Case Study: a large South American national oil company achieves $160 million in savings with KBC A Yokogawa Company

South American Refinery Recoups Projected Costs Before Project Completion

KBC A Yokogawa Company worked with a large South American national oil company refinery that was facing production losses, difficulty meeting local gasoline demand, rising imports, and declining safety, reliability, and operational capability. The refinery needed a full transformation, and KBC A Yokogawa Company supported the effort using Petro-SIM digital twin technology and a broad turnaround program.

KBC A Yokogawa Company delivered a holistic solution covering profit improvement, workforce capability, business process improvement, organizational restructuring, and change management. By building a Petro-SIM digital twin, training staff, and creating more than 15 work processes and 1,800 procedures, the refinery identified over USD 250 million per year in potential improvements and achieved more than USD 160 million in savings before project completion. The program also produced 20 million incident-free man hours, trained 150 new engineers, and improved unit availability, including increasing crude unit throughput from 80% to 100% of design.