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Oil Sands Mining and Extraction

Colt is the world leader in the design and construction of mineable oil sands processing and transportation facilities.

Since our first project in 1973, we have striven to take a leadership role in applying proven and new technologies to

reduce the life-cycle costs for our clients.  Our clients include small to major oil producers, mining companies, pipeline transportation companies, power and cogeneration plants, refining and upgrading facilities.

Expertise

  • Ore preparation
  • Hydrotransport
  • Bitumen extraction
  • Tailings thickening and transportation systems
  • Froth treatment
  • Diluent recovery
  • Vapour recovery
  • Water treatment
  • Tank farms and product pipelines
  • Cogeneration
  • Alternative fuels
  • SCADA design
  • Distributed control systems (DCS)
  • Remote area logistics
  • New technologies for CAPEX/OPEX reduction
  • Patented process for oil and water treatment
  • Infrastructure design
  • Modular designs
  • Pilot plants/commercial plants

Scope of Services
(Conceptual, DBM, FEED, EPCM/EPC)

Colt provides design innovation during the early study phases for all types of production and processing alternatives.  From these early studies we then provide

detailed E, P, CM or EPC services to construct the selected execution plan through to commissioning, start-up and post-start-up operations support.

Experience

Since 1973 Colt has worked on the following types of production systems:

  • Ore preparation plants
  • Bitumen extraction plants
  • HRSG and GRUG cogeneration units
  • Naphthenic froth treatment
  • Paraffinic froth treatment
  • Tailings thickening and transportation

Successful implementation of these production systems requires application of Colt's industry-leading expertise in this technically-challenging sector. We have brought our world-class knowledge to several specific design challenges, including:

  • Crushing and conveying
  • Surge bins and stockpiles
  • Application of MixBex technology
  • Application of rotary breaker technology
  • Rejects processing
  • First commercial hydrotransport pipeline
  • First warm water bitumen extraction system
  • Application of screens and hydrocyclones
  • Application of IPS and centrifuges
  • Application of tailings thickeners
  • First low-temperature paraffinic froth treatment system
  • First high-temperature paraffinic froth treatment system
  • Warm and hot lime softening
  • Development of emulsion fuels

 

Typical Project Experience

Mineable Oil Sands

Colt has recently completed the design and procurement for several commercial (75 000 – 165 000 BCOD) mineable oil sands projects in northern Alberta.  The scope included the early conceptual designs followed by step-by-step gated processes through to preparation of a design basis memorandum (DBM) and front-end engineering and design (FEED).  Capital costs and schedules were prepared for ultimate client approval.

The scope also included the preparation of the overall project execution plan (PEP), final cost budgets, EPC schedules and preparation of equipment specifications, bid

evaluations, detailed engineering design and quality assurance.  As materials and equipment arrived at site Colt provided expediting services, shop inspection, logistics support, construction engineering and support, commissioning support, preparation of as-builts, operating and maintenance manuals, start-up assistance and client operations support after start-up.

Alternative Fuels Studies

Colt has established a strong reputation in applying innovative solutions and new technologies for our heavy oil clients.  We have conducted numerous studies to evaluate and design new methods to replace natural gas as fuel for steam and power generation.  We have evaluated both liquid and solid fuel sources, and have included design and calculations for heat and material balances, flue gas

desulphurization, NOX control, particulate emission control, CO2 treatment and syngas production.  The input of all other engineering disciplines was included to allow creation of CAPEX, OPEX and life-cycle cost estimates.  The ultimate goal is to substitute appropriate alternatives to natural gas that meet current and projected energy-efficiency and emissions-friendly goals for our clients.