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If you want to "upgrade" long hydrocarbon molecules to shorter ones you have to add hydrogen at some point. If not "upstream" then "downstream", i.e. at the refinery at the other end of the pipeline. The usual source of this hydrogen is natural gas. Theoretically the hydrogen source could be water, but that would require even more energy, that would have to come from something, e.g. coal or nuclear. In this case they probably are just trying to get around the limited amoung of NG available "upstream".
This process cracks the longer molecules. The plant only did the lowest part of the upgrading to 19 API. It incorporated a process called fluid cracking and fluid coking. There was some coke produced as a result of the operation. There was also a desulphurization unit to remove sulphur from the emissions. There was less surface disturbance and no tailings ponds to clean up. The layers containing tar sands are already polluted with the oil that occurs in a natural formation.
Another company called Petrobank has been trying underground THAI fireflood recovery. Other companies tried vertical fireflood methods for decades then gave up as SAGD appeared better to them. Per a recent presentation they have been able to get an average 12 API oil (12 is heavier than 19). This is similar to the API grade output that Suncor gets from its SAGD Firebag steaming operations. In the lab tests of the THAI process the initial API output was supposed to be higher (lighter oil). In the field testing the lab process cannot be duplicated. There is also a problem with sand production and irregular flow of liquids.
In a previous Drumbeat (maybe six weeks ago) a story described difficulty with the THAI -Toe to Heel Air Injection- process having big emissions problem. Too much air pollution and CO2 coming out with the bitumen. THAI does not look promissing for getting tar out of the sand in Alberta.
I did as much research as I could about the THAI process and after learning that the API increase in the process was less than what the initial lab tests suggested was possible, became skeptical. Later I learned of sand control issues. More recently there were issues about well control and well flow stated without quantitative data to define the situation. Am not sure whether or not these issues will be resolved. They seem to be planning as if the issues might be resolved, yet cannot state they have solved these problems. Their holdings in the Bakken field might help them generate cash flow while they try to resolve their issues.
if something sounds too good to be true........, well, you know.
the fortunate thing for petrobank is that their heavy oil operations are a small part of their business. they are doing very well in columbia, or so it would appear.
From the article, it sounds like they're getting the hydrogen from the feedstock itself, disproportionating the tar into lighter hydrocarbons and coke. It doesn't necessarily require the addition of water, but apparently does involve quite a lot of "cooking". And of course all that cooking is going to lower the EROEI of your product.