Oil Shale Technology - Old & New Extracting oil from the shale is no simple task. The earliest attempts to extract the oil utilized an environmentally unfriendly process known as "retorting." Stated simply, retorting required mining the shale, hauling it to a processing facility that crushed the rock into small chunks, then extracted a petroleum substance called kerogen, then upgraded the kerogen through a process of hydrogenation (which requires lots of water) and refined it into gasoline or jet fuel. But the difficulties of retorting do not end there, as my colleague, Byron King explains: "After you retort the rock to derive the kerogen (not oil), the heating process has desiccated the shale (OK, that means that it is dried out). Sad to say, the volume of desiccated shale that you have to dispose of is now greater than that of the hole from which you dug and mined it in the first place. Any takers for trainloads of dried, dusty, gunky shale residue, rife with low levels of heavy metal residue and other toxic, but now chemically-activated crap? (Well, it makes for enough crap that when it rains, the toxic stuff will leach out and contaminate all of the water supplies to which gravity can reach, which is essentially all of 'em. Yeah, right. I sure want that stuff blowin' in my wind.) Add up all of the capital investment to build the retorting mechanisms, cost of energy required, cost of water, costs of transport, costs of environmental compliance, costs of refining, and you have some relatively costly end-product." But a new technology has emerged that may begin to tap the oil shale's potential. Royal Dutch Shell, in fact, has recently completed a demonstration project (The Mahogany Ridge project) in which it produced 1,400 barrels of oil from shale in the ground, without mining the shale at all. Instead, Shell utilized a process called "in situ" mining, which heats the shale while it's still in the ground, to the point where the oil leaches from the rock. Shell's Terry O'Connor described the breakthrough in testimony before Congress earlier this summer (And Congress may have an acute interest in the topic, since the U.S. government controls 72% of all U.S. oil shale acreage): "Some 23 years ago, Shell commenced laboratory and field research on a promising in ground conversion and recovery process. This technology is called the In-situ Conversion Process, or ICP. In 1996, Shell successfully carried out its first small field test on its privately owned Mahogany property in Rio Blanco County, Colorado some 200 miles west of Denver. Since then, Shell has carried out four additional related field tests at nearby sites. The most recent test was carried out over the past several months and produced in excess of 1,400 barrels of light oil plus associated gas from a very small test plot using the ICP technology... "Most of the petroleum products we consume today are derived from conventional oil fields that produce oil and gas that have been naturally matured in the subsurface by being subjected to heat and pressure over very long periods of time. In general terms, the In-situ Conversion Process (ICP) accelerates this natural process of oil and gas maturation by literally tens of millions of years. This is accomplished by slow sub-surface heating of petroleum source rock containing kerogen, the precursor to oil and gas. This acceleration of natural processes is achieved by drilling holes into the resource, inserting electric resistance heaters into those heater holes and heating the subsurface to around 650-700F, over a 3 to 4 year period. "During this time, very dense oil and gas is expelled from the kerogen and undergoes a series of changes. These changes include the shearing of lighter components from the dense carbon compounds, concentration of available hydrogen into these lighter compounds, and changing of phase of those lighter, more hydrogen rich compounds from liquid to gas. In gaseous phase, these lighter fractions are now far more mobile and can move in the subsurface through existing or induced fractures to conventional producing wells from which they are brought to the surface. The process results in the production of about 65 to 70% of the original "carbon" in place in the subsurface. "The ICP process is clearly energy-intensive, as its driving force is the injection of heat into the subsurface. However, for each unit of energy used to generate power to provide heat for the ICP process, when calculated on a life cycle basis, about 3.5 units of energy are produced and treated for sales to the consumer market. This energy efficiency compares favorably with many conventional heavy oil fields that for decades have used steam injection to help coax more oil out of the reservoir. The produced hydrocarbon mix is very different from traditional crude oils. It is much lighter and contains almost no heavy ends. "However, because the ICP process occurs below ground, special care must be taken to keep the products of the process from escaping into groundwater flows. Shell has adapted a long recognized and established mining and construction ice wall technology to isolate the active ICP area and thus accomplish these objectives and to safe guard the environment. For years, freezing of groundwater to form a subsurface ice barrier has been used to isolate areas being tunneled and to reduce natural water flows into mines. Shell has successfully tested the freezing technology and determined that the development of a freeze wall prevents the loss of contaminants from the heated zone." It may seem, as O'Conner said, counter-intuitive to freeze the water around a shale deposit, and then heat up the contents within the deposit. It's energy-intensive. And it's a lot of work. What's more, there's no proof yet it can work on a commercial scale. Yet both technologies, the freeze wall and the heating of shale, have been proven in the field to work. The freeze wall was used most recently in Boston's Big Dig project. It was also used to prevent ground water from seeping into the salt caverns at the Strategic Petroleum reserve in Weeks Island, LA. But still, you may be wondering, does it really make sense to heat the ground up a thousand feet down for three or four years and wait? Of course it does. In case you missed O'Conner's math, Shell could harvest up to a million barrels per acre, or a billion barrels per square mile, on an area covering over a thousand square miles. It's still early days in the oil shale fields of Colorado and Wyoming, but it looks to me like someone's gonna make a lot of money out there. I'm working hard to discover how we outside investors can play along.
Shell's Mahogany Ridge Last week, I paid a visit to Royal Dutch Shell's oil shale project in Colorado. The visit left me with more questions than answers, but I came away from the place with the sense that this opportunity is very real...or, at least, it soon will be. After driving across a vast expanse of "Nowhere," Colorado, my brother and I met up with a few geologists from Shell. Of course it's just those large, unpopulated tracts of high desert that make the area so appealing from a geopolitical point of view. Tapping into the oil shale 2,000 feet underground isn't going to bother too many people. And there are no spotted owls around either. If the technology to turn shale into oil works, the entire area will become a new American boom patch. Soon after we arrived, the geologists escorted us around the facility, chatting all the while about the successes and challenges of their venture. The two trickiest aspects of oil shale development, as the geologists and engineers explained, are heating the shale to extreme temperatures, while simultaneously surrounding the heated area with a subterranean ice wall. Shell doesn't know, or isn't saying, which part of the project will be the most challenging. If you were about to change the world by making it economic to tap into as much as 2 trillion barrels of oil under the Colorado plateau, you'd be pretty careful about showing your competitors how you were going to do it. First, anything that heats up rock around it to around 600 or 700 degrees Fahrenheit has to conduct electrically generated heat well. The most conductive metals on the Periodic Table of Elements are, in order, silver, copper, and gold. Naturally, the number of heaters you put in a place affects the amount of time it takes to turn the shale goo into API 34 crude. The more heaters, the more cost, though. And given the fact that Shell does not know yet if the heaters will be recoverable, you can see that sticking silver, copper, or gold heaters 2000 meters underground and then leaving them there once the kerogen has been pumped has a serious effect on the economics of your operation. At the moment, Shell is not sure what the optimal size of production zones ought to be. The big issue here is how big can a freeze-wall be to be effective and freezing the groundwater surrounding a shale deposit? The test projects, as you can see, were quite small. Shell doesn't know, or isn't saying, what the optimum size is for a each "pod" or "cell". That's what they'll have to figure out at the next stage...and the picture with the dirt is a football field sized project....where rather than creating the freeze-wall at 50 meters down...they will do it at 1,000 ft. down.... with 2,000 being the desired and necessary depth for commercial viability. I'm not sure anyone has ever created a freeze-wall at that depth....neither is shell. But we'll find out. The oil itself that comes from the process looks like...oil. No heavy refining needed. Shell thinks the whole thing is economic at a crude price of $30. So barring a major reversal of geopolitical trends, they're forging ahead. Since the Bureau of Land Management owns about 80% of the oil shale acreage in Colorado, there is no investment play on private companies that might own land with rich shale deposits. Although, if Shell and the DOE are right that you can recover a million barrels of oil per acre...it wouldn't take much land to make a man rich out here. Oil Shale: Testing Public Lands The Bureau of Land Management recently received ten applications (by eight companies) for a pilot program to develop Colorado's shale reserves. The program allows the companies access to public lands for the purpose of testing shale-extraction technologies. You see below an interesting mix of large, publicly traded oil giants and small, privately held innovators. - Natural Soda, Inc. of Rifle, Colorado.
- EGL Resources Inc. of Midland, Texas.
- Salt Lake City-based Kennecott Exploration Company.
- Independent Energy Partners of Denver, Colorado
- Denver-based Phoenix Wyoming, Inc.
- Chevron Shale Oil Company.
- Exxon Mobil Corporation.
- Shell Frontier Oil and Gas Inc
There is dispute within the industry over how long, if ever, demonstration extraction technologies can become commercially viable. I've spoken with some of the smaller companies that have applied for leases from the BLM. Some of them will have to raise money to conduct the project. And some of them have been less than forthcoming about how exactly their extraction technology is different or better than previous methods. How will it all unfold? Well, for starters, it could all utterly fail. To me, Shell's in-situ process looks the most promising. It also makes the most sense economically. There may be a better, less energy-intensive way to heat up the ground than what Shell has come up with. But Shell, Chevron, and Exxon Mobil clearly have the resources to scoop up any private or small firm that makes a breakthrough. And there are a host of smaller firms involved with the refining and drilling process that figure to play a key role in the development of the industry, should that development pick up pace. The Energy Policy Act of 2005, otherwise known as a listless piece of legislation without any strategic vision, does, at least, make provision for encouraging research into the development of shale. But government works slow, when it works at all. It's going to take an external shock to the economy to really ratchet up interest and development of the nation's energy reserves...say...something like a nuclear Iran. Dan Denning for The Daily Reckoning P.S. We also encourage you to sign up for the free, Daily Reckoning E-Letter, written by the authors of the New York Times business #1 bestseller Financial Reckoning Day, The Daily Reckoning has the most innovative way of weaving valuable information about investing and living into a format that is not only educational but also entertaining. Learn what you can expect from today's markets -- and how to prosper in the face of uncertainty. You won't find more thought provoking writing anywhere on the Internet. |