product<br />

density and colour and by shipment data. The phase<br />

oil generated in transit when various products<br />

“meet” is separated and returned to the refinery for<br />

re-processing. Only then may discharge into storage<br />

tanks commence.


Developing today’s pipeline<br />

management and supervisory<br />

system<br />

By the 1990s, the average product pipeline<br />

was over 20 year’s old, however, 50 year-old<br />

pipelines and 30 year-old pumping stations were<br />

also still in service. Metering equipment installed<br />

at transfer/delivery points was obsolete, making<br />

the accounting of quantities delivered problematical,<br />

thus tank-level gauging had to be used<br />

anew, in some cases. Moreover, the monitoring<br />

and management system was also not in compliance<br />

with requirements of the time. All these factors<br />

together threatened the operational reliability<br />

of pipeline distribution operations.<br />

Product mixing presented additional problems.<br />

The so-called “multi-batch” transport method<br />

used in the distribution system involved different<br />

products, already blended to reach their desired<br />

qualities, being sent down the pipeline without<br />

the use of a separating element, thus coming into<br />

direct contact and thus mixing with each other.<br />

Separation of different products was performed<br />

manually - for example, on the basis of colour.<br />

Among the others, methods of definition of a suitable<br />

product sequence was used in order to try to<br />

reduce mixed amounts (mixed product had to be<br />

forwarded to the Zalaegerszeg refinery for re-processing,<br />

thus increasing costs significantly).<br />

From the beginning of the 1990s, pipelines were<br />

frequently drilled by product thieves, which, in addition<br />

to economic damage caused to our company, also<br />

resulted in serious environmental pollution. It became<br />

obvious that of all the facilities operated by MOL, the<br />

pipeline network was both the most exposed to unlawful<br />

human intervention, and, at the same time, the least<br />

protected. However, the feasibility of classic security<br />

/protection measures (fences, cameras, guards) was<br />

limited, and thus only up-to-date electronic monitoring<br />

techniques could hope to provide on-going security.<br />

The monitoring system<br />

12<br />

To increase security, an upgraded metering<br />

project was launched in 1994, followed by the<br />

introduction of the crude oil and product<br />

pipeline operations monitoring system.<br />

The monitoring system provides full, centralised<br />

supervision of the pipeline network. This<br />

is a complex system comprising remote actuation<br />

and data inputting, and product monitoring<br />

modules, covering MOL’s total crude oil and oil<br />

product pipeline system. For implementation of<br />

this monitoring system, MOL and Cason Plc.,<br />

which was involved in the installation work,<br />

were awarded an Innovation Prize in 1999, followed<br />

by special recognition by the Chamber for<br />

Innovation in 2004, in acknowledgement of the<br />

additional upgrades.<br />

The monitoring system performs four basic<br />

functions:<br />

– process supervision<br />

– product monitoring<br />

– leakage and breakage detection<br />

– excise accounting (the product pipeline system<br />

functions as an bonded storage facility)<br />

The GEOFLO flow computer used for metering products<br />

(subject to excise duty)<br />

Communications within the system were set<br />

up in a completely new way using wireless data<br />

transfer (GPSR). Its function, in addition to<br />

transmitting process data – flow rate through the<br />

pipeline, density, pressure and temperature – is<br />

to monitor the security of the pipeline area, and<br />

detect intruders. The new system’s benefits are<br />

significant – some 50% reduction in operating<br />

costs, primarily because of the “intelligent”<br />

devices installed transmit data only if a change<br />

occurs in the above-mentioned parameters.


The other great advantage of the wireless<br />

data transfer system is its very high rate of operating<br />

performance, a typical index of which is<br />

99.9 % availability.<br />

Since 1999, this modern control system, with<br />

minimum personnel, has facilitated the forwarding<br />

of products to wholesale fuel depots to meet<br />

changing customer demand. Lower stock levels<br />

than previously needed have today become a<br />

norm – on both the seller and the buyer sides –<br />

while safety and security of supply has not been<br />

impaired.<br />

A very significant achievement, in addition to<br />

the monitoring system upgrade, is the accurate<br />

separation of product in the pipeline, with no<br />

deterioration in quality. This is because the location<br />

of specific materials (product “plugs”) is<br />

always known accurately, and thus the mixture<br />

generated when two products “meet”, which cannot<br />

be sold as a product, and can only be used for<br />

re-processing, can be reduced to a minimum.<br />

Central dispatch room<br />

13<br />

The system provides a very low rate of oil loss<br />

since leaks, spills and illegal siphoning can<br />

immediately be detected in the logistics dispatch<br />

centre, together with an accurate determination<br />

of the precise threat point, along the<br />

pipeline. Detection and location are based on<br />

excellent surge admittance property of liquids.<br />

At such times, the primary goal is the fast<br />

response, so that damage caused by product<br />

loss and leakage may be minimised. MOL and<br />

Cason plan to install a net made of thick fabric,<br />

positioned some 2 feet above the pipeline to be<br />

constructed to transport twin products between<br />

the Százhalombatta refinery and the TVK<br />

Tiszaújváros process unit. This net, when<br />

touched, will sound the alarm even before physical<br />

damage is done to the pipeline.


Changes in the role of<br />

rail transportation<br />

Railways still play an important but decreasing<br />

role in the transportation of refinery products,<br />

namely the expedition of exports, and the<br />

provision of feedstock to refineries. Currently,<br />

the most important rail transport tasks are:<br />

– feedstock supply<br />

– transportation of “twin products” generated<br />

by TVK (until the new Százhalombatta-<br />

/Tiszaújváros pipeline is ready)<br />

– supply to the Algyô wholesale storage<br />

depot, which has no pipeline access<br />

– export deliveries<br />

– services to customers (limited to the few<br />

who have the necessary railway sidings<br />

and discharge gantries).<br />

Owing to the nature of the products, rail distribution<br />

requires special tanker cars. Our company<br />

employs both its own and leased transport (the<br />

proportion of our own rail tanker cars being hardly<br />

more than 10 %), and is aiming to use blocktrains<br />

for distribution purposes in future.<br />

Unlike so-called “dispersed traffic”, deliveries<br />

by block-train in general, accrue lower<br />

freight costs, faster forwarding, and a more<br />

efficient and economic use of specialised<br />

transportation. A pre-condition to implementing<br />

the block-train concept is the size<br />

of demand for relatively large quantities.<br />

The Százhalombatta refinery has 3 high-capacity<br />

rail loading gantries in place for the loading of<br />

diesel, motor gasoline grades, aromatics, JET-A1<br />

aircraft fuel, heating oils and other products.<br />

Their combined loading capacity totals 2.5 million<br />

t/year. In addition, another rail tank-car loading<br />

gantry, with a capacity of 150 thousand t/year, is<br />

operated for liquefied gases, whilst loading of<br />

base oils, bitumen grades and sulphur into rail<br />

tanker cars is also possible. Some 1.2 million<br />

tons of product are distributed by rail from the<br />

refinery, annually. A significant proportion of rail<br />

deliveries to the refinery concerns domestic<br />

crude oil and LPG, the BT fraction from TVK Plc.,<br />

styrene and imported products (naphtha and<br />

kerosene). Rail deliveries to the refinery amount<br />

to about 1.5 million tons, annually.<br />

14<br />

The rail point-loading gantry at the Tiszaújváros<br />

refinery loads diesel oil exclusively for<br />

export. The annual quantity delivered by rail<br />

totals about 200 thousand tons. Tiszaújváros<br />

receives LPG and iso-pentane by rail, which are<br />

then used as gasoline blending components.<br />

Some of the logistics depots (Komárom,<br />

Székesfehérvár, Pécs, Ebes, Szajol), which are<br />

supplied by pipeline, also expedite products by<br />

rail, primarily to export markets. The Algyô<br />

base depot, which is supplied by rail, typically<br />

receives goods from Szajol.<br />

Rail transport<br />

The role of rail transport will gradually fade<br />

into the background in the long term. Whereas,<br />

in the past, it was of great importance to heating<br />

oil distribution, today, owing to refinery<br />

upgrades, and in particular to residue processing<br />

upgrades, executed in line with changing<br />

environmental regulations and market demand,<br />

the production of heavy, sulphur-containing<br />

heating oil has been discontinued, and low sulphur<br />

heating oil has lost market share. At the<br />

same time, with the upgrading of residue processing,<br />

commissioned in November 2001, a<br />

new product, petcoke, was launched, the transportation<br />

of which is primarily carried out by rail.


Loading petcoke into rail wagons<br />

Trends clearly show that the shares of<br />

pipeline and road tanker lorry distribution have<br />

increased at the expense of rail. Increasing road<br />

transportation is also due to the profile of<br />

today’s customers, since the majority of endusers,<br />

the most important target group, is technically<br />

unable to receive and discharge rail<br />

tanker cars.<br />

Moreover, customers mostly purchasing<br />

small or medium annual quantities, operate with<br />

relatively low inventories, partly due to limited<br />

storage capacities, and partly to reasons of<br />

liquidity. Thus, these customers order frequently<br />

and relatively small quantities for one occasion<br />

and, in order to meet this demand, a much<br />

more flexible type of transportation than rail<br />

is required.<br />

Shares by transport type – 1997 and 2004<br />

15<br />

Transportation by barge<br />

More economic than rail, transportation of<br />

crude oil by barge was used as early as the 19 th<br />

century. The use of barges to transport petroleum<br />

products only started in Hungary in the<br />

1950s. Initially, heating oil was shipped from<br />

Komárom to Csepel by barge, and later diesel<br />

oil was distributed by barge from Százhalombatta<br />

to Ordas, located near Kalocsa, from<br />

the 1960s onwards.<br />

Barge loading gantry<br />

Today, MOL’s two Danube sites – the<br />

Százhalombatta Duna Refinery and the<br />

Komárom storage depot – have barge-loading<br />

facilities, from which shipments, exclusively<br />

for export, sail to Austria and Germany. The<br />

advantage of transportation by water is the relatively<br />

low cost, while its disadvantage is that<br />

navigability of the River Danube is influenced<br />

significantly by water levels and weather conditions.<br />

In periods of low river levels, vessels’<br />

draughts may be limited, impacting their efficiency.<br />

In wintertime, navigation may be interrupted<br />

by heavy ice-floes.


Revamp and rationalisation<br />

of wholesale storage depots<br />

MOL inherited a wholesale storage depot<br />

network from ÁFOR of low efficiency, broken up<br />

into small sites, mostly obsolete, and larger in<br />

capacity than necessary. Accordingly, network<br />

rationalisation was started soon afterwards.<br />

Parallel to this, the revamping of depots designated<br />

for continuing operations in the longer<br />

term was being carried out to a uniform concept.<br />

Thus the goal here was to improve economically-operated<br />

high capacity depots in<br />

engineering and environment terms, whilst<br />

closing down lower capacity and un-economic<br />

storage facilities. The decision to revamp and<br />

rationalise was made a short time after MOL<br />

was established. The upgrade was implemented<br />

partly with World Bank financing. In executing<br />

this large scale project, MOL – just as in the<br />

quality upgrading of fuels, implemented from<br />

the beginning of 1990s – took standard and<br />

ever more stringent EU engineering and environmental<br />

directives into consideration, long<br />

before Hungary entered the European Union.<br />

This upgrade had<br />

a jump-start due to<br />

the appearance of<br />

new, modern, non-<br />

MOL owned fuel<br />

storage depots,<br />

Lifting a storage tank roof<br />

into position<br />

established to store<br />

the country’s strategic<br />

reserves. More-<br />

over, owners rented their free capacity to new<br />

players appearing on the deregulated oil industry<br />

scene (competition in the field of storage<br />

grew in other ways as well).<br />

During the upgrade of the longer-term<br />

depots, tank farms were modernised. To<br />

reduce risk of leakage, vertical cylindrical<br />

tanks were fitted with double- bottoms, and<br />

internal floating roofs were installed in storage<br />

tanks containing gasoline grades. The installation<br />

of double walls in underground horizontal<br />

cylindrical tanks was also implemented.<br />

16<br />

Tank farms were also equipped with state-ofthe-art<br />

electronic level gauging and process control<br />

systems. Through listed upgrades – in addition<br />

to compliance with statutory specifications – envi-<br />

Tank farm<br />

ronmental pollution was removed, or minimised,<br />

the evaporation losses encountered during storage<br />

and distribution were significantly reduced,<br />

and MOL inventory management efficiency was<br />

improved through the creation of a modern and<br />

accurate inventory monitoring system.<br />

Before this, tanks had been fitted with<br />

fixed roofs where large or small volumes<br />

of vapour volume could appear between<br />

liquid surfaces and roofs, at a rate according<br />

to discharging. In tanks with floating<br />

roofs, roofs are always located at liquid<br />

level so, no such vapour can develop. This<br />

system reduces the chance of explosive<br />

mixture developing in tank volume, loss<br />

arising from tank venting, and the burden<br />

on the environment due to evaporation.


At the same time, the closing down of obsolete<br />

and uneconomic depots was started - a long<br />

process implemented step-by-step over the<br />

years, that is still in progress today. In 1992,<br />

whereas 63 such depots were in operation in<br />

Hungary, by 1994 there were only 40 to 45, and<br />

this number was further reduced to 21 by the<br />

end of 1995. In 1996, a fresh wave of “rationalisation”<br />

occurred. Low capacity depots at<br />

Salgótarján, Sátoraljaújhely, Baja, Békéscsaba,<br />

Cegléd and Ócsa (all without pipeline connections<br />

except the last two) were closed down.<br />

Vertical cylindrical tanks and other equipment<br />

were demolished, underground tanks removed,<br />

required earthworks and soil replacement<br />

(necessary mostly for old “railway” depots)<br />

completed, and groundwater cleaned. Minor<br />

environmental follow-up work is still in progress.<br />

By closing smaller depots, depot supply<br />

costs were reduced, capacity utilisation<br />

improved, and significant savings in operating<br />

costs accrued. To optimise depot inventory levels,<br />

to ensure trouble-free discharge, and to fully<br />

comply with Excise Duty Act requirements, it<br />

has become vital to keep accurate records of<br />

inventories in depots and in transit, and to operate<br />

the different depot systems in a coordinated<br />

manner. This has been achieved by the development<br />

and introduction of depot monitoring systems.<br />

The reliability and general standards of<br />

customer service have had to be improved to<br />

cater for engineering, computer and organisa-<br />

MOL’s current domestic wholesale depots<br />

and depots closed or to be closed down<br />

between 1993 and 2006<br />

Vép<br />

Zalaegerszeg I. telep<br />

Nagykanizsa<br />

Mosonmagyaróvár<br />

Gyôr<br />

Csorna<br />

Veszprémvarsány<br />

Sümeg<br />

Marcali<br />

Barcs<br />

Kaposvár<br />

Komárom<br />

Székesfehérvár<br />

Tata<br />

Százhalombatta<br />

Simontornya<br />

Csepel<br />

Dunaújváros<br />

Kalocsa<br />

Dombóvár<br />

Tolna-Mözs<br />

Bonyhád<br />

Baja<br />

Pécs<br />

Szécsény Salgótarján<br />

Bp. Gyömrôi u.<br />

Ócsa<br />

Cegléd<br />

Füzesabony<br />

Kecskemét<br />

Kistelek<br />

Szajol<br />

Szentes<br />

Algyô<br />

Miskolc<br />

Tiszaújváros<br />

Orosháza<br />

Polgár<br />

Békéscsaba<br />

17<br />

Szeghalom<br />

Loading a tanker lorry<br />

tional upgrades executed in parallel, and to meet<br />

the needs of improved planning accuracy.<br />

Today, other upgrades are also in progress: they<br />

focus firstly on the upgrading of process control<br />

software, used by road tanker lorry loading stations.<br />

By doing so, the reliability of accounting<br />

of quantity of expedited products has increased.<br />

Sátoraljaújhely<br />

Remaining depots<br />

Product pipeline<br />

The risk of overfilling a road tanker lorry may<br />

either be caused by human error, or by failure of<br />

the automatic gantry meter. This device, used to<br />

prevent overfilling when bottom loading, is an<br />

electronic system called LIBERTY. Connected to<br />

the road tanker lorry, this device detects when<br />

its compartments are full, and stops the loading<br />

procedure automatically. When top loading, the<br />

driver keeps a switch closed throughout the<br />

loading process, which, if released, causes loading<br />

to shut down immediately.<br />

Nyíregyháza<br />

Nyírbogdány<br />

Date of<br />

closure:<br />

1993<br />

1994<br />

1995<br />

1996<br />

1999<br />

2000<br />

2004<br />

2005<br />

2006<br />

An additional objective<br />

has been to make loading<br />

activity more efficient and<br />

safe through use of protection<br />

against overfilling, on a<br />

broad scale.


Development of the tanker lorry fleet<br />

As early as the 1950s, just like today, transport<br />

of products from logistics depots was primarily<br />

carried out using purpose-built tanker lorries.<br />

The ÁFOR fleet then consisted of 70 to 80<br />

vehicles, with a typical capacity of just a few<br />

thousand litres. In addition to motor gasoline<br />

and diesel, vacuum residue and kerosene were<br />

also frequently transported by road. Since the<br />

number of filling stations was very low – 60 to 70<br />

in all – supply to important end-users, among<br />

them a large number of industrial plants, naturally<br />

took on a higher priority.<br />

Semi-trailer type Tanker Lorry<br />

With the increase in consumption of petroleum<br />

products and with the gradual expansion of<br />

the filling station network, distribution tasks<br />

increased at a fast rate. In the 1970s, the number<br />

of tanker lorries reached 300, but gradually<br />

decreased thereafter.<br />

Following the change in political régime, the<br />

task of effectively meeting demand from new<br />

retail players, in addition to that caused by economic<br />

diversification – the partial disappearance<br />

of traditional large consumers and the<br />

simultaneous appearance of large numbers of<br />

new ventures – and the need to satisfy the<br />

requirements of ever-increasing competition,<br />

combined to present a significant new distribution<br />

challenge.<br />

18<br />

Automated tanker lorry filling gantry in Százhalombatta,<br />

on the territorry of Danube Refinery<br />

The modernisation of road tanker fleet, in<br />

connection with improvement of wholesale storage<br />

depots meant the purchase of up-to-date,<br />

high-capacity tanker lorries, in line with new<br />

technology, which permitted much higher loading<br />

rates compared to the previous ones, and<br />

the removal of low-capacity obsolete vehicles<br />

from service.<br />

The current vehicle pool operated by<br />

MOLTRANS Ltd consists of hardly more than<br />

one hundred tanker lorries, but their average<br />

size, however, is much greater than those made<br />

obsolete. The majority of these larger vehicles is<br />

of the semi-trailer type. Semi-trailers have 35m 3<br />

capacity aluminium tanks split into 5 compartments<br />

and equipped with two flow meters. For<br />

customers ordering smaller quantities, or for<br />

delivery to locations where larger vehicles cannot<br />

gain access, deliveries are made using<br />

smaller, rigid tanker lorries with a capacity of<br />

13 m 3 to 15m 3 .<br />

Automated top loading of a tanker lorry


Vehicles equipped with pumps are also used<br />

to fill above-ground tanks. As a result of ongoing<br />

improvements, the majority of tanker lorries<br />

is very modern and reliable. Between 2004<br />

and 2005, 45 new tractors for semi-trailers were<br />

purchased, and the renewal of tanker lorries and<br />

semi-trailers continued (which means improvements<br />

in metering systems, and the installation<br />

of pumps and turbine-discharge systems).<br />

LPG tanker lorry<br />

Since the fuel demand varies seasonally,<br />

from time to time MOL hires freight services<br />

from third-party hauliers; the requirements set<br />

for the latter are as stringent as those applied to<br />

MOL’s own tanker lorry fleet.<br />

The majority of MOL’s 7000 current domestic<br />

wholesale customers is supplied with fuels,<br />

LPG products, bitumen and other crude oil<br />

derivatives through use of both MOL-owned<br />

and contractor tanker lorries.<br />

19<br />

The establishment of a Central Freight<br />

<strong>Logistic</strong>s Unit<br />

Whereas purchase orders used to be<br />

received and fulfilled by individual depots, since<br />

2002, both order-taking and freight dispatching<br />

– in respect of road distribution – have been performed<br />

centrally.<br />

Customer orders are received through several<br />

channels – telephone, fax, or email – and then<br />

recorded in the ERP (SAP) system of the Company.<br />

Based on the status of orders, depot inventories<br />

and tanker lorry availability for the following<br />

day, the Central Freightage <strong>Logistic</strong>s Unit<br />

decides, using a scheduling and optimising software,<br />

from which depot and which tanker lorry<br />

will supply an individual customer.<br />

Supplies to MOL Filling Stations are performed<br />

using the same system, based on continuous<br />

monitoring of their inventory levels,<br />

and daily sales figures. When “allocating”<br />

transport tasks, the size and type of tanker<br />

lorry (e.g. equipped with pump) that individual<br />

customers are technically capable of receiving,<br />

must also be considered.<br />

After the closure of the Vép depot, near<br />

Szombathely, in 2005, supplying customers in<br />

Western Hungary was carried out by Slovnaft’s<br />

Bratislava refinery, in Slovakia.<br />

MOL promises to supply motor fuels – the<br />

highest proportion of its fuel sales – the workday<br />

following date of order. Deliveries are typically<br />

made during work-days because supplying<br />

over weekends is restricted by “truck stop” laws.


<strong>Logistic</strong>s of Chemical products<br />

TVK, the leading company in the Hungarian<br />

petrochemical industry, is a member of MOL<br />

Group. MOL supplies TVK with feedstock, most<br />

of the 1.7 million tons of petrochemical feed<br />

(naphtha, petrochemical grade diesel) being<br />

transported to TVK through a 236 km-long<br />

pipeline from the Százhalombatta refinery.<br />

The remaining free capacity of this pipeline is<br />

used by MOL to supply its Tisza Refinery, as<br />

well as the Region, with diesel components, or<br />

gas oil end-product.<br />

Ethylene tank at TVK, with a pipeline in the foreground<br />

MOL purchases by-products, generated during<br />

the TVK pyrolytic process, and uses a small<br />

portion of them (low-sulphur xylene fraction) in<br />

the Tiszaújváros refinery, and the rest (benzenetoluene<br />

fraction, high-sulphur xylene fraction) –<br />

in the Százhalombatta refinery. The low-sulphur<br />

fraction arrives at the Tisza Refinery by pipeline,<br />

whilst the benzene-toluene (BT) and high-sulphur<br />

xylene fractions are transported to Százhalombatta<br />

by rail.<br />

Present construction of a new transport pipeline<br />

between Tiszaújváros and Százhalombatta is<br />

expected to be completed by the end of 2006. This<br />

pipeline will be capable of delivering benzenetoluene<br />

fraction and xylene fraction to Százhalombatta<br />

(a total of 278kt/year) with free capacity being<br />

used for the movement of other chemical products.<br />

In light of increases in quantities of feedstock<br />

and by-products to be transported, MOL is carrying<br />

out large-scale modernisation measures,<br />

both at Tiszaújváros and Százhalombatta, to<br />

provide the technical conditions required for<br />

increased logistics capability.<br />

20<br />

Quality Maintenance function<br />

of the <strong>Logistic</strong>s<br />

It is a priority goal of the <strong>Logistic</strong>s and its<br />

operators to maintain product quality. Products<br />

must meet quality specifications all along the<br />

line, not merely “at the refinery gates”, but at<br />

Filling Stations and wholesale purchaser premises,<br />

at the moment of on-site product discharge<br />

into storage tanks. Up to the mid-90s,<br />

several justifiable complaints were raised<br />

about MOL product quality, which, in some<br />

cases, could be traced back to deficiencies in<br />

logistical equipment and procedures in force at<br />

the time.<br />

These problems occurred despite the fact<br />

that the refineries were producing products<br />

with significant ”quality reserve”. In the second<br />

half of the 90s, efforts were made to<br />

improve <strong>Logistic</strong>s capability to maintain quality.<br />

This involved some engineering/process<br />

upgrades (e.g. elimination of former corrosion<br />

problems), the implementation of very detailed<br />

and stringent <strong>Logistic</strong>s process regulations<br />

and the strengthening of Quality Control<br />

measurements.<br />

Quality Control laboratory


Storing strategic stocks<br />

Establishment and functions of the International<br />

Energy Agency (IEA)<br />

In 1973, when oil prices shook world markets,<br />

and with developed industrialised countries meeting<br />

a significant portion of their crude oil demand<br />

from imports, the need to stockpile reserves of<br />

crude oil and petroleum products became clear,<br />

and thus the International Energy Agency (IEA)<br />

was established in 1974. Its most important function<br />

was to guarantee the security of energy supplies.<br />

To partly reduce their dependence on crude<br />

oil imports, member countries – with the participation<br />

of market players, and in an environment free<br />

of competition – established reserve stocks to be<br />

used under controlled and agreed conditions.<br />

These stocks may be released only in cases of<br />

serious interruption to crude oil and petroleum<br />

product supply that upsets the balance between<br />

production and consumption. Like the European<br />

Union, this organisation specifically obligates its<br />

members to stockpile inventories equal to their<br />

90-day consumption levels.<br />

Establishment and functions of Association of<br />

Crude Oil & Petroleum Product Stockpiling<br />

(KKKSZ)<br />

The need for a market-based energy reserve<br />

in Hungary became clear after its conversion to<br />

a market economy. At the time, the country only<br />

had reserves of liquid hydrocarbons sufficient<br />

for 2 to 3 weeks, but there had been times when<br />

inventories dropped to a 4-day supply level. In<br />

1993, as the first ex-socialist country to do so,<br />

Hungary introduced legislation based on IEA<br />

directives, and in line with Western European<br />

practices. The 1993 Act Number IL prescribed<br />

the strategic stockpiling of crude oil and the<br />

establishment of the Association of Crude Oil &<br />

Petroleum Product Stockpiling (KKKSZ).<br />

By the end of 1998, KKKSZ had created more<br />

than 1.2 million tons of crude oil and petroleum<br />

product reserves that can provide 90 days of<br />

trouble-free consumption for the country. In<br />

doing so, Hungary both satisfied the obligations<br />

set as a pre-condition to joining both the EU and<br />

the IEA, and the provisions of the Act.<br />

21<br />

The Association initiated five storage companies<br />

(IPR Celdömölk, IPR Vámosgyörk, Petrotár,<br />

Kôolajtároló, and Terméktároló) which by now<br />

are owned fully or partly by KKKSZ. During the<br />

last 10 years, these companies have established<br />

new modern storage capacities.<br />

Storing emergency reserves<br />

MOL Plc. regularly participates in open<br />

KKKSZ tenders for storage and procurement.<br />

About one third of the Association’s inventories<br />

are stored at MOL depots on the basis of<br />

long-term availability contracts. Established<br />

with a majority MOL ownership in 1996,<br />

Kôolajtároló Plc. has constructed crude oil<br />

storage tanks for reserve stockpiling purposes,<br />

each with a capacity of 80,000 m 3 , 4 of<br />

them at the Duna- and 2 others at the Tisza<br />

refineries; the company was acquired by<br />

KKKSZ in 2001. Commissioned by KKKSZ,<br />

MOL also stores petroleum products at its<br />

Komárom and Szajol depots, in addition to<br />

those at its two refineries.


Business relations between<br />

MOL and NATO<br />

Business relations between MOL and<br />

NATO go back 10 years. MOL regularly submitted<br />

tenders for supply of fuel to NATO, for<br />

the South Slavic countries, and was awarded<br />

contracts in several cases.<br />

US Government representatives contacted<br />

MOL for the first time in early November<br />

1995 – prior to Hungary’s entry into NATO –<br />

regarding the matter of providing, storing and<br />

supplying JET A-1 aviation fuel. Following<br />

many rounds of negotiation agreement was<br />

reached for MOL to make available the total<br />

storage capacity of its Dombóvár depot, with<br />

the required operational structure, to the US<br />

Government.<br />

This contracting process was preceded by<br />

significant technical preparation. The whole<br />

depot had to be emptied, tanks and pipelines<br />

flushed and cleaned. It also became necessary<br />

to rearrange technological systems at the pumping<br />

station and the road tanker lorry loading<br />

gantry, and to purchase and install special filters.<br />

A suitable additive-dosing system had to be<br />

configured, and other process equipment purchased.<br />

In 1999, Ferihegy Airport was the base<br />

for military operations over Bosnia.<br />

NATO fuel transport aircraft<br />

For departing fighter helicopters, MOL<br />

supplied fuel under an “into-plane” contract,<br />

partly from its own production, and partly<br />

from imports, since demand exceeded<br />

MOL’s refinery capacity.<br />

22<br />

Discharge of product shipped by barge was<br />

performed in the logistical facilities at<br />

Százhalombatta, and then – together with locally-produced<br />

fuel – JET A-1 was delivered by<br />

pipeline to Ferihegy Airport. All this required<br />

extremely well-orchestrated production, commercial<br />

and logistical activities, to meet the high<br />

standards expected by NATO, both in terms of<br />

product quality and logistical services.<br />

In September 2005, the Hungarian Ministry of<br />

Defence concluded a contract with MOL whereby<br />

the company agreed to place specified storage<br />

capacity, together with transport and loading<br />

equipment, all meeting required technical<br />

standards, at the disposal of NATO in emergency<br />

situations, and, if required, to provide aviation<br />

and motor vehicle fuels to meet NATO<br />

demand. For the very first time in the history of<br />

NATO the need for supply of large amounts of<br />

fuel was resolved not from military-operated<br />

storage facilities – the construction and maintenance<br />

of which would have required significant<br />

expenditure – but, in Hungary, through a longterm<br />

leasing of MOL depot facilities, necessary<br />

in a national economy anyway, and requiring<br />

less upgrade measures. The airfield at Kecskemét<br />

is connected to a pipeline which permits<br />

direct access to MOL’s distribution system. The<br />

revamp of these external storage facilities and<br />

pipeline construction were funded from NATO<br />

resources.


MOL and the airline industry<br />

At most airports around the world, aircraft<br />

fuel is supplied directly by oil companies, under<br />

so-called “into-plane” service agreements.<br />

In Hungary, the most significant airport fuel<br />

supply operations take place at Ferihegy<br />

International Airport. Here, the aircraft refuelling<br />

company Repülôtéri Üzemanyag<br />

Kiszolgáló (RÜK) delivers 70 % of fuel supplies<br />

to aircraft, in addition to meeting Hungarian<br />

national carrier MALÉV demand, thus accounting<br />

for the refuelling needs of most airlines<br />

using the airport. RÜK Ltd purchases JET A-1<br />

fuel from MOL under a delivery and commercial<br />

contract.<br />

In recent years, with the participation of<br />

major foreign investors, the upgrading of other<br />

airports around Hungary (Debrecen, Sármellék,<br />

Gyôr-Pér) has commenced, resulting in a spectacular<br />

increase in demand for jet fuel. By maximising<br />

its production capacity, MOL has made<br />

preparations to meet this demand.<br />

23<br />

JET A-1 (kerosene) fuel is used by modern jetengine<br />

aircraft and turbine-driven helicopters.<br />

The development of the jet engine to power<br />

aircraft was started in the 1930s. The first<br />

flight of an aircraft mounted with a jet<br />

engine took place in Germany in 1939, the<br />

invention of Hans von Ohain. Jet aircraft<br />

started to be commonplace all over the<br />

world during the ‘70s.<br />

The most important requirement of jet fuel<br />

is that it has to be clean, clear, and free<br />

of water and mechanical impurities. This<br />

must also be kept in mind in production,<br />

marketing and use.<br />

Delivery of kerosene requires extreme<br />

care, whether by pipeline, tanker lorry<br />

or other means.<br />

To satisfy JET A-1 fuel demand, MALÉV constructed<br />

a 38km pipeline between Százhalombatta<br />

and Budapest Ferihegy Airport in<br />

1983/1984. MOL’s legal predecessor, ÁFOR,<br />

commissioned this kerosene supply pipeline,<br />

and MOL still operates it to this day.<br />

Passing through a variety of filters, JET A-1<br />

refuels aircraft under strict quality control.


MOL Group’s regional logistics<br />

system and its activities<br />

The target market for the sales by MOL<br />

Group is the Mid-East-European region, which<br />

includes Hungary, Slovakia, Poland, Czech<br />

Republic, Austria, Romania, Serbia-Montenegro,<br />

Bosnia, Croatia and Slovenia. These are the<br />

areas that can be – partly or fully – supplied economically<br />

from MOL Group’s wholesale storages<br />

connected by pipeline.<br />

MOL Group’s share in the fuel market in the countries<br />

of the region<br />

For a decade MOL has been trying to<br />

increase its sales and strengthening its market<br />

positions in the Mid-East-European region. From<br />

the mid 1990’s the regional expansion meant<br />

primarily the construction of filling stations in<br />

the countries neighbouring Hungary. Starting<br />

from 2000 the company increased its markets<br />

through a set of acquisitions: in 2000 it obtained<br />

minority share followed by majority share in<br />

2002 in the Slovakian oil company Slovnaft, in<br />

2003 became 25 % owner of the Croatian INA,<br />

and in 2004 purchased both Shell’s Romanian<br />

subsidiary and the majority share in an Austrian<br />

oil product marketing business Roth Heizöle.<br />

MOL, Slovnaft and INA are all market leaders<br />

domestically, and also have significant positions<br />

in the other countries of the region.<br />

24<br />

Slovnaft railway tanker car<br />

The logistical system of MOL and Slovnaft<br />

operates in an integrated manner under a joint<br />

management. Its strengths are the possibility of<br />

crude oil purchase via pipeline and operating the<br />

nearly 1700 km long product pipeline system with<br />

an efficient fuel storage depot system; the latter<br />

has a key role in the supply to the domestic markets.<br />

In order to optimise the costs, the two companies<br />

also supply each other’s domestic market:<br />

Eastern part of Slovakia is supplied partly from<br />

Tisza Refinery, and part of the customers in<br />

Western Hungary receive goods from Bratislava.<br />

Half of the products, some 6 million tons, lifted<br />

from the MOL and Slovnaft refineries find<br />

their buyer in third markets, mostly within the<br />

region; based on the sales volume the most<br />

important markets abroad are Austria and the<br />

Czech Republic. MOL’s farthest fuel market is<br />

Germany (Bavaria). For handling this huge<br />

amount of goods an advanced logistical system<br />

and harmonised activities are required.<br />

An engine in Slovnaft’s colours


MOL’s business objectives include that the<br />

so-called sale in “bulk”, i.e. at large quantities to<br />

retailers without providing services should gradually<br />

be replaced by a direct supply to the filling<br />

stations and end users abroad. This means that<br />

a high number of local customers are to be supplied<br />

with relatively low quantities. Performing<br />

this function very important expectations against<br />

the logistical activity are in place – in addition to<br />

the cost effectiveness – the fast response –<br />

product delivery within a short time from purchase<br />

order - and reliability. To satisfy these<br />

expectations the availability of a suitable logistical<br />

background (storage depots, transport<br />

means) is necessary.<br />

In order to meet the objectives mentioned<br />

above, MOL Group had purchased the wholesale<br />

fuel storage depot at Korneuburg, near<br />

Vienna, from company Avanti, which after a<br />

significant upgrading was opened at the end<br />

of September 2003.<br />

This depot at Korneuburg can be supplied<br />

by both barge and rail from the refineries at<br />

Százhalombatta and Bratislava. Through the<br />

acquisition of the Roth Company MOL Group’s<br />

asset inventory in Austria has been increased<br />

with one more depot.<br />

The depot at Korneuburg<br />

Slovnaft’s refinery at Bratislava has a direct<br />

pipeline connection to the Czech product pipeline<br />

system, which facilitates a cost effective supply.<br />

MOL Group’s high rate of presence in the Czech<br />

Republic is supported by several depots connected<br />

to this pipeline and also by a leased depot.<br />

The deliveries to the customers in Poland are<br />

made from three leased depots, which are supplied<br />

with fuels by rail from Bratislava and Tiszaújváros.<br />

25<br />

The supply to the South-Slavic markets is<br />

performed by both rail and road transport.<br />

MOL also delivers to these countries significant<br />

amounts of bitumen, a product typically<br />

transported on the road to the buyer. The loading<br />

of the bitumen transport trucks is made at<br />

Százhalombatta.<br />

In Romania, where MOL has a significant<br />

retail network that provides a countrywide coverage,<br />

<strong>Logistic</strong>s has an even more important<br />

function, since it is to ensure the supplies more<br />

than 130 filling stations with partly MOL’s own<br />

fuels, and partly with fuels purchased from local<br />

refineries on a continuous basis. In order to<br />

perform this function, Company operates its<br />

own depot at Tileagd, and a leased depot in<br />

Prejmer (near Brasov).<br />

MOL Group’s logistic system<br />

There is no pipeline connection between the<br />

two largest refineries (Százhalombatta and<br />

Bratislava) of MOL Group .<br />

The feasibility of connecting the product<br />

pipeline systems of the two countries is being<br />

reviewed, considering the current and expected<br />

order of magnitude and continuity of the<br />

product flows between them. Through this<br />

connection the Hungarian and Czech networks<br />

would be linked in between, and a chance to<br />

supply semi-finished products amongst the<br />

refineries could become possible.


Notes<br />

27

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