An overview of Canadian oil sand mega projects

Abstract

There are currently a number of existing oil sand Mega-Projects as well as many other related projects planned and under construction in the Alberta oil sands region. There are many challenges facing the oil sands. The demanding climate conditions cost of extraction, environmental, energy constraints as well as the rising construction costs are examples. To develop this huge petroleum reserve, these factors must be considered. It also requires the utilization of unique technologies unusual to the oil & gas industry. These techniques include: open pit mining, and in situ techniques such as steam assist gravity drainage (SAGD) and toe to heel air injection (THAI) processes. Open pit mining requires the handling of vast quantities of ore material by utilizing mining and material handling equipment as well as slurry conditioning and transfer pump stations. This equipment is involved in the extraction process. Further along in the process are the froth and tailings operations which have high pump utilization. In-situ techniques do not require material handling but make use of a variety of specialized pumps. These include progressive cavity pumps (PCP) and electric submersible pumps (ESP) for the SAGD and THAI processes. This paper will discuss various techniques & considerations as well as approaches to project design, construction and management when dealing with large projects in the booming Alberta economy. A number of factors have influenced the extensive use of ASDs (adjustable speed drives) on the associated applications. These factors include: the unique techniques required for flow and process control, the high torque requirements common to the materials handling portion of the process (Shovels, crushers, apron feeders, and conveyors drives) as well as environmental factors. The need for efficiency, energy conservation and emission reductions are important environmental considerations. A unique application to the open pit mining process is the slurry conditioning and handling system as well as tailings pumps. These specialized pumps are required to transfer the large quantities of slurry and tailing materials involved in the process. Pumps and other applications will be discussed relative to the above factors.