Field Condensate

With Alberta’s bitumen production rising to record levels of late, finding more ways to export this molasses-like heavy oil has become more important than ever. In early 2020, Gibson Energy and US Development Group embarked on the construction of a diluent recovery unit in Hardisty, AB, to greatly reduce the need for diluent and retain more of it for reuse. With the unit’s commercial start-up at the end of 2021, another unique pathway for transporting Canadian bitumen to the U.S. Gulf Coast — and, possibly, overseas markets — has become a reality. In today’s RBN blog, we provide an update on this venture and discuss where it might lead next.

As bitumen production in Alberta’s oil sands has grown over the past decade, so has demand for diluent, which is blended with molasses-like bitumen to help it flow through pipelines or be transported by rail. With bitumen output expected to continue rising through the first half of the 2020s, we have estimated that Alberta demand for field condensate, natural gasoline and other diluent will increase by more than 40% — to almost 1 MMb/d — by 2025. The catch is, diluent production in Western Canada isn’t growing fast enough to keep pace, and there are limits to how much diluent can be imported on the two existing pipelines from the U.S. What if there were a way to slash how much diluent is needed to put bitumen in rail tank cars — and make rail transport safer in the process? Today, we discuss Gibson Energy and US Development Group’s new diluent recovery unit in Hardisty, AB.

Since the mid-2010s, MPLX has been developing a far-reaching pipeline system for delivering heavier natural gas liquids and field condensate from the Utica and “wet” Marcellus plays to Midwest refineries for gasoline blending and refining, and to the Alberta oil sands for use as diluent. The multi-year, multi-project effort, which has involved the construction of new pipelines, the repurposing of existing pipes, and the development of new storage capacity, will reach another milestone next month, when MPLX starts batching normal butane and isobutane through most of the pipeline system. And further enhancements are on the horizon. Today, we provide an update on the master limited partnership’s long-running strategy for moving Marcellus/Utica-sourced liquids to market more efficiently and at a lower per-barrel cost.

The Utica and “wet” Marcellus plays in eastern Ohio, northern West Virginia and western Pennsylvania are producing increasing volumes of natural gas liquids and field condensates that need to be moved to market. In response, MPLX, a master limited partnership formed by Marathon Petroleum Corporation (MPC) six years ago, has been implementing a multi-part strategy to develop new or expanded pipeline takeaway capacity through the Midwest to deal specifically with the heaviest NGLs — natural gasoline and other pentanes — and with field condensates. That work is now largely done, the results have been positive, and MPLX is now undertaking the next phase of its strategy that will further expand the system’s capacity and add a new element: the ability to transport batches of two other, lighter NGLs — normal butane and isobutane — on a few of the same pipelines. Today, we discuss the next steps the company is taking to facilitate the transport of liquid hydrocarbons out of the Utica and Marcellus.

MPLX is wrapping up a three-part, $500 million plan to facilitate the pipeline transport of large volumes of field condensate and natural gasoline from the Marcellus and Utica plays to Midwest refineries, western Canadian heavy-crude shippers and other end users. But “wrapping up” may be the wrong phrase. In fact, MPLX sees its Cornerstone Pipeline, Utica Build-Out Projects and other elements of the company’s Midwest pipeline push as part of a larger and continuing effort to deal with remaining inefficiencies in the delivery of Marcellus/Utica liquids to market. Today we review what has been accomplished so far, and what expansions and enhancements to MPLX’s pipeline plan may be in the offing.

Several oil-sands expansion projects committed to when crude oil prices were double what they are today are finally coming online, and midstream companies active in Alberta are building new crude/diluent pipelines and storage capacity to keep pace. New storage caverns for natural gas liquids are also in the works, giving a much-needed boost to Canada’s Energy Province. Today we conclude our series on midstream infrastructure under development in or near Western Canada’s oil sands region that move and store hydrocarbon liquids.

Oil-sands expansion projects coming online and the resulting need for more diluent are among the drivers behind a number of midstream infrastructure projects in the province of Alberta, including natural gas processing plants and fractionators; oil and diluent pipelines; and oil/NGL storage facilities. The total volume of work is surprising, considering the fact that oil-sands production economics are iffy right now, if not downright upside down. Today, we continue our look at midstream projects under development within Canada’s Energy Province, this time focusing on gas processing and fractionation facilities.

More midstream projects than you might expect are “goin’ on” in the Western Canadian province of Alberta, considering the challenges that bitumen/crude oil and natural gas producers there continue to face. There are several drivers behind the relatively long list of oil and diluent pipelines; gas processing plants and fractionators; and oil/NGL storage facilities being built in Canada’s Energy Province, but much of the work is being done to meet the expected needs of oil-sands expansion projects approved during better times and set to come online soon. Today we begin a blog series on Alberta midstream projects with an overview of where the province’s energy sector stands today.

The U.S. has a surplus of light hydrocarbon liquids – much of it in the form of field condensate produced at the wellhead and plant condensate extracted from natural gas at processing plants. Declining domestic demand leaves both field and plant condensate increasingly reliant on export markets. Trouble is those export markets are far from secure and the oil price crash isn’t making things any easier. Today we preview RBN’s latest Drill Down report – a deep dive into the supply and demand balance for field and plant condensate.

Supplies from the three main branches of the US condensate family are increasing faster than demand can keep up. Field condensate production from shale basins is nearing 1 MMb/d - headed to 1.6 MMb/d by 2018. Plant condensate – aka natural gasoline - will increase from just over 0.3 MMb/d in 2013 to more than 0.5 MMb/d in 2018. Because field condensates cannot be exported to overseas markets, more of this material will be refined traditionally or using a splitter – pushing out existing refinery demand for natural gasoline and creating an excess of naphtha range material. Petrochemical demand for natural gasoline has dried up in the face of cheap ethane feedstocks. Canadian demand for natural gasoline as diluent will soak up some but not the entire natural gasoline surplus. With US gasoline demand declining, the only outlet for excess naphtha and natural gasoline will be more exports (beyond Canada). Today we look at changing condensate demand patterns.