Shale oil : potential economies of large-scale production, preliminary phase

Abstract

Producing shale oil on a large scale is one of the possible alternatives for reducing dependence of the United States on imported petroleum. Industry is not producing shale oil on a commercial scale now because costs are too high even though industry dissatisfaction is most frequently expressed about "non-economic" barriers: innumerable permits, changing environmental regulations, lease limitations, water rights conflicts, legal challenges, and so on. The overall purpose of this study is to estimate whether improved technology might significantly reduce unit costs for production of shale oil in a planned large-scale industry as contrasted to the case usually contemplated: a small industry evolving slowly on a project-by-project basis. In this preliminary phase of the study, we collected published data on the costs of present shale oil technology and adjusted them to common conditions; these data were assembled to help identify the best targets for cost reduction through improved large-scale technology They show that the total cost of producing upgraded shale oil (i.e. shale oil accpetable as a feed to a petroleum refinery) by surface retorting ranges from about $18 to $28/barrel in late '78 dollars with a 20% chance that the costs would be lower than and 20% higher than that range. The probability distribution reflects our assumptions about ranges of shale richness, process performance, rate of return, and other factors that seem likely in a total industry portfolio of projects. About 40% of the total median cost is attributable to retorting, 20% to upgrading, and the remaining 40% to resource acquisition, mining, crushing, and spent shale disposal and revegetation. Capital charges account for about 70% of the median total cost and operating costs for the other 30%. There is a reasonable chance that modified in-situ processes (like Occidental's) may be able to produce shale oil more cheaply than surface retorting, but no reliable cost data have been published; in 1978, DOE estimated a saving of roughly $5/B for in-situ. Because the total costs of shale oil are spread over many steps in the production process, improvements in most or all of those steps are required if we seek a significant reduction in total cost. A June 1979 workshop of industry experts was held to help us identify possible cost-reduction technologies. Examples of the improved large-scale technologies proposed (for further evaluation) to the workshop were: - Instead of hydrotreating raw shale oil to make syncrude capable of being refined conventionally, rebalance all of a refinery's processes (or develop new catalysts/processes less sensitive to feed nitrogen) to accommodate shale oil feed -- a change analogous to a shift from sweet crude to sour crude. - Instead of refining at or near the retort site, use heated pipelines to move raw shale oil to existing major refining areas. - Instead of operating individual mines, open-pit mine all or much of the Piceance Creek Basin. - Instead of building individual retorts, develop new methods for mass production of hundreds of retorts.