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Alberta

Oil sands technology competition to generate low emissions carbon fibre moves into final phase

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Bryan Helfenbaum, associate vice-president of clean energy with Alberta Innovates, holds a hockey stick made with carbon fibre derived from oil sands bitumen. Photo by Dave Chidley for the Canadian Energy Centre

From the Canadian Energy Centre

By Will Gibson and Deborah Jaremko

Study found carbon fibre made from oil sands bitumen has 69 per cent lower emissions than conventional sources

Having spent most of a long and distinguished academic career working with metals, Weixing Chen became fascinated by the potential of repurposing a heavy hydrocarbon from Alberta’s oil sands into a high-value product for a low-carbon economy. 

The product is carbon fibre – thin as human hair but four times stronger than steel – and research has shown producing it from oil sands bitumen generates lower greenhouse gas emissions than today’s sources.  

“This is a great opportunity for me to challenge myself moving forward to develop this technology that will benefit society,” says Chen, a chemical and material engineering professor at the University of Alberta.  

His team at Edmonton-based Thread Innovations is one of five receiving a total $15 million in funding in the final round of the Carbon Fibre Grand Challenge, announced in December. 

Great potential for carbon fibre 

With its light weight and high strength, today carbon fibre is used in products like aircraft and spacecraft parts, racing car bodies, bicycles, hockey sticks and golf clubs. 

It has great potential, but its use is limited by cost. Carbon fibre averages $10 to $12 per pound, compared to less than $1 per pound for steel.   

Part of the Alberta competition is that the carbon fibre derived from oil sands bitumen must cost 50 per cent less than current carbon fibre products.  

This would unlock new markets for carbon fibre, says Byran Helfenbaum, associate vice-president of clean energy for Alberta Innovates, which is funding the challenge along with Emissions Reduction Alberta.  

“At the end of this phase, the intention is the technology is at a point where a company could make a funding decision for if not a commercial project, then at least a commercial demonstration project,” he says. 

“It’s really to get it out of the lab and start hitting the key specifications, identifying the existing and new markets, and pumping out prototypes that can be tested.  We have already generated our first two prototypes, a truck side mirror and a hockey stick, but we need to go bigger and faster and test a wide range of market opportunities.” 

Long-term need for carbon-based products 

The future is likely to be full of carbon fibre products, Helfenbaum says. 

“This ‘low-carbon future’ is a misnomer. When we say low-carbon future, what we mean is let’s keep carbon out of the atmosphere. Carbon is still going to be around us in solid form, and probably in increasingly higher amounts,” he says.  

“We’re going to have 10 billion people on the planet by mid-century. They need energy, but they also need stuff. They need housing, infrastructure, and consumer goods. And most of that stuff is or can be made of pure carbon.” 

Lower emissions from oil sands carbon fibre 

Most carbon fibre today is generated from a chemical compound called polyacrylonitrile (PAN), which is derived from a component of natural gas. 

recent study by researchers at the University of Alberta found that life cycle emissions from carbon fibre derived from oil sands bitumen are 69 per cent lower than PAN-based product.  

It’s the high carbon content of oil sands bitumen that provides the benefit, Helfenbaum says.  

“The heaviest fraction of bitumen takes more energy to break down to be turned into fuels. But that same fraction can be used to produce carbon fibre with fewer greenhouse gas emissions than the current PAN process,” he says. 

“If we are successful in reducing its cost, then it can be deployed into new markets that will further reduce carbon emissions, such as lightening passenger vehicles and improving the longevity of concrete infrastructure.” 

Adding value while reducing emissions 

The Carbon Fibre Grand Challenge is part of Alberta Innovates’ broader Bitumen Beyond Combustion  research program. The work considers opportunities to use bitumen to create value-added products other than fuels like gasoline and diesel.   

“From an economic perspective, the Bitumen Beyond Combustion program could triple the value of a barrel of bitumen,” Helfenbaum says.  

“Carbon fibre is among the most valuable of those products, but it’s not the only one. This is potentially in the tens of billions of dollars a year of gross revenue opportunity, so this is transformational.” 

It also presents environmental benefits.  

“Eighty per cent of the emissions associated with petroleum happen at combustion of gasoline, diesel, and jet fuel so by diverting into these products, that becomes carbon that is sequestered forever and doesn’t get into the atmosphere,” he says.  

Pathway to commercial production 

Winners of the grand challenge will have a credible pathway to manufacturing 2,000 tonnes or more of carbon fibre per year. The challenge is scheduled to end in summer 2026.  

Thread Innovations is building a new facility to produce samples for potential buyers and demonstrate the ability to scale up production. This phase will also focus on improving characteristics of the carbon fibre produced by their technology to build commercial demand. 

“Our target is to complete the current project and then establish a commercialization plan in 2025,” says Chen.  

Alberta

Alberta’s grand bargain with Canada includes a new pipeline to Prince Rupert

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From Resource Now

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Alberta renews call for West Coast oil pipeline amid shifting federal, geopolitical dynamics.

Just six months ago, talk of resurrecting some version of the Northern Gateway pipeline would have been unthinkable. But with the election of Donald Trump in the U.S. and Mark Carney in Canada, it’s now thinkable.

In fact, Alberta Premier Danielle Smith seems to be making Northern Gateway 2.0 a top priority and a condition for Alberta staying within the Canadian confederation and supporting Mark Carney’s vision of making Canada an Energy superpower. Thanks to Donald Trump threatening Canadian sovereignty and its economy, there has been a noticeable zeitgeist shift in Canada. There is growing support for the idea of leveraging Canada’s natural resources and diversifying export markets to make it less vulnerable to an unpredictable southern neighbour.

“I think the world has changed dramatically since Donald Trump got elected in November,” Smith said at a keynote address Wednesday at the Global Energy Show Canada in Calgary. “I think that’s changed the national conversation.” Smith said she has been encouraged by the tack Carney has taken since being elected Prime Minister, and hopes to see real action from Ottawa in the coming months to address what Smith said is serious encumbrances to Alberta’s oil sector, including Bill C-69, an oil and gas emissions cap and a West Coast tanker oil ban. “I’m going to give him some time to work with us and I’m going to be optimistic,” Smith said. Removing the West Coast moratorium on oil tankers would be the first step needed to building a new oil pipeline line from Alberta to Prince Rupert. “We cannot build a pipeline to the west coast if there is a tanker ban,” Smith said. The next step would be getting First Nations on board. “Indigenous peoples have been shut out of the energy economy for generations, and we are now putting them at the heart of it,” Smith said.

Alberta currently produces about 4.3 million barrels of oil per day. Had the Northern Gateway, Keystone XL and Energy East pipelines been built, Alberta could now be producing and exporting an additional 2.5 million barrels of oil per day. The original Northern Gateway Pipeline — killed outright by the Justin Trudeau government — would have terminated in Kitimat. Smith is now talking about a pipeline that would terminate in Prince Rupert. This may obviate some of the concerns that Kitimat posed with oil tankers negotiating Douglas Channel, and their potential impacts on the marine environment.

One of the biggest hurdles to a pipeline to Prince Rupert may be B.C. Premier David Eby. The B.C. NDP government has a history of opposing oil pipelines with tooth and nail. Asked in a fireside chat by Peter Mansbridge how she would get around the B.C. problem, Smith confidently said: “I’ll convince David Eby.”

“I’m sensitive to the issues that were raised before,” she added. One of those concerns was emissions. But the Alberta government and oil industry has struck a grand bargain with Ottawa: pipelines for emissions abatement through carbon capture and storage.

The industry and government propose multi-billion investments in CCUS. The Pathways Alliance project alone represents an investment of $10 to $20 billion. Smith noted that there is no economic value in pumping CO2 underground. It only becomes economically viable if the tradeoff is greater production and export capacity for Alberta oil. “If you couple it with a million-barrel-per-day pipeline, well that allows you $20 billion worth of revenue year after year,” she said. “All of a sudden a $20 billion cost to have to decarbonize, it looks a lot more attractive when you have a new source of revenue.” When asked about the Prince Rupert pipeline proposal, Eby has responded that there is currently no proponent, and that it is therefore a bridge to cross when there is actually a proposal. “I think what I’ve heard Premier Eby say is that there is no project and no proponent,” Smith said. “Well, that’s my job. There will be soon.  “We’re working very hard on being able to get industry players to realize this time may be different.” “We’re working on getting a proponent and route.”

At a number of sessions during the conference, Mansbridge has repeatedly asked speakers about the Alberta secession movement, and whether it might scare off investment capital. Alberta has been using the threat of secession as a threat if Ottawa does not address some of the province’s long-standing grievances. Smith said she hopes Carney takes it seriously. “I hope the prime minister doesn’t want to test it,” Smith said during a scrum with reporters. “I take it seriously. I have never seen separatist sentiment be as high as it is now. “I’ve also seen it dissipate when Ottawa addresses the concerns Alberta has.” She added that, if Carney wants a true nation-building project to fast-track, she can’t think of a better one than a new West Coast pipeline. “I can’t imagine that there will be another project on the national list that will generate as much revenue, as much GDP, as many high paying jobs as a bitumen pipeline to the coast.”

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Alberta

Alberta Premier Danielle Smith Discusses Moving Energy Forward at the Global Energy Show in Calgary

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From Energy Now

At the energy conference in Calgary, Alberta Premier Danielle Smith pressed the case for building infrastructure to move provincial products to international markets, via a transportation and energy corridor to British Columbia.

“The anchor tenant for this corridor must be a 42-inch pipeline, moving one million incremental barrels of oil to those global markets. And we can’t stop there,” she told the audience.

The premier reiterated her support for new pipelines north to Grays Bay in Nunavut, east to Churchill, Man., and potentially a new version of Energy East.

The discussion comes as Prime Minister Mark Carney and his government are assembling a list of major projects of national interest to fast-track for approval.

Carney has also pledged to establish a major project review office that would issue decisions within two years, instead of five.

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