The Shell Scotford Upgrader is an oilsand upgrader, a facility which processes crude bitumen from oil sands into a wide range of synthetic crude oils. The upgrader is owned by Athabasca Oil Sands Project (AOSP), a joint venture of Shell Canada Energy (60%), Marathon Oil Sands L.P. (20%) and Chevron Canada Limited (20%). The facility is located in the industrial development of Scotford, just to the northeast of Fort Saskatchewan, Alberta in the Edmonton Capital Region. [1]
The Scotford Upgrader is a part of a larger site known as Shell Scotford located 40 km northeast of Edmonton, Alberta. Shell Scotford comprises three operating units: the Upgrader, a Refinery, and a Chemical plant. The Scotford Cogeneration Plant is also located on the site. Currently, work is being done on the first Upgrader expansion. In 1984, Shell opened both the Refinery and Chemical plant on the Scotford site. As one of North America's most modern and efficient refineries, the Scotford Refinery was the first to exclusively process synthetic crude oil from Alberta’s oil sands. Benzene that is produced during the refining process is sent to the adjacent Chemical plant and is used in the production of Styrene Monomer, a chemical needed to make many of the hard plastics people use daily. In 2000, a glycol plant was opened at Scotford Chemicals. Much of the output of the Scotford Upgrader is sold to the Scotford Refinery. Both light and heavy crudes are also sold to Shell's Sarnia Refinery in Ontario. The rest of the synthetic crude is sold to the general marketplace and shipped by pipeline.
In 1891, a group of immigrants from Galicia, Austria settled on the land south of the North Saskatchewan River, near the South Victoria Trail. Philip Krebs, along with his son John, settled on the north side of South Victoria Trail. Their home became a popular stopping place for those travelling along the trail. Besides being a hospitable natured man, John was fluent in four European languages (German, English, Polish, and Ukrainian) and could speak Cree - making him popular with those who stopped by.
When the Canadian Northern Railway was being built into Fort Saskatchewan, Philip Krebs’ homestead was a natural place for a stop. In 1905, a loading station was erected there, and on the siding of the building was the name “Scotford” (named after Walter Scott and Alexander Rutherford, the premiers of the two provinces – Saskatchewan and Alberta - that were formed that same year). The area is still referred to by that name.
The Scotford Upgrader has a rated processing capacity of 255,000 barrels per day (40,500 m3/d). [2] It was shut down after being damaged in a fire 19 November 2007. The production was resumed in December 2007. [3]
The facility uses hydrogen addition to convert the bitumen from CNRL's Muskeg River Mine in the Athabasca oil sands into refinery-ready sweet, light crude oil. The Muskeg River Mine is the first commercial unit using Shell's Enhance froth treatment technology — a process for removing sand, fine clay and water from oil sands froth to make clean bitumen suitable for upgrading via hydrogen addition. [4]
According to Shell, the hydrogenation process is well suited to the very clean bitumen produced at the Muskeg River Mine, and results in the upgrader producing more light crude oil than it inputs in the form of heavy bitumen. It also produces lower levels of sulfur dioxide emissions than the alternative coking method which removes carbon to produce petroleum coke as a by-product. The Scotford Upgrader has its own hydrogen manufacturing unit and produces most of the hydrogen required for the hydrogen-addition process.
The Scotford Upgrader capacity was expanded by 100,000 bbl/d (16,000 m3/d) in March 2010, an increase of 60% in capacity. In May 2007, the US$9 billion to US$11.3 billion expansion contract was awarded to TIC, Bantrel Constructors, PCL & KBR. KBR built 160 modules and performed construction work for the Atmospheric and Vacuum (A&V) unit and Sulphur Recovery Unit (SRU). Bantrel completed the tank farm, Utilities, Waterblock and Flare units, PCL completed the Residue Hydroconversion Complex (RHC) and TIC constructed the Hydrogen Manufacturing Unit (HMU) . [5]
Bitumen is an immensely viscous constituent of petroleum. Depending on its exact composition it can be a sticky, black liquid or an apparently solid mass that behaves as a liquid over very large time scales. In American English, the material is commonly referred to as asphalt. Whether found in natural deposits or refined from petroleum, the substance is classed as a pitch. Prior to the 20th century, the term asphaltum was in general use. The word derives from the Ancient Greek word ἄσφαλτος (ásphaltos), which referred to natural bitumen or pitch. The largest natural deposit of bitumen in the world is the Pitch Lake of southwest Trinidad, which is estimated to contain 10 million tons.
Oil sands, tar sands, crude bitumen, or bituminous sands, are a type of unconventional petroleum deposit. Oil sands are either loose sands or partially consolidated sandstone containing a naturally occurring mixture of sand, clay, and water, soaked with bitumen, a dense and extremely viscous form of petroleum.
The Athabasca oil sands, also known as the Athabasca tar sands, are large deposits of bitumen, a heavy and viscous form of petroleum, located in northeastern Alberta, Canada. These reserves are one of the largest sources of unconventional oil in the world, making Canada a significant player in the global energy market.
Synthetic crude is the output from a bitumen/extra heavy oil upgrader facility used in connection with oil sand production. It may also refer to shale oil, an output from an oil shale pyrolysis. The properties of the synthetic crude depend on the processes used in the upgrading. Typically, it is low in sulfur and has an API gravity of around 30. It is also known as "upgraded crude".
Shell Canada Limited is the principal Canadian subsidiary of British energy major Shell plc and one of Canada's largest integrated oil companies. Exploration and production of oil, natural gas and sulphur is a major part of its business, as well as the marketing of gasoline and related products through the company's approximately 1,800 stations across Canada.
An upgrader is a facility that upgrades bitumen into synthetic crude oil. Upgrader plants are typically located close to oil sands production, for example, the Athabasca oil sands in Alberta, Canada or the Orinoco tar sands in Venezuela.
Petroleum production in Canada is a major industry which is important to the overall economy of North America. Canada has the third largest oil reserves in the world and is the world's fourth largest oil producer and fourth largest oil exporter. In 2019 it produced an average of 750,000 cubic metres per day (4.7 Mbbl/d) of crude oil and equivalent. Of that amount, 64% was upgraded from unconventional oil sands, and the remainder light crude oil, heavy crude oil and natural-gas condensate. Most of the Canadian petroleum production is exported, approximately 600,000 cubic metres per day (3.8 Mbbl/d) in 2019, with 98% of the exports going to the United States. Canada is by far the largest single source of oil imports to the United States, providing 43% of US crude oil imports in 2015.
Dilbit is a bitumen diluted with one or more lighter petroleum products, typically natural-gas condensates such as naphtha. Diluting bitumen makes it much easier to transport, for example in pipelines. Per the Alberta Oil Sands Bitumen Valuation Methodology, "Dilbit Blends" means "Blends made from heavy crudes and/or bitumens and a diluent, usually natural-gas condensate, for the purpose of meeting pipeline viscosity and density specifications, where the density of the diluent included in the blend is less than 800 kg/m3." If the diluent density is greater than or equal to 800 kg/m3, the diluent is typically synthetic crude and accordingly the blend is called synbit.
Canada's oil sands and heavy oil resources are among the world's great petroleum deposits. They include the vast oil sands of northern Alberta, and the heavy oil reservoirs that surround the small city of Lloydminster, which sits on the border between Alberta and Saskatchewan. The extent of these resources is well known, but better technologies to produce oil from them are still being developed.
Bantrel Co. is a Canadian private corporation owned by Bechtel Corporation and McCaig Investments. Bantrel's core business is in Engineering, Procurement, and Construction Management in the Canadian Marketplace. Bantrel is active in Canada's energy sector, and is a supplier of engineering services to oil sands developers in Alberta. In addition to oil sands, Bantrel is also engaged in refining, power generation, gasification, and pipeline construction projects.
Albian Sands Energy Inc. is a mining company which operates the Muskeg River Mine and Jack Pine Mine, an oil sands mining project located 75 kilometres (47 mi) north of Fort McMurray, Alberta, Canada. It is a joint venture between Shell Canada (10%), CNRL (70%) and Chevron Canada (20%).
Oil reserves in Canada were estimated at 172 billion barrels as of the start of 2015 . This figure includes the oil sands reserves that are estimated by government regulators to be economically producible at current prices using current technology. According to this figure, Canada's reserves are third only to Venezuela and Saudi Arabia. Over 95% of these reserves are in the oil sands deposits in the province of Alberta. Alberta contains nearly all of Canada's oil sands and much of its conventional oil reserves. The balance is concentrated in several other provinces and territories. Saskatchewan and offshore areas of Newfoundland in particular have substantial oil production and reserves. Alberta has 39% of Canada's remaining conventional oil reserves, offshore Newfoundland 28% and Saskatchewan 27%, but if oil sands are included, Alberta's share is over 98%.
Refinery Row is the unofficial name given to the concentration of oil refineries in west Sherwood Park, Strathcona County, Alberta, just east of the city of Edmonton.
The Long Lake oil sands upgrader project is an in situ oil extraction project near Anzac, Alberta, 40 km (25 mi) southeast of Fort McMurray in the Athabasca oil sands region of Alberta.
The Cenovus Lloydminster Refinery is an asphalt refinery located in the city of Lloydminster, Alberta, Canada owned by Husky Energy. The refinery provides oil products, primarily 30 different grades of asphalt, as well as light distillate, kerosene distillate, atmospheric gas oil, light vacuum gas oil (VGO), and heavy vacuum gas oil. This refinery is Canada's largest asphalt supplier, processing 27,000 barrels of heavy crude oil per day to produce asphalt. Husky is the "largest marketer of paving asphalt in Western Canada with a 29 mbbls/day capacity asphalt refinery located at Lloydminster, Alberta "integrated with the local heavy oil production, transportation and upgrading infrastructure."
The Strathcona Refinery is an oil refinery located in Strathcona County adjacent to Edmonton, Alberta, Canada, owned by Imperial Oil. The refinery provides oil products, primarily gasoline, aviation fuel, diesel, lubricating oils, petroleum waxes, heavy fuel oil and asphalts.
Western Canadian Select (WCS) is a heavy sour blend of crude oil that is one of North America's largest heavy crude oil streams and, historically, its cheapest. It was established in December 2004 as a new heavy oil stream by EnCana, Canadian Natural Resources, Petro-Canada and Talisman Energy. It is composed mostly of bitumen blended with sweet synthetic and condensate diluents and 21 existing streams of both conventional and unconventional Alberta heavy crude oils at the large Husky Midstream General Partnership terminal in Hardisty, Alberta. Western Canadian Select—the benchmark for heavy, acidic crudes—is one of many petroleum products from the Western Canadian Sedimentary Basin oil sands. Calgary-based Husky Energy, now a subsidiary of Cenovus, had joined the initial four founders in 2015.
Bitumen froth treatment is a process used in the Athabasca oil sands (AOS) bitumen recovery operations to remove fine inorganics—water and mineral particles—from bitumen froth, by diluting the bitumen with a light hydrocarbon solvent—either naphthenic or paraffinic—to reduce the viscosity of the froth and to remove contaminants that were not removed in previous water-based gravity recovery phases. Bitumen with a high viscosity or with too many contaminants, is not suitable for transporting through pipelines or refining. The original and conventional naphthenic froth treatment (NFT) uses a naphtha solvent with the addition of chemicals. Paraffinic Solvent Froth Treatment (PSFT), which was first used commercially in the Albian Sands in the early 2000s, results in a cleaner bitumen with lower levels of contaminates, such as water and mineral solids. Following froth treatments, bitumen can be further upgraded using "heat to produce synthetic crude oil by means of a coker unit."
The Quest Carbon Capture and Storage Project captures and stores underground 1m tonnes of CO2 emissions per year. Between 2015 and 2019, 5m tonnes were captured, but the facility emitted 7.5m, more than offsetting any carbon saving. The capture unit is located at the Scotford Upgrader in Alberta, Canada, where hydrogen is produced to upgrade bitumen from oil sands into synthetic crude oil.
The Sturgeon Refinery also NWR Sturgeon Refinery is an 80,000 bbl/d (13,000 m3/d) crude oil upgrader—built and operated by North West Redwater Partnership (NWRP) in a public-private partnership with the Alberta provincial government. It is located in Sturgeon County northeast of Edmonton, Alberta, in Alberta's Industrial Heartland. Premier Jason Kenney announced on July 6, 2021, that the province of Alberta had acquired NWRP's equity stake, representing 50% of the $10-billion project, with the other 50% owned by Canadian Natural Resources.