By Ross Kelly 
 

SYDNEY--Australia's biggest oil refiner, Caltex Australia Ltd. (CTX.AU), said earnings slumped as production hiccups added to its growing headache trying to compete with larger regional companies able to produce transport fuel more cheaply.

Caltex said net profit in the six months through June fell 13% to 171 million Australian dollars (US$154 million) on a measure that excludes the value of inventories. A sharp drop in the local currency also contributed to an operating loss at its refinery business.

Australia's refiners are facing hardening competition from Asian operators whose larger and more efficient processing facilities have sprung up in places like India, Singapore and elsewhere.

"We have high labor costs compared to other Asian refineries and it costs a reasonable amount of money to ship oil down here," said Evan Lucas, a Melbourne-based strategist at IG, a brokerage firm.

Caltex, whose earnings have been squeezed in recent months, has responded with moves to convert one of its Australian refineries into a fuel-import terminal, where it plans to receive gasoline and jet-fuel produced by other refiners, and then selling them directly to motorists and businesses. The Australian firm is half-owned by U.S.-based Chevron Corp. (CVX).

The impact from tighter competition was compounded in the latest results by a series of setbacks that hampered production at Caltex's two refineries. A small fire at the Lytton facility in Brisbane, Queensland state, stalled fuel production there in May, while the following month output was dented by damage to a pipeline serving the Kurnell refinery in Sydney, New South Wales.

A further burden for Caltex has been a decline in the Australian dollar from as high as A$1.04 in April to A$0.92 at the end of June that pushed up the cost of its U.S.-dollar payables--including the crude oil that it refines.

Caltex isn't the only Australian operator facing problems. Last year, Royal Dutch Shell PLC. (RDSA) converted its Sydney-based Clyde refinery into a fuel-import terminal and is considering doing the same at Geelong, in Victoria state, if it can't find a buyer for it.

In recent years, the performance of Caltex's direct fuel-marketing business has held up better than earnings at its refining division, as Australia's booming resources industry supported economic growth. On Monday, Chief Executive Julian Segal shrugged off concern that a recent slowdown in China's demand for Australia's mineral resources would crimp fuel demand from the domestic mining industry.

"What is really slowing down is not actually the digging from existing projects, it's investment in new projects, so we don't see volumes at all slowing down," Mr. Segal told reporters.

In the latest results, Caltex said it benefited from higher margins at its refining business in the first half, but that the longer-term outlook was gloomy.

"As we see more capacity additions coming online over the next two, three, or four years, we anticipate that refiner margins will be negatively impacted," Caltex's Chief Financial Officer Simon Hepworth said on a conference call with reporters.

Caltex paid out an interim dividend of 17 cents a share, unchanged from a year earlier.

Write to Ross Kelly at ross.kelly@wsj.com

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