
This history is part two of a history of the Canadian petroleum industry, which I wrote for Wikipedia. It is about northern and offshore petroleum frontiers and oil sands. For early development of Canada's conventional petroleum resources and pipelines, see History of the petroleum industry in Canada, part one.
Canada's petroleum frontiers are of two types.
The
technological frontiers include the oil sands of Alberta, and the huge heavy oil belt that stretches from central Alberta into Saskatchewan, and straddles the borders between the two provinces. Here the resources are known, but technologies to produce oil from them in cost-effective ways are still being developed.
The
geographical frontiers are the vast petroleum basins in the north, in the Arctic Islands and offshore, and off the coast of Atlantic Canada. These areas are difficult and expensive to explore and develop, but successful projects can be profitable using known production technology.
This article covers the early development of both.
Oil sands and heavy oilChemistry of Petroleum: An early history of Canada’s petroleum industry would not be complete without a chronicle of pioneering efforts to produce the tar sands (now commonly called “oil sands”) of northern Alberta. To appreciate these resources, it is important to understand the "gravity" of oil and gas.
Gravity refers to the weight spectrum of hydrocarbons, which increases with the ratio of hydrogen to carbon in a chemical compound's molecule. Methane (CH4) - the simplest form of natural gas - has four hydrogen atoms for every carbon atom. It has light gravity, and takes the form of a gas at atmospheric pressure. The next heavier hydrocarbon, ethane, has the chemical formula C2H6 and is a slightly heavier gas. Gases, of course, have no gravity at atmospheric temperatures and pressures.
Organic compounds combining carbon and oxygen are many in number. Those with more carbon atoms per hydrogen atom are heavier, and less likely to be gaseous. Most hydrocarbons are liquid under standard conditions, with greater viscosity associated with greater gravity. The American Petroleum Institute has developed a formula to measure the API gravity of petroleum liquids.
Heavy oil and bitumen, which have more carbon than hydrogen, are heavy, black, sticky and either slow-pouring or so close to being solid that they will not pour at all unless heated. Although the dividing line is fuzzy, the term heavy oil refers to slow-pouring heavy hydrocarbon mixtures. Bitumen refers to mixtures with the consistency of cold molasses that pour at room temperatures with agonizing slowness.
It is difficult to grasp the immensity of Canada's oil sands and heavy oil resource. Sand deposits in northern Alberta include four major deposits which underlie almost 70,000 square kilometres of land. The volume of bitumen in those sands dwarfs the light oil reserves of the entire Middle East. One deposit, the Athabasca oil sands, is the world's largest known crude oil resource.
Early Exploration: Explorer and fur trader Peter Pond noticed the deposits when he travelled the Clearwater River to its junction with the Athabasca in 1778 - the first European to do so. He noted “...along the banks of the river are found springs of bitumen which flow along the ground.” Reaching the same area nearly a decade later, Alexander Mackenzie also became interested in the oil sands and the way the Ojibwe Indians used the thick black oil for water-proofing their canoes. Despite the fascination of the early explorers, however, the existence of the sands did not excite commercial interests for more than a century.
In 1875, John Macoun of the Geological Survey also noted the presence of the oil sands. Later reports by Dr. Robert Bell and later by D.G. McConnell, also of the Geological Survey, led to drilling some test holes. In 1893, Parliament voted $7,000 for drilling. This first commercial effort to exploit the oil sands probably hoped to find free oil at the base of the sands, as drillers had in the gum beds of southern Ontario a few decades earlier. Although the Survey's three wells failed to find oil, the second was noteworthy for quite another reason.
Drilled at a site called Pelican Portage, the well blew out at 235 metres after encountering a high-pressure gas zone. According to drilling contractor A.W. Fraser,
“ The roar of the gas could be heard for three miles or more. Soon it had completely dried the hole, and was blowing a cloud of dust fifty feet into the air. Small nodules of iron pyrites, about the size of a walnut, were blown out of the hole with incredible velocity. We could not see them going, but could hear them crack against the top of the derrick . . . . There was danger that the men would be killed if struck by these missiles. ”
Fraser's crew unsuccessfully tried to kill the well by casing it, then abandoned the well for that year. They returned in 1898 to finish the job, but again they failed. In the end, they simply left the well blowing wild. Natural gas flowed from the well at a rate of some 250,000 cubic metres per day until 1918. In that year a crew led by geologist S.E. Slipper and C.W. Dingman finally shut in the well.
These wells helped establish that the bitumen resource in the area was huge. There was now clear recognition of the commercial potential of the oil sands, and a long period of exploration and experimentation followed. The point of this research was to find a method of getting oil out of the tar sands at a reasonable price.
Alfred Von Hamerstein, who claimed to be a German count, was one of the colourful early players in the oil sands. He had been en route to the Klondike, but stayed and turned his interest from gold to the oil sands. In 1906 he drilled at the mouth of the Horse River, but struck salt instead of oil. He continued working in the area, however.
In 1907 Von Hamerstein made a celebrated presentation to a Senate committee investigating the potential of the oil sands.
“ I have all my money put into (the Athabasca oil sands), and there is other peoples' money in it, and I have to be loyal. As to whether you can get petroleum in merchantable quantities . . . I have been taking in machinery for about three years. Last year I placed about $50,000 worth of machinery in there. I have not brought it in for ornamental purposes, although it does look nice and home-like. ”
History has not been kind to the count, however. He is now generally thought to have been a bit of a dreamer, a lot of a con.
In 1913, Dr. S.C. Ells, an engineer with the federal department of mines, began investigating the economic possibilities of the oils sands. It was then that the idea of using the sands as road paving material was born. In 1915, Dr. Ells laid three road surfaces on sections of 82nd Street in Edmonton. Materials used included bitulithic, bituminous concrete and sheet asphalt mixtures. A report, ten years later, by a city engineer stated that the surface remained in excellent condition. McMurray asphalt also saw use on the grounds of the Alberta Legislature, on the highway in Jasper Park and elsewhere in Alberta.
Although private contractors also mined oil sand as a paving material, the proposition was not economic. Fort McMurray (the village closest to the near-surface deposits) was small and far from market, and transportation costs were high.
Bitumen Production: Instead, researchers began to look for ways to extract the bitumen from the sand. The Alberta Research Council set up two pilot plants in Edmonton and a third at the Clearwater River. These plants were part of a successful project (led by the Research Council’s Dr. Karl A. Clark) to develop a hot water process to separate the oil from the sands. In 1930, the Fort McMurray plant actually used the process to produce three car loads of oil.
At about that time two American promoters, Max Bell and B.O. Jones from Denver, entered the oil sands scene. They reportedly had a secret recovery method known as the McClay process, and they claimed substantial financial backing. They negotiated leases with the federal and Alberta governments and also bought the McMurray plant of the Alberta Research Council. In 1935, Abasand Oils Limited, Bells’ American-backed operating company, started construction of a new plant west of Waterways.
Under the agreement with the government, the plant was to be in operation by September 1, 1936. But forest fires and failure of equipment suppliers to meet delivery dates delayed completion.
The agreement called for mining 45,000 tonnes of sands in 1937 and 90,000 tonnes each year after 1938. The 1,555-hectare lease carried a rental of $2.47 per hectare per year. There was to be a royalty of $0.063 per cubic metre on production for the first five years, and $0.31 per cubic metre thereafter.
Mining at the Abasand plant began May 19, 1941. By the end of September, 18,475 tonnes of oil sand had produced 2,690 cubic metres of oil, but in November fire destroyed the plant. Rebuilt on a larger scale, it was fully operational in June 1942. Between 1930 and 1955, the International Bitumen Company Limited under R.C. Fitzsimmons operated a smaller scale pilot plant at Bitumount.
In 1943, the federal government decided to aid oil sands development, and took over the Abasand plant. The federal researchers concluded that the hot water process was uneconomic because of the extensive heat loss and proposed a “cold” water process. But work at the plant came to an end with a disastrous fire in 1945.
Meanwhile, in July 1943, International Bitumen Company reorganized as Oil Sands Limited. When the Alberta government became disenchanted with federal efforts in the oil sands and decided to build its own experimental plant at Bitumount, the province engaged Oil Sands Limited to construct the plant.
The company agreed to buy the plant within a period of ten years for the original investment of $250,000. The cost of the plant was $750,000, however. A legal claim against Oil Sands Limited resulted in the province taking possession of the plant and property at Bitumount. The plant consisted of a separation unit, a dehydrating unit and a refinery. The plant conducted successful tests using the Clark hot water process in 1948/49 then closed, partly because the recent Leduc discoveries had lessened interest in the oil sands.
Oil Sands Limited eventually reorganized as Great Canadian Oil Sands Limited (now Suncor}, which built and started operation of the first commercial-sized integrated oil sands project in 1967. It had found solutions to the problems of extracting a commercial grade of oil from the sands - problems that had been the concern of financiers, chemists, petroleum engineers, metallurgists, mining engineers, geologists, physicists and many other scientists and pseudo-scientists for may decades. A much later development - although its roots go back to the 1940s, the massive Syncrude plant did not go into operation until 1978 - now supplies some 14 per cent of Canada's crude oil production, in the form of synthetic oil.
Heavy Oil Story:Heavy oil is a sister resource to bitumen. It is lighter than bitumen and its reservoirs are much smaller than the great oil sands deposits. Even so, its dimensions are impressive. But like the oil sands, only a small percentage is producible.
Often called conventional heavy oil, this low-density oil can be recovered by conventional drilling techniques or by waterflood, a technique of injecting water into the reservoir to increase pressure, thus forcing the oil toward the well bore. When these techniques work, heavy oil is like the more commercially attractive lighter grades of oil. But heavy oil can also be quite viscous. It can need some form of heat or solvent and pressure before it can flow into a well bore to be produced. When heavy oil requires these techniques to go into production, it is known as non-conventional heavy oil.
The first heavy oil discoveries came with the pursuit of conventional light and medium crude oil. Because much of western Canada's heavy oil is in pools close to the surface, early explorers using older rigs discovered many of those pools before they came upon the deeper light oil reservoirs.
One of the first finds was in the Ribstone area near Wainwright, Alberta in 1914. The province's first significant production of heavy oil came from the Wainwright field in 1926. Producers drew almost 6 000 barrels of heavy oil from the field in that year. A small-scale local refinery distilled the heavy goo into usable products.
Elsewhere in Alberta, petroleum explorers made other heavy oil finds as they pursued the elusive successor to the Turner Valley oil field. They developed production from many of these fields, but only in small volumes. The recovery techniques of the day combined with the low price of oil and the nature and size of the finds meant that most of the oil remained undeveloped.
The most important exception was at Lloydminster. While the first discovery occurred in 1938, serious development did not begin until Husky Oil moved into the area after the second world war.
Husky Oil was born during the Depression through the efforts of Glenn Nielson, an Alberta farmer driven to bankruptcy when the bank called a loan on his farm. Nielson had moved to Cody, Wyoming, by the time he founded Husky as a refining operation. He turned his attention back to Canada after the second world war, and decided to set up a refinery at Lloydminster. Steel was scarce, so Husky dismantled a small Wyoming refinery constructed during the war to provide bunker fuel to the American Navy. It loaded the pieces onto 40 gondola cars and shipped them north by railway.
The company began reassembling the 400 cubic metre per day facility in 1946, and the refinery went on production the following year. Strategically located between the Canadian Pacific and Canadian National railroad tracks in Lloydminster, the refinery soon began to get contracts for locomotive bunker fuel. The company also found a strong market for asphalt for road building.
Husky's move into the area spurred drilling and production. Within two years of Husky's arrival, there were oversupplies of heavy oil and shortages of storage space. Producers solved the problem by storing the oil in earthen pits holding up to 16,000 cubic metres each. For a while Husky bought the oil by weight rather than volume since it was clogged with earth, tumbleweed and jackrabbits. The company had to strain and remeasure the stuff before it could begin refining.
Husky began producing heavy oil from local fields in 1946, and by the 1960s was easily the biggest regional producer. In 1963 the company undertook another in a series of expansions to the refinery. To take advantage of expanding markets for Canadian oil, it also began a program to deliver heavy oil to national and export markets.
The key to the $35 million project was the construction of a reversible pipeline which could move the viscous heavy oil into the marketplace. The 116-kilometre "yo-yo" pipeline - the first in the world - brought condensate from the Interprovincial Pipe Line station at Hardisty, Alberta. The company began mixing this very light hydrocarbon with heavy oil, enabling it to flow more easily. The company then pumped the blend through its pipeline (hence the nickname "yo-yo") back to Hardisty. From there the Interprovincial took it eastward to market.
These developments made heavy oil for the first time more than a marginal resource. Within five years, area production had increased five-fold to nearly 2,000 cubic metres per day. By the early 1990s, production from the heavy oil belt was some 40,000 cubic metres per day. And Husky was still one of Canada's biggest heavy oil producers.
True NorthNorman Wells: The first great story in Canada's exploration of the geographical frontiers is that of Norman Wells in the Northwest Territories. During his voyage of discovery down the Mackenzie River to the Arctic Ocean in 1789, Sir Alexander Mackenzie noted in his journal that he had seen oil seeping from the river’s bank. R.G. McConnell of the Geological Survey of Canada confirmed these seepages in 1888. In 1914, T.O. Bosworth, later Imperial Oil’s chief geologist, staked three claims near the spot. Imperial Oil acquired the claims and sent two geologists there in 1918-1919. They recommended drilling.
Led by a geologist, a crew comprised of six drillers and an ox (Old Nig by name) began a six-week, 1,900-kilometre journey northward by railway, river boat and foot to the site now known as Norman Wells. They found oil - largely by luck, it turned out later - after Ted Link, the geologist, waved his arm grandly and said, “Drill anywhere around here.” The crew began digging into the permafrost with pick and shovel, unable to put their cable tool rig into operation until they had cleared away the mixture of frozen mud and ice. At about the 30-metre level they encountered their first oil show. By this time, the river ice had frozen to 1.5 metres and the mercury had plunged to -40 degrees. The crew decided to give up and wait out the winter. They survived, but their ox did not. Old Nig provided many a meal during the long, cold winter.
Drilling resumed in the spring and a relief crew arrived in July. Some of the original crew stayed around to help the newcomers continue drilling. On August 23, 1920, they struck oil at 240 metres. The world’s most northerly oil well had come in. In succeeding months, Imperial drilled three more holes - two successful, one dry. The company also installed enough equipment to refine the crude oil into a type of fuel oil for use by church missions and fishing boats along the Mackenzie. But the refinery and oil field closed in 1921 because northern markets were too small to justify the costly operations. Norman Wells marked another important milestone when in 1921 Imperial flew two all-metal 185-horsepower Junkers airplanes to the site. These aircraft were among the first of the legendary bush planes which helped to develop the north, and forerunners of today’s commercial northern air transport.
A small oil refinery using Norman Wells oil opened in 1936 to supply the Eldorado Mine at Great Bear Lake, but the field did not take a significant place in history again until after the United States entered World War II.
When Japan captured a pair of Aleutian Islands, Americans became concerned about the safety of their oil-tanker routes to Alaska and began looking for an inland oil supply safe from attack. They negotiated with Canada to build a refinery at Whitehorse in the Yukon, with crude oil to come by pipeline from Norman Wells. If tank trucks had tried to haul the oil to Alaska, they would have eaten up most of their own load over the vast distance.
This spectacular project, dubbed Canol - a contraction of “Canadian” and “oil” - took 20 months, 25,000 men, 10 million tonnes of equipment, 1,600 kilometres of road, 1,600 kilometres of telegraph line and 2,575 kilometres of pipeline. The pipeline network consisted of the 950-kilometre crude oil line from Norman Wells to the Whitehorse refinery. From there, three lines carried products to Skagway and Fairbanks in Alaska, and to Watson Lake, Yukon. Meanwhile Imperial was drilling more wells. The test for the Norman Wells oilfield came when the pipeline was ready on February 16, 1944. The field surpassed expectations. During the one year remaining of the Pacific war, the pipeline pumped about 160,000 cubic metres of oil to the Whitehorse refinery.
The total cost of the project (all paid by US taxpayers) was $134 million, in 1943 US dollars. Total crude production was 315,000 cubic metres (7,313 cubic metres of which spilled.) The cost of the crude oil was $426 per cubic metre ($67.77 per barrel). Refined petroleum product output was just 138,000 cubic metres. Cost per barrel of refined product was thus $975 per cubic metre, or 97.5 cents per litre. Adjusted to current dollars using the US Consumer Price Index, in 2000 dollars the oil would have cost $4,214 per cubic metre ($670 a barrel), while the refined product woul