EFFECTIVE CNG HANDLING & LOGISTICS FOR INDUSTRIES (AN INDONESIAN CASE STUDY) Presented by Robbi R. Sukardi, Secretary General APCNGI Ho Chi Minh, Vietnam, 01-03 August 2012
Background behind the growth of CNG for Industrial in Indonesia
(1). INDONESIA S CONDITION Indonesian dependency on oil fuel, as we re NO LONGER a Nett Oil Exporter Country; Huge potential gas reserve, with proven reserve of 94,78 TCF and potential reserve of 87.73 TCF, Indonesia is considered as country with largest natural gas reserve; Limited pipeline infrastructure; LNG is NOT yet available for domestic use; Government program to reduce emission level and increase the monetization of stranded gas. Industrial gas demand exceeds supply due to lack of pipeline infrastructure. Many stranded small scale gas reserves. CNG as another means of gas transportation aside from conventional pipeline and LNG
(2). VOLUME With CNG bulk sale selling can reach your economies of scale of the CNG Station.
SAMPLE PARAMETERS OF A CNG MOTHER STATION Large Size Category CNG Station Parameters Minimum Capital Expenditure Capacity Compressors minimum 2,000m3/hr CNG Main Equipments $ 1,883,770 Capacity Compressors maximum 4,000m3/hr Pipeline Construction $ 154,000 - # of compresion stages 4stages Civil Construction $ 550,000 - Minimum Power Capacity 1MW Land Lease 5 years $ 525,000 Size of Land is below 3,000m2 Approvals & Certifications $ 90,000 Unit Nozzels Filling is minimum 6units.. Total Minimum Capex $ 3,202,770 Storage Tank Capacity at Site 2,000m3 Gas Dryer Systems 2units Monthly Operational Expense High Pressure Piping Lengths 200meters Maintenance Equipments $ 11,887 VAT taxes, Import Tax 19.0% Power Usage $ 15,429 Minimum Operational Time 18hours Man Power & GA $ 8,000 Total Minimum Monthly Opex $ 35,316 Capital Structure Requirements Large Size CNG Stations Capex $ 3,202,770 Interest During Construction $ 112,097 Working Capital Gas $ 1,080,777 Working Capital Operation $ 70,631 Total Funds Required $ 4,466,275. Cost of Fund & IRR Requirements Cost of Debt 13%annual Maximum Debt Maturity 5.00 years Corporate Tax Rate 20% Cost of Equity 26%annual Minimum IRR 20%. Debt 40%$ 1,786,510 Equity 60%$ 2,679,765 Total 100%$ 4,466,275. Required Minimum Cash Received $ 117,733 / month Operation Cost $ 35,316 Required Minimum Cash Received $ 117,733 Monthly Minimum Cost Coverage $ 153,049
COST STRUCTURE TO CLOSED OUT YOUR REQUIRED RETURN ON INVESTMENT Minimum Volume Sale per Day (m3) 36,000 Minimum Volume Sale per Month (m3) 1,080,000 Minimum CNG Station Margin $ 0.14 Cost of Pipeline Gas $ 0.25 Cost of CNG at Station $ 0.39 VAT 10%$ 0.04 Net Price of CNG at CNG Station $ 0.43 EQUIVALENT TO MMBTU Minimum CNG Station Margin $ 3.80 Cost of Pipeline Gas $ 6.70 Cost of CNG at Station $ 10.50 VAT 10%$ 1.05 Net Price of CNG at CNG Station $ 11.54 Maximum Volume Sale per Day (m3) 72,000 Maximum Volume Sale per Month 2,160,000 Minimum CNG Station Margin $ 0.07 / m3 Cost of Pipeline Gas $ 0.25 / m3 Cost of CNG at Station $ 0.32 / m3 VAT $ 0.03 / m3 Net Price of CNG at CNG Station $ 0.35 / m3 EQUIVALENT TO MMBTU Minimum CNG Station Margin $ 1.90 / mmbtu Cost of Pipeline Gas $ 6.70 / mmbtu Cost of CNG at Station $ 8.60 / mmbtu VAT $ 0.86 / mmbtu Net Price of CNG at CNG Station $ 9.46 / mmbtu
: Cost of Running Your Stations $0.50 $0.45 $0.40 Target Sale Price at Mother Stations $0.35 $0.30 $0.25 $0.20 $0.15 $0.10 $0.05 $- Volume m3/month 1,080,000 1,200,000 1,320,000 1,440,000 1,560,000 1,680,000 1,800,000 1,920,000 2,040,000 2,160,000 Economical CNG Station Margin $ 0.14 $ 0.13 $ 0.12 $ 0.11 $ 0.10 $ 0.09 $ 0.09 $ 0.08 $ 0.08 $ 0.07 Assumption Pipeline Gas $ 0.25 $ 0.25 $ 0.25 $ 0.25 $ 0.25 $ 0.25 $ 0.25 $ 0.25 $ 0.25 $ 0.25 Sale Price before VAT at Station $ 0.39 $ 0.38 $ 0.37 $ 0.36 $ 0.35 $ 0.34 $ 0.34 $ 0.33 $ 0.33 $ 0.32 VAT 10% $ 0.04 $ 0.04 $ 0.04 $ 0.04 $ 0.03 $ 0.03 $ 0.03 $ 0.03 $ 0.03 $ 0.03 Sale Price of CNG at Station $ 0.43 $ 0.42 $ 0.40 $ 0.39 $ 0.38 $ 0.38 $ 0.37 $ 0.36 $ 0.36 $ 0.35
Well Head Gas Plant Metering System Gas Upstream Infrastructure NGV Customers Gas Downstream Infrastructure Gas Customers / Daughter Stations Gas Customers / Factories
(3). COMMERCIALLY MORE PROFITABLE The competitor in selling CNG to industries in Indonesia are other fuel energy that are more expensive.
THE PRICE DEVIATION BETWEEN GAS AND OTHER FUEL IN INDONESIA Fuel unit Heating Value Price Btu/unit kcal/unit US$/MMBTU KEROSENE Liter 35,079 8,840 32.94 GASOLINE Liter 33,000 8,316 28.00 HSD Liter 35,964 9,063 23.06 MFO Liter 36,786 9,270 19.76 HFO Liter 38,754 9,766 21.41 LPG Kg 44,524 11,220 21.97 NG Pipeline (PT. PGN price Jakarta) m3 36,798 8,919 8.90 NG Pipeline (PT. PGN price Surabaya) m3 37,257 9,031 9.10 NG Pipeline (PT. PGN price Medan) m3 37,257 9,031 10.00 CNG at Mother Station (FOB Price) m3 35,526 9,224 10.50 CNG transported to Customer < 100 km m3 35,526 9,224 15.00 CNG transported to Customer > 100 km m3 35,526 9,224 18.00 CNG Price
$ 5 -$ 6 / mmbtu + $ 3 -$ 4 / mmbtu + $ 2 -$ 4 / mmbtu + $ 2 -$ 4 / mmbtu = $ XX / mmbtu Natural Gas Supplier Natural Gas Pipeline CNG On-line Station CNG Trucking Fleets Industrial Gas Customers / Factories
KEY SUCCESS FACTORS FOR EFFECTIVE CNG HANDLING & LOGISTICS FOR INDUSTRIES IN INDONESIA
UNDERSTAND YOUR INDUSTRIAL CUSTOMER NEEDS Gas energy consumption rate per month, days, and hourly per cubic meters. The distance between the industrial customer to the CNG Mother Station. The traffic and road condition to the industrial customer from the CNG Mother Station. The CNG carrier and Pressure Reduction System must be tailored made toward the Industrial need and specific surrounding area to avoid miscalculation of an over investment or a too highly operating cost
Kilometers distance and ease of traffic Interval [? ] time [? ] filling per day MOTHER STATION CNG CASCADE CYLINDER FILLING CNG CASCADE CYLINDER DOWNLOADING AT INDUSTRY INDUSTRY CUSTOMERS CAPEX: CNG Station Land OPEX : Gas supply Workers Depreciation of the Station CAPEX: Storage Cylinder (type I, II, III, or IV) Truck Trailer (10 ft, 20 ft, or 40 ft Module truck carrier) OPEX : Compressed Natural Gas Supply (if bought FOB) Transportation cost (travel distance for fuel and operating costs) Depreciation of your assets CAPEX: Site Development RegulatorsSystem\ New Piping ( if needed ) CNG PROVIDER CUSTOMERS
Volume btu Sale per month : equivalento to : or equivalento to : Distance from Station to Customers : Minimum Number of GTM Skids Required: Gas Required / Day - Minimum per hour - Maximum per hour Gas PRODUCTION - NET Hours Production Conversion Factor Gas PRODUCTION - NET Compression Capacity at CNG Station Distance roundtrip Speed of HVD for delivery mmbtu m3 monthly M3 daily km units MMBtu / Day MMBtu / Day m3 / hour m3/mmbtu m3 m3/hour km km/hour customer GTM Type (Capacity m3) 10/20/40 ft Number of GTM Required units xxx Designing and custom made, if necessary, toward the customer gas requirement consumption and road conditions.
Typical Industrial Daughter Station Equipment
COMPRESSOR PIPELINE METERING SYSTEM DRYER BY PASS SYSTEM COMPRESSOR DISPENSER #1 DISPENSER #2 DISPENSER #3 STORAGE CYLINDER FILL POINT #1
CAREFULL ON CONVERSION DEVIATION AND DISTRIBUTION LOSSES GAS PGN MMBTU TURBIN METER EVC MICRO MOTION M3 PLE COMPRESSOR TURBIN METER
LaporanKomposisiPGN BULAN : RATA RATA APRIL 2012 KOMPOSISI APRIL GAS RATA RATA C1 89.2493 C2 3.4380 C3 1.2903 N - C4 0.2884 I - C4 0.3293 N - C5 0.1451 I - C5 0.0881 N - C6 0.1807 N - C7 0.0067 N - C8 0.0034 N - C9 0.0008 N2 0.5381 CO2 4.4411 H2O 0.0006 H2S 0.0001 TOTAL 100.000 S.G 0.6467 GHV 1038.1113
Methane : CH4 89.2% Base Temperature : C 27.0 : K 300.0 PJBG PGN & PENGUJIAN : F 80.6 Standard Temperature : C 15.6 : K 288.6 CNG Equipment Standards : F 60.0 1 BTU : Kkal 0.2520 Compressibility Factor : Z 0.99798 at PGN 27 C 1 SCF : Z 35.3147 M3 1 BTU / Scf : Kkal / m3 8.5596 at PGN 27 C 8.8990 Standard Specific Gravity Nat Gas : SpGr 0.64675 PGN APRIL 2012 Specific Gravity Nat Gas : SpGr 0.67239 standard Real Gross Heating Value : BTU/CF 1038.111 PGN APRIL 2012 1.0 : MMBTU 8,885.8 kkal/m3 (Base) 1.0 : MMBTU 28.36 m3 (Base) Density of Gas Standard at Avg. Temperature Air Density at 0 C : Sm3 1.286 Air Density at 27 C : Sm2 1.170 Air Density at 30 C : Sm3 1.158 Air Density at 35 C : Sm3 1.140 Gas Density at 0 C : Kg/m3 0.7566 Air Pressure : Mpa 101,325 Avg. Temperature @ Cust : Celcius 27.00 Air Density at X Celcius : kg/m3 1.16988 Gas Density pada suhu : Kg/m3 0.6467 MASS FLOW METER KG TO M3 1.5462 HEATING VALUE FUEL UNIT Btu/UNIT kcal/unit KEROSENE Liter 35,079 8,840 GASOLINE Liter 33,000 8,316 HSD Liter 35,964 9,063 MFO Liter 36,786 9,270 LPG Kg 44,524 11,220 CNG m3 36,607 9,224 1 m3 is equal to Btu/Unit LSP 1.1093 1 LSP is equal to Btu/Unit M3 0.9015
CNG INDUSTRIES PROVIDERS IN INDONESIA
AREA OF OPERATIONS
INDUSTRIAL CNG MARKET PLAYERS PT. CITRA NUSANTARA GEMILANG 3,5 mmscfd capacity Mother Station Supplied by PT. Pertamina Gas contract amounted to 3,5 mmsfdand all already sold to industrial customers. PT. BERKAH MIRZA INSANI 3,0 mmscfd capacity Mother Station Supplied by PT. Perusahaan Gas Negara Gas contract amounted to 2,5 mmsfdand all already sold to industrial customers. PT. PETROSS GAS 1 mmscfd capacity Mother Station Supplied by PT. Perusahaan Gas Negara Gas contract amounted to 0,7 mmsfdand sold to the Bus Transjakarta market. PT. T ENERGY 1,5 mmscfd capacity Mother Station Supplied by PT. Perusahaan Gas Negara Gas contract amounted to 0,5 mmsfdand 0,5 sold to the Bus Transjakarta market & industrial PT. IEV 3,5 mmscfd capacity Mother Station Supplied by PT. OdiraGas Gas contract amounted to 3,5 mmsfdand all already sold to industrial customers. PT. CIPTA NIAGA GAS 4,0 mmscfd capacity Mother Station Supplied by PT. Perusahaan Gas Negara Gas contract amounted to 2,5 mmsfdand all already sold to industrial customers.
AREA OF OPERATIONS
CHALLENGES IN CNG INDUSTRIAL (a case of stranded gas)
CNG Mother Station is located at desa Kalidawir, Sidoarjo, East Java. 6 DIA FLOWLINE TGA-2 WELL TGA-5 WELL TGA-1 WELL KALIDAWIR CNG MOTHER STATION TGA GAS PLANT
LAPINDO/INDOGAS TGA #5 WELL AVAILABILITY TO SUPPLY 3,0 BBTU/DAY LAPINDO gas contain energy : is equivalent to 1 ltr of Solar : is equivalent to kkallevel of : is equivalent to m3 gas of : 1.011,9 btu/scfm 36,171 scfm 9.004,8 kkal/m3 1,024 m3
THE SURROUNDING AREA OF THE NATURAL GAS RESERVE WELL HEAD
THANK YOU Asosiasi Perusahaan CNG Indonesia (APCNGI) Secretariat Office Address: GrahaCNG. JL. TebetTimurdalamII No. 35 Jakarta 12820. Indonesia Telp.: +62-21-8319878; Fax: +62-21-8291391 Website: www.apcngi.org PT. RAJA RAFA SAMUDRA Jl. PertaniRaya No. 18 Kav. A Duren Tiga, Pancoran.Jakarta Selatan Phone: 021-7990467. Fax: 021-79109902 email: robbi_sukardi@rajarafasamudra.com Website: www.rajarafasamudra.com