Originally posted by Dr Mordrid
Could hydrocarbons dug out of the sand in western Canada hold future promise as a feedstock for the petrochemical industry? As a key player in the Athabasca Oil Sands Project, Shell is at the forefront of tapping a vast reserve of oil sands hydryocarbons, from which synthetic crude is produced. But time and economics are critical factors in determining whether this could provide an effective long-term replacement for diminishing sources of ethane extracted from conventional natural gas.
Riddle of sands
The Athabasca Oil Sands Project became fully operational in June this year (2005 -BE), producing up to 155,000 barrels of heavy crude oil, in the form of bitumen, per day. At full production it can potentially produce the equivalent of 10 percent of Canada's oil needs.
A joint venture of Shell Canada Limited (60 percent), Chevron Canada Limited (20 percent) and Western Oil Sands LP (20 percent), the AOSP consists of two components: the Muskeg River Mine, located 75 kilometres north of Fort McMurray, Alberta, and the Scotford Upgrader, located adjacent to Shell's Scotford Refinery, near Fort Saskatchewan, Alberta. Shell Canada serves as the overall project administrator.
Mining for oil
At the Muskeg River Mine, a mix of oil and sand is removed from just below the surface using massive trucks and shovels. The largest of the mines' four electrical and two hydraulic shovels can hold about 100 tons - a scoop about the size of a school bus. Its mining trucks can carry up to 400 tons. To put the scale of the mining operations into perspective, one heavy-hauler truck tire stands one-and-a-half stories tall, 1.5 metres wide and weighs 4,900 kilograms, or almost as much as five cars.
You obviously know better than Shell how to extract the bitumen, so maybe you could get a job as a consultant to tell them how to do it!

And remember, it is bitumen, not crude, so the cracking is much more energy-intensive. I did a consultancy job for a company here, a few years ago. They had been engaged by the Cyprus refinery to advise on the disposal of still bottoms: they had accumulated a massive dump over the years, covering hectares. Essentially, the bottoms were a mixture of very heavy bitumen and sand that comes suspended in the crude. The MP was too high for it to be incorporated in road aggregate. My analysis showed that it was 30-40% sand, so there were megatonnes of useless hydrocarbons. I enquired about cracking it, but was told that it was technically possible to crack 60-70% of the HCs, but the energy required was so high that it could not be economical by a whole order of magnitude. I don't know, but I could easily imagine that the Alberta sands are quite similar. I think crude, at that time, was about $28/bbl. In the end, we mixed it (1-2%) into the HFO used for calcining cement.
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