In The Spotlight
Emerson opens new manufacturing hub in Saudi Arabia
Emerson has opened a new manufacturing and innovation hub at the King Salman Energy Park (SPARK) as part of its Middle East expansion
The 13,000 sq m facility brings the company’s automation technology portfolio together under one roof, including mission-critical control and safety systems, measurement instrumentation, control valves, isolation valves, pressure relief valves, solenoid valves and industrial lighting assemblies.
It is envisaged that the hub will reduce dependency on imported goods, strengthen supply chains and improve self-sufficiency in critical industrial manufacturing value chains within the Kingdom, in line with Saudi Vision 2030.
In furtherance of Emerson’s net zero emission goals, the manufacturing hub is equipped with energy-efficient technologies and renewable energy sources, including rooftop solar power generation, compressed air optimisation and lighting system optimisation.
Contributing to Vision 2030
"This new facility reinforces Emerson’s position as a key player in the industrial sector in the Kingdom and contributes to Saudi Arabia’s long-term Vision 2030 of strengthening local talent, boosting supply chain localisation and advancing sustainable growth," said Mathias Schinzel, president of Emerson Middle East and Africa.
“We are proud to collaborate with Emerson to support their new cutting-edge manufacturing hub at SPARK,” said Mishal I. AlZughaibi, SPARK President and CEO. “With the establishment of these facilities, we are closer than ever to achieving our localisation goals.”
"As part of Emerson's contribution to the 'Made in KSA' initiative, Emerson’s facility will serve domestic and regional markets with advanced technologies designed to meet the evolving needs of various industries, further solidifying Saudi Arabia's position as a leader in localised manufacturing and innovation," added Hussein Zein, vice president of Emerson in Saudi Arabia and Bahrain.
Emerson opened its first local valves manufacturing facility in Jubail in 2011 and has expanded its manufacturing footprint over the years to include facilities in Dammam and its Saudi headquarters Dhahran Techno Valley in 2018.
Growing momentum for low-emissions hydrogen but further support needed: IEA
A new report from the IEA finds that investment and projects in low-emissions hydrogen are growing, but it still accounts for less than 1% of total hydrogen production.
The IEA’s annual Global Hydrogen Review 2024 finds that the momentum for low-emissions hydrogen is growing, as illustrated by a wave of new projects, despite challenges due to regulatory uncertainties, persistent cost pressures and a lack of incentives to accelerate demand from potential consumers. The number of projects that have reached final investment decision has doubled in the past 12 months, which would increase today’s global production of low-emissions hydrogen fivefold by 2030. The total electrolyser capacity that has reached final investment decision now stands at 20 gigawatts (GW) globally. Global electrolyser manufacturing capacity doubled in 2023, with China accounting for 60% of this.
If all announced projects are realised worldwide, total production could reach almost 50 million tonnes a year by the end of this decade. However, this would require the hydrogen sector to grow at an unprecedented compound annual growth rate of over 90% between now and 2030.
Lack of clarity on government support, along with uncertainly around demand and regulatory frameworks means that installed capacity for electrolysers and low-emissions hydrogen volumes remain low, with most potential production still in planning or early-stage development, with some larger projects facing delays or cancellations due to these barriers along with permitting challenges or operational issues.
“The growth in new projects suggests strong investor interest in developing low-emissions hydrogen production, which could play a critical role in reducing emissions from industrial sectors such as steel, refining and chemicals,” said IEA executive director Fatih Birol. “But for these projects to be a success, low-emissions hydrogen producers need buyers. Policymakers and developers must look carefully at the tools for supporting demand creation while also reducing costs and ensuring clear regulations are in place that will support further investment in the sector.”
The report highlights a gap between government goals for production and demand, as well as technology and production cost pressures, with progress in electrolysers in particular stalling due to higher prices and tight supply chains. A continuation of cost reductions relies on technology development, as well as optimising deployment processes and moving to mass manufacturing to achieve economies of scale.
Unabated fossil fuels continue to dominate
Despite the growth in momentum, the report points out that low-emissions hydrogen accounted for less than 1% of total hydrogen production in 2023. Producing renewable hydrogen today is generally one-and-a-half to six times more costly than unabated fossil-based production, the IEA notes. It forecasts that hydrogen production is likely to continue to be largely dependent on unabated fossil fuels this year, with unabated natural gas accounting for around two-thirds of total production. The Middle East is a key player, producing 20% of all hydrogen from unabated natural gas.
China leads in terms of production, accounting for almost 30% of the global total, followed by the USA and Middle East with 14% each, and India with 9%. Total hydrogen production reached 97Mt in 2023, and could approach 100Mt by the end of 2024.
Industrial hubs – where low-emissions hydrogen could replace the existing large demand for hydrogen that is currently met by production from unabated fossil fuels – remain an important untapped opportunity by governments to stimulate demand, the IEA says.
The Middle East saw stronger growth in hydrogen demand than other regions (more than 6% growth year-on-year, due to an increase in demand in refining and methanol production). The region accounted for 14% of hydrogen use in 2023. The Middle East was the second largest consumer of hydrogen in industrial applications after China, with 4% growth, mainly driven by methanol production.
Onshore Middle East cheapest source of new oil production
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.
Eni and bp resume exploration activities in Libya
Eni and BP have resumed their exploration activities in Libya after halting drilling operations in the onshore region in 2014, according to Libya’s National Oil Corporation (NOC)
This follows the formal revocation of force majeure status by Eni and NOC in August 2023 on exploration areas A&B (onshore) and C (offshore), where Eni is operator with 42.5% along with bp (42.5%) and Libya Investment Authority (15%), as a result of a favourable security assessment. Some of these areas are close to the Wafa gas facilities that export production to Italy.
On October 26, Eni began its exploration activities in the Area B (96/3) of Ghadames Basin, where the first exploratory well, A1-96/3 (Hasheem Prospect), was drilled. This well is the first under the contractual obligations for Area B in Ghadames Basin, according to the Fourth Bid Round Contract of 2007. Mellitah Oil & Gas, which has extensive experience in the region, particularly in developing and managing the Wafa field, is overseeing the drilling operations and all related activities for this well.
Several promising geological formations in the A1-96/3 well are set to be tested, which are expected to contain both oil and gas. The well is projected to reach a final depth of approximately 3,147 m.
The A1-96/3 well is located around 35 km from the Wafa field and approximately 650 km from the capital, Tripoli.
Eni is the leading international gas producer in Libya, where it has been operating since 1959, and currently has a large portfolio of assets in exploration, production and development. Production activities are operated through the joint venture company Mellitah Oil and Gas BV (Eni 50%, NOC 50%).
Repsol and OMV are also set to restart operations sin the Murzuq Basin and Sirte Basin respectively, NOC says.
IFS Unleashed highlights the power of Industrial AI
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 launches new olefin production process
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.
Viridien’s real-time rock data analysis optimises gas storage drilling
With gas and carbon storage activities expanding across the Middle East as operators pursue carbon reduction and energy efficiency goals, Viridien offers specialised geological analysis solutions for effective well placement in UBCTD
Underbalanced coil tubing drilling (UBCTD) technology is being utilised to re-enter existing vertical wells in depleted fields, allowing for the drilling of multiple horizontal legs, which significantly improves direct access to the reservoir. UBCTD lowers drilling costs and reduces formation damage, preserving permeability.
Specialised geological analysis is key for effective well placement in UBCTD. Advanced rock analysis of drill cuttings at the wellsite involves biosteering (microscopic fossil analysis), rock-typing, and visual porosity assessment (see figure). This approach is primarily used in limestone reservoirs, such as the Khuff, Arab, Habshan, Lekhwair, Kharaib, Shu’iaba, Natih and Misrif formations, where the integration of these techniques helps to accurately determine a borehole's position within the reservoir. Continuous analysis during drilling provides real-time data, enabling informed decision-making that can lead to successful well delivery with improved production rates or increased storage capacity.
Advantages of using Viridien’s real-time rock data analysis for well placement
These analytical techniques provide critical insights for maintaining or repositioning the borehole within the reservoir, offering several advantages:
• Accurate wellbore placement using biosteering, which, when combined with lithofacies and porosity data, is crucial for optimal reservoir targeting, especially when Logging While Drilling (LWD) is unavailable.
• Cost-effective solution for gas and carbon storage drilling.
• Real-time updates of the field’s static reservoir model while drilling.
• Fault identification with biosteering, including vertical displacements, allowing precise steering back to the target horizon.
Viridien's legacy in the Middle East
Viridien, formerly CGG, operating from its Abu Dhabi Geoscience hub, has undertaken biosteering, rock-typing and porosity evaluation in the region since 1994. These techniques have been applied to develop fields including the Shu’aiba, Kharaib, Lekhwair and Habshan and Khuff reservoirs. In 2003, Viridien participated in the first UBCTD project in the UAE and biosteering was key to successful well delivery. Viridien has undertaken UBCTD projects in Saudi Arabia since 2009, supported by its state-of-the-art laboratories in the UK. The adoption of these specialist geological techniques has become more widespread in the UAE recently, where Viridien is providing expert well placement services for several clients. The future of wellsite geological services for field development is bright, and the Middle East is leading the way.
Learn more about Viridien integrated solutions for exploration and reservoir development drilling including wellsite biostratigraphy and other advanced techniques at:
Viridien: Wellsite Services (https://www.viridiengroup.com/expertise/geological-services/wellsite-services)
Advancing pipeline isolation: real-world solutions for the Middle East
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
Looking to the future
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.”