refining PEMEX S business unit dedicated to the REFINING of crude oil
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1 refining REFINERY PRODUCTION (thousands barrels per day) 2002 Gasolines 398 Fuel Oil 450 Diesel 267 Jet Fuel 57 DOMESTIC SALE (thousands barrels per day) 2002 Gasolines 566 Fuel Oil 406 Diesel 271 Jet Fuel 53 PEMEX S business unit dedicated to the REFINING of crude oil is responsible for the production, distribution and marketing of fuels and other petroleum products. Its position in the value chain of the oil industry is fundamental: it contributes to the economic development of the country by strengthening the internal market and its competitive capacity. The expansion of the Company s industrial infrastructure also contributes to economic growth. The strategic initiatives set forth by Pemex Refinación to achieve its objectives are the following: To enhance operating efficiency To improve the supply and quality of fuels To integrate the supply and distribution chains To modernize sales and marketing To increase labor productivity To care for environmental and occupational health To facilitate the planning of investments To streamline administrative infrastructure To strengthen management systems. p. 20,21 ANNUAL REPORT 2002
2 The Company has six refineries with a primary processing capacity of 1.54 million barrels per day. The refineries have an aggregate crude oil storage capacity of 13.9 million barrels. The Company operates crude oil and products pipeline system nearly 14.2 thousand kilometers in length. Crude oil lines cover some 5.3 thousand kilometers while product lines extend nearly 8.9 thousand kilometers. There are 77 product distribution terminals. There are 19 large tankers, 92 smaller vessels and a dry dock. For ground transportation the Company operates its own fleet of 1,255 tank truck and 525 railcars; in addition, there are 2,685 tank truck under lease. Of the 5,555 franchised service stations in Mexico that carry the Pemex brand, 55 belong to the Company. Reconfiguration of the refinery system The evolution of the world market for petroleum products and the greater competition among participants has led not only to an increase in the complexity of the refineries but to a lowering of operating margins and a greater volatility in prices. In this context, as of several years ago, Pemex Refinación Company began a program of multiannual investments with the aim of reconfiguring its nationwide refining system and improving operating margins. In this way, and in view of the international environment, the Company is looking for the most efficient way to maintain its leadership position in the market and to capture a greater number of niche opportunities that market conditions permit. In relation to fuel quality, the tendency in the industry worldwide is toward the reduction of contaminants emitted from mobile and stationary sources of combustion. In 2002 Pemex Refinación continued its efforts to offer fuels that meet the specifications of international standards. In relation to fuels for automobile use, specifically gasoline, international trends are toward the lowering of the contents of aromatics, olefins and sulfur. The goal is to reduce the atmospheric contamination in urban areas by ozone, particulates and toxic waste. The efforts of the Company to improve fuels has led to the result that, at present, the components of Mexican gasoline are equivalent except for sulfur content to those sold in markets in the United States and Europe. In relation to diesel, the international market is looking for an optimal range of components: trends point to an increase in the cetane index while lowering the level of aromatics and sulfur. These specifications comply with the technological and environmental requirements of new diesel-fueled vehicles that operate in the United States and Europe. The situation in Mexico is radically different, given that diesel quality is superior than the international average. In relation to industrial fuels in particular, fuel oil, with its high level of emissions of contaminants the international trend has been to substitute fuel oil by natural gas and to eliminate its use entirely in
3 Pemex Refinación is deeply engaged in the process of expanding the capacity of its plants and upgrading the quality of its fuels. By year the end of 2002, the unit had reconfigured its refineries at Madero, Cadereyta, Tula and Salamanca. urban areas. Fuel oil would be restricted to electric power generation and industrial use. Crude oil processing and refined products Investment in the country s petroleum industry has been increased in order to achieve a greater supply of products of national origin as well as to capture export opportunities. The purpose of reconfiguring the Company s national refining system is to achieve these goals: Redesign the refineries to accept a new slate of crudes characterized by an increased use of heavy crude oil, Produce refined products that meet rigorous environmental standards. As is well known, the hydrocarbon endowment of Mexico is strongly inclined toward heavy crudes. In view of this fact over the past decade the Company has worked to reconfigure and modernize its refinery system with the purpose of favoring this grade of crude oil. Since 2001, this program has continued with additional and complementary investments intended to increase the utilization index of installed capacity as well as to increase the volume and quality of fuels. A parallel goal is to reduce the negative balance of the Company s exports. In 2002, the Company s refineries processed 1.2 million barrels per day of crude oil, a volume slightly below that observed in The mix of crude oil that was processed had the following composition: light oils (65.7%), heavy oils (27.7%), superlight oil (0.9%) and the remainder of reconstituted crude and other currents. Two refineries alone, Salina Cruz, on the Pacific Coast, and Tula, in the Central Highlands, accounted for 47.1% of the total volume of crude oil processed in The capacity utilization index for atmospheric distillation was 82.4%. The production of refined products (and excluding those processed abroad) was 1.3 million barrels per day, a volume slightly higher than that obtained in The increase was due to a greater output of gasoline and fuel oil, which occurred simultaneously with a decrease in the production of diesel. The total volume of refined products obtained from processing abroad (known as maquila in Mexico) was thousand barrels per day. Products processed abroad included (in thousand barrels per day) gasoline and its components (94.5), diesel (10.0), fuel oil (1.2), jet fuel (0.947) and isobutane (1.2). Distribution and sales In 2002, some 73.7 billion tons-kilometer of crude oil and refined products were shipped by the Company s transportation system: pipelines (61.8%), marine transportation (34.6%), tank cars (3.6%) and the rest by rail cars. Total shipments were 2.2% less than those of 2001, owing to the reconfigurations of the refineries of Cadereyta and Madero, which resulted in larger volumes sent by tanker. The contraction of the domestic market corresponded to the slow economic recovery of the country. The final three quarters of 2002 the Mexican economy, measured by GDP, showed dynamic growth; nevertheless, the weak performance of the first quarter lowered the overall economic growth rate for the year to 0.9% in real terms. The area of the economy that was most affected was the industrial sector, which performed poorly in domestic and international markets. In 2002, the sale of petroleum products declined by 60.5 thousand barrels per day, a reduction of 4.4% change in comparison with Gasoline. Despite an overall decline in the internal market, sales of gasoline reached an average of thousand barrels per day, a level 2.6% p. 22,23 ANNUAL REPORT 2002
4 higher higher than than that that of of This This market market behavior is explained by the increase in sales of the Company s premium-grade gasoline, the demand for which increased by 19.7%. This grade of gasoline was preferred by customers despite the prevailing unfavorable conditions in the Mexican economy. Diesel. The sale of diesel was thousand barrels per day, a volume lower than that reported for the previous year. Of this amount, 84.2% was Pemex Diesel, which showed a positive growth rate. With these sales an objective was achieved of placing in the market a greater volume of fuels of high environmental quality. The product with the most dramatic decline in sales was marine diesel, which declined on account of the government s pricing policies. Jet fuel. During 2002, jet fuel sales dropped to 53.3 thousand barrels per day, some 3.7% less than that reported in the previous year. Airports that registered an increase in the sale of jet fuel included Monterrey, Toluca and San José del Cabo. Fuel oil. During 2002 the sale of fuel oil fell to thousand barrels per day, its lowest level since 1995 and 68.8 thousand barrels per day, or 14.5%, lower than that reported for This result reflected the reduced demand for fuel oil by the electric sector. Investment The Company s investment funds in 2002 were oriented towards improving the operating efficiency of the refinery system, increasing the throughput of heavy crudes and expanding the capacity of the refineries to produce high-quality fuels. The modernization of the Cadereyta refinery stands out: the total processing capacity of the refinery will be increased, including a new coker which will expand the capacity of the refinery to process heavy crude oil. At the same time, a similar reconfiguration project was begin in the refinery at Ciudad Madero, and other programs differing in size and complexity were launched in the refineries at Salamanca and Tula. Total capital expenditures in 2002 were 14.3 billion pesos. from this amount, 63.2% were spent on the reconfiguration of the refineries at Madero and Tula as well as on the change in the configuration of the refinery at Cadereyta. The Cadereyta project began operation at the end of 2000, and in 2002 it was responsible for an increase in the production of gasoline by 11 thousand barrels per day. Investments carried out in the Madero, Salamanca and Tula refineries led to the following results:
5 Madero. By October 2002 ten plants had been constructed as well as the expansion and modernization of additional seven plants, each integrated with its own auxiliary services. Salamanca. A naphtha desulfurization unit, a reformer and a fractionator were constructed and put into operation. Also constructed were auxiliary services and advanced controls. Tula. A gasoil desulfurization unit was completed, as well as a butane isomerization plant and the modernization of two fractionating towers. These facilities were equipped with auxiliary services and control systems. The remainder of the investment funds were allocated to the following areas: Improvement of the gasoline pool of gasolines at the Madero refinery Environmental Quality Program, specifically the butane isomerization plant and residuals desulfurization unit, Pipeline expansion, notably the extension of the supply of distillates for the Yucatan peninsula, Capitalized maintenance and procurement, Safety and environmental protection, Research and development. Safety and environmental protection Industrial safety. In 2002 the accident rates (scaled to million man-hours worked) reversed their downward tendency. The frequency index in this year was 1.10, a level 59.4% higher than that reported in The severity index for the year was 138 days lost, compared to 85 for the previous year. These results arose from an accident with multiple injuries at the Tula refinery in January, as well serious accidents in April, September and October, with a fatality in each of these months. In relation to audits of industrial safety and environmental protection, in 2002 there were 33 programmed activities. There were nine audits of industrial safety, 18 follow-up visits, two visits related to international reinsurance in the Tula and Salamanca refineries, and four visits to work centers, again with representatives of international reinsurance companies, at refineries located at Tula, Minatitlan, Ciudad Madero and Salamanca. At the end of the 2002 there were 87 environmental audits that had been concluded. The Company had been awarded 100 certifications of ISO 9000 and eight of ISO Environmental protection. In relation to environmental protection, total emissions by the Company in 2002 were 6.9% less than those reported in the previous year, and water discharges were 37.4% less. The Company consumes vast quantities of water, and with the end of making the most efficient use of this resource there are water treatment plants at each of its six refineries. In addition, there are sewage water treatment plants at the refineries of Salamanca, Minatitlan and Salina Cruz. An important reduction in the amount of water discharges was achieved in 2002, equivalent to some 24.2 million cubic meters in It was possible to avoid the discharge of nearly one thousand tons of contaminants in bodies of water. The primary use of water was reduced, achieving a savings of 139 million liters per day. Quality Assurance. As part of its program to improve the quality of fuels, the Company contracted the Mexican Petroleum Institute (IMP) to carry out a Quality Monitoring Program (Progasol). This program permitted the identification and correction of variations from the specifications established in different regions of the country for Pemex s Magna and Premium grades of gasoline. In 2002, by means of a random sampling technique, some 527 samples of Magna and 472 samples of Premium gasoline were tested, in all covering the universe of all six refineries, 80% of the storage and distribution terminals, 10% of the service stations as well as other facilities and channels of distribution. The survey showed that the octane index of the premium-grade gasoline at the Minatitlan and Cadereyta refineries had an average value of 92.5, below the specification of p. 24,25 ANNUAL REPORT 2002
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