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Onshore Middle East is the cheapest source of new oil production, as the cost of developing new upstream oil projects continues to rise, according to new research from Rystad Energy

According to Rystad Energy, the average breakeven cost of a non-OPEC oil project grew to US$47 per barrel of Brent crude, a 5% increase in the last year alone, thanks to inflationary pressure and supply chain issues. Offshore deepwater and tight oil projects remain the most economical new supply sources, with oil sands still the most expensive.

The report found that onshore Middle East is the cheapest source of new production, with an average breakeven price of just US$27 per barrel. This segment also boasts one of the most significant resource potentials. Offshore shelf is the next cheapest (US$37 per barrel), followed by offshore deepwater (US$43) and North American shale (US$45). Conversely, oil sands production breakevens average US$57 per barrel, but can go as high as around US$75.

Cost pressures

"Rising breakeven prices reflect the increasing cost pressures on the upstream industry. This challenges the economic feasibility of some new projects, but certain segments, including offshore and tight oil, continue to offer competitive costs, ensuring supply can still be brought online to meet future demand. Managing these cost increases will be critical to sustaining long-term production growth,” said Espen Erlingsen, head of Upstream Research at Rystad Energy.

As well as breakevens, average payback for new projects, internal rate of return (IRR) and carbon dioxide (CO2) intensity are vital metrics for evaluating new oil development economics. The tight oil sector’s payback time is just two years, assuming an average oil price of US$70 per barrel, illustrating how quickly operators are recovering their investments. Payback time is closer to 10 years or more for the other supply segments. Tight oil also leads the pack in terms of IRR, with an estimated IRR of around 35% in the same average oil price scenario. Conversely, oil sands, the most expensive supply source, has the lowest IRR of approximately 12%.

Over the last three years, the average CO2 intensity for tight oil has been 14 kilograms per barrel of oil equivalent (kg per boe), while deepwater has a slightly higher average CO2 intensity of 15 kg per boe. The oil sands sector again falls behind the other segments, with the highest future estimated emissions at around 70 kg per boe.

Mark Moffat, CEO of IFS,  gave an inspiring opening address at the IFS Unleashed event on the power of Industrial AI, underlining the company’s ambition to become the undisputed leader in industrial software

Taking place in Orlando Florida from 15-17 October, the event hosted by the leading provider of Industrial AI and enterprise software brings together the most innovative and forward-thinking businesses and leaders from across the world, attracting thousands of users, technology leaders and executives to unlock the transformative power of Industrial AI.

“The next industrial revolution is being powered by industrial AI, and Industrial AI is ifs.ai,” said Moffat.

“We are seeing an exponential impact in the computing power and innovation that is impacting every single aspect of enterprise technologies and software, which has seen vast innovations happening at scale and lightning speed, which is literally going to change the face of industry and business and companies in this room as we know it today.”

Moffat pointed out that according to Goldman, between 2-4% of developed economies will spend one to two trillion dollars in the foreseeable future on AI capabilities, while Accenture has estimated it will add 14 trillion to the global economy in the next 10 years. This represents a gigantic opportunity which should be grabbed with both hands, he said.

New vision

“We’re setting a new and evolved vision for IFS. Our vision is to become the undisputed category leaders in industrial software, the number one brand,” he said.

All the businesses and customers it serves will benefit from this ambition, which will see IFS build on its depth of knowledge and understanding of the six core industries it serves, powered by the IFS cloud platform which manages the company white data that will be needed to unlock value.

“It’s supported by an AI mission that never been more relevant than it is today, creating a class-leading AI platform that helps our customers manage their mission-critical assets, workflows and people in a responsible way,” continued Moffat.

“We’ve already been doing this for a long time; we have a market-leading scheduling and optimisation engine that has demonstrated productivity improvements and the carbon reduction that comes with that. This AI engine can be used to optimise any arrangement of plants and assets and field resources right across the industrial software value chain. We’ve also got an operational intelligence platform that delivers phenomenal AI capability, ingesting vast amounts of time series data from some of the biggest natural resources companies in the world.” He gave the example of Basra Energy, where a real-time video feed from a refinery is used to determine basic AI algorithms enabling the adjustment of production processes to reduce methane and carbon emissions.

Underlining the importance of collaboration and partnership Moffat said, “Driving transformation isn’t easy. It requires courage, teaming and collaboration, and we get that from our partners together, being stronger, better and faster. We innovate more and we bring our customers more choice.”

He said that the company is significantly upping its investment in R&D, with over 30% of its manpower today invested in products. “It’s enabled us to accelerate rapidly our investment in AI,” he said, noting that the company is working on over 300 high value use cases which will deliver real ROI to businesses, using its proven value engineering capability.

He added that IFS has been strengthened by recent acquisitions, mostly recently acquiring Copperleaf Technologies, a leader in asset investment planning, which helps companies make smarter capital investment decisions.

Moffat also highlighted the company’s focus on responsibility and sustainability in leading this new industrial revolution, in particular in its commitment to drive sustainable outcomes from industrial AI.

“This also makes good business sense, as the type of actions that reduce carbon also allow the optimisation of processes, improving productivity, increasing uptime and reducing fuel consumption.”

He added that among the new products being developed is a new sustainability module, which will help customers track and manage sustainability KPIs.

Moffat concluded by urging the audience to take full advantage of the learning and networking opportunities over the three days of IFS Unleashed. “Don’t waste this opportunity,” he said. “You need an AI business plan. And if you already have an AI business plan, you can improve it. We can help you do that this week. Let’s go, and let’s go get unleashed.”

At IFS Unleashed, the 2,500 attendees will hear from multiple IFS customers across different industries as they showcase practical applications of IFS Cloud, IFS.ai and Industrial AI in action, including BAE Systems, Continental Resources, Ericsson, Exelon, Keurig Dr Pepper, Kimberly-Clark, Konica Minolta, LATAM Airlines, Mars, Nestle, Tomra, and Xcel Energy. Immersive, real-world demonstrations will show how AI, machine learning, virtual reality, and automation solve industry challenges and drive efficiency.

IFS will also provide early insight into the forthcoming IFS Cloud 24R2 product release – including the latest AI, sustainability and industry-specific capabilities – and customer case studies. The event also features an exhibition of 50+ partners and customers, with dedicated Industry Zones demonstrating the impact of AI on industry.

Honeywell has launched a new process to improve the efficiency and sustainability of light olefin production

The naphtha to ethane and propane (NEP) technology generates a tunable amount of ethane and propane from naphtha and/or LPG feedstocks, generating more high-value ethylene and propylene with reduced production of lower-value by-products compared to a traditional mixed-feed steam cracking unit and resulting in net cash margin increases. An NEP-based olefins complex also reduces CO2 intensity per metric ton of light olefins produced by 5 to 50% versus a traditional mixed-feed steam cracker.

More efficient production

“The petrochemical industry faces strong competition and challenges in obtaining raw materials globally,” said Matt Spalding, vice president and general manager of Honeywell Energy and Sustainability Solutions in MENA. “Our technology helps to enable more efficient production of ethylene and propylene, two chemicals which are in high demand, while also helping our customers lower their carbon emissions.”

The new solution is a part of Honeywell’s Integrated Olefin Suite technology portfolio to enhance the production of light olefins.

Data and analytics company GlobalData has released a thematic report, Robotics in Oil and Gas, which highlights the role of major oil and gas companies, such as ADNOC, BP, Eni, Equinor, ExxonMobil, Repsol, Rosneft, Shell, and TotalEnergies in the development and adoption of robotics to enhance safety and productivity on the field

With the applications of robotics continuously evolving, the oil and gas industry has emerged as a significant adopter of the technology to improve safety and efficiency of operations. According to the GlobalData report, robots equipped with advanced technologies are yielding increasingly positive results, bringing a continued transformation in the operations of oil and gas companies.

Ravindra Puranik, oil and gas analyst at GlobalData, said, “Robots are proving invaluable to execute complex tasks at production facilities, thereby protecting workers from hazardous environments and reducing the likelihood of costly shutdowns. As a result, companies such as Equinor, TotalEnergies, and Shell are deploying them to work alongside humans on offshore sites. For instance, robotic automation can manage remote operations, such as those conducted on Equinor's Oseberg H platform in the North Sea. Their ability to perform repetitive and mundane tasks with minimal errors is saving time and internal resources for companies. Furthermore, it allows them to deploy field technicians on more critical issues.”

Oil and gas operations are labor-intensive and involve numerous repetitive tasks, many of which occur in hazardous environments and face various obstacles. Robotics presents an excellent solution to many challenges within the industry, as they can handle more strenuous tasks and complex procedures more effectively than humans.

Puranik said, “Robots provide greater reliability and efficiency in completing assigned tasks while also enhancing operational safety. The integration of terrestrial, aerial, and underwater robots is already playing a crucial role in several high-stakes oil and gas projects throughout the value chain. French oil major TotalEnergies, in collaboration with Oceaneering, recently conducted a pilot inspection of subsea pipelines in the North Sea using autonomous underwater vehicles (AUVs).”
Robots can access hard-to-reach areas, carry out tasks beyond human capabilities, and operate continuously without needing breaks. Hence, they are being utilized as effective solutions for conducting inspections in difficult or hazardous environments, thereby avoiding preventing human exposure to such sites. Recently, cleaning of storage tanks is emerging as another prominent use case for robotics with companies, such as Saudi Aramco, Woodside, SK Innovation, and Indian Oil Corp, exploring the potential of robotic crawlers in this application.“Advancements in technology have equipped robots to effectively replace field personnel on oil rigs. Additionally, there is an increase in collaboration between oil and gas companies and technology vendors, enabling the diversification of robotic use cases with the integration of AI, IoT, cloud, and edge computing. These developments are anticipated to drive future growth in robotics within the oil and gas sector, reducing risks to human workers who operate alongside heavy machinery in often remote and challenging environments,” said Puranik.

GPT Industries, in association with Oil Review Middle East, is hosting a free webinar tailored specifically for pipeline corrosion and integrity professionals on Tuesday 29 October at 2pm GST

In the fast-paced world of pipeline integrity, innovation and safety are paramount to achieving operational success.

The session will explore the latest advancements in isolation gasket technology and how they are transforming pipeline operations in the Middle East, sharing practical insights gained from decades of GPT Industries’ industry leadership.

Our expert speaker Ian Kinnear, product manager at GPT Industries, the leading manufacturer of critical pipeline sealing and electrical isolation products, will provide valuable insights on how the company is addressing critical challenges, such as corrosion, extreme environmental conditions and the increasing demand for sustainability in pipeline operations. The webinar will cover:

• Combatting pipeline corrosion: Discover how modern isolation technologies are tackling corrosion issues, ensuring the safety and integrity of your pipelines.
• Supporting emerging energy markets: Learn how our gaskets are evolving to meet the demands of new energy sectors, including hydrogen.
• Lessons from the field: Gain insights from real-world case studies addressing challenges such as extreme temperatures, chemical exposure, and high-pressure environments.
• Reducing emissions: Understand how the latest sealing technologies are contributing to emissions reduction and advancing sustainability goals.
• Best practices for long-term sealing integrity: Benefit from practical tips and lessons learned from years of troubleshooting complex pipeline challenges.

Don’t miss this opportunity to gain expert knowledge and practical tips for enhancing your pipeline systems and tackling pipeline integrity challenges.

You can register for the free webinar at https://alaincharlestraining.com/webinar2/gpt-industries-webinar

Abu Dhabi-based Emirati fully independent EPC contractor and technology integrator MMEC Mannesmann has rebranded as Mannesmann Energy, reflecting its increased focus on new energies and support for the energy transition

Oil Review Middle East spoke to its CEO, Eng. Anas Aljuaidi, who explained the rationale behind the new brand identity, officially announced at the Investing in Green Hydrogen conference in London in September.

Aljuaidi explains that the company, with its MMEC Mannesmann heritage, has a strong background in oil and gas, construction and heavy engineering, but has since 2020, when it became a wholly-owned Emirati company, diversified into renewable energy and sustainability sectors.

“We are still supporting the decarbonisation of oil and gas, in for example EOR projects, but are looking to do more in renewable energy and energy generally, in support of the energy transition,” Aljuaidi says. The new name therefore more accurately reflects the scope of the company’s activities, with 50-70% of its projects envisaged to be in renewables by 2030.

Mannesmann Energy plays a key role in the UAE’s energy transition, focusing on low-carbon pilot projects and contributing to decarbonisation and net-zero goals. Its expertise supports the UAE Hydrogen Strategy by accelerating the adoption of advanced technologies through strategic partnerships with leading renewable sector providers. Eng. Aljuaidi notes that the company was the first contractor in the UAE to be involved in green hydrogen, having acted as the EPC contractor for the supply and operation of a high-speed hydrogen refuelling station in Masdar City, the first of its kind in the region, with recharging capabilities of 750 bar. It is about to announce its second blue hydrogen project in the region.

“We are emphasising our capabilities as an EPC contractor and technology integrator, and adding value from an engineering perspective to accelerate hydrogen implementation in the UAE,” he says. “Our ambition is to keep the highest market share when it comes to clean energy and clean hydrogen, whether blue or green, to support the UAE’s hydrogen strategy.

“Being a technology integrator is our strength, as we can work with any technology to meet our clients’ expectations. That’s one of our areas of expertise. We have an excellent engineering team with international expertise that can evaluate technologies and advise the project developer on the best technology for the application, and how to reduce the CAPEX and OPEX cost to make it more viable for the market.”

Keeping costs down

While hydrogen is rapidly gaining momentum, the cost of developing projects can be prohibitive, with many calling for increased government support and incentives. Eng. Anas Aljuaidi has a strong opinion on this.

“Our philosophy is that is we should not rely on governments to bring costs down; there is a lot we, the EPC companies, can be doing ourselves to reduce costs, for example expanding our supply chain by engaging new technology providers and SMEs rather than going to the top tier companies, whose costs are often unbelievably high, and by using competitive sources of components. In any hydrogen project, the electrolyser accounts for only 20% of the total cost; 80% is accounted for by the EPC. So the project developer should engage the EPC contractor at an early stage to reduce the risk and costs. That’s how we can really accelerate hydrogen production.”

So there is always room for reducing the price, but you can only do that by engaging the EPC contractor.

“When it comes to the OEMs, we can help them as well by advising them on the right elements for their electrolysers or their products. These should be obtained locally or where they are readily available, to avoid unnecessary transportation costs and the risk of supply chain disruption.

“Some elements are by nature very expensive, so it is important to select a competitively priced element to keep the end product cost lower. In China an electrolyser based on alkaline technology can costs US430,000 per kilowatt, compared with US$1,400,000 per kilowatt in Europe. That’s a massive difference and will have a big impact on the project capex.

“The project developer needs to select the right geographic location for their development and ensure that it is near to its customers, to avoid unnecessary costs, such as those entailed by converting hydrogen to ammonia for transportation and cracking it back to hydrogen when it reaches its destination.

“So instead of complaining that governments are not giving incentives, or not paying premiums, EPCs should take it upon themselves to reduce the costs, then everyone will come to you and purchase from you. That is how we, as EPC contractors can guide our customers to enable them to accelerate hydrogen implementation, and we are involved in some early-stage projects where we are doing this.”

Supporting localisation

Mannesmann Energy is also supporting the UAE’s efforts to localise electrolyser manufacturing in the country. Aljuaidi comments that the UAE is one of the most advanced countries when it comes to enabling clean energy, with the ‘Make it in the Emirates’ programme offering incentives for local manufacture, thereby enabling companies to produce products at a competitive price (hydrogen is one of the priority sectors). The Emirates Development Bank also provides financial support for businesses in strategic sectors, including renewables. Progress has been encouraging, and Aljuaidi is optimistic about the future.

“A number of agreements were signed during the Make it in the Emirates Forum last year and this year,” Aljuaidi says. “It’s a new market, and it will take time for projects to get off the ground, but I am sure it will come.”