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What's next: OilsandsThe collapse of oil prices has possibly set back Canadian production growth as much as five years.
By Matthew McClearn
From Canadian Business magazine, January 26, 2009
Canadian Natural Resources Ltd. (TSX: CNQ) will soon produce the first barrels of oil at Canada’s newest oilsands mining operation. The Calgary-based company’s Horizon Oil Sands Project, located 70 km northwest of Fort McMurray, consumed about five years’ strenuous labour by thousands of workers, and billions of investment dollars. Despite this achievement, COO Steve Laut found himself apologizing. “We are not on time, and we are not on budget,” he declared during a conference call this fall. “Horizon does not meet our criteria for success.”
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To assess the damage sustained lower oil prices might do to the industry, Horizon’s price tag is a good place to begin. In 2005, CNRL thought the first phase would cost $4.9 billion. The company assured shareholders that cost overruns were something that happened to other oilsands companies, and that it had “achieved a high level of cost certainty.”
Nobody dares repeat that phrase these days.
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With so many companies tripping over each other in northern Alberta’s remote wilderness, costs inevitably rose. Specialized heavy mining equipment, such as trucks and shovels, was in high demand. Despite a rapidly growing population, the region still had nowhere near enough skilled craftsmen and labourers. Developers had to scour the continent for contractors. Overtime became routine as projects fell behind schedule, and more work had to be done in extreme cold weather. Meanwhile, global prices of steel, concrete and other raw materials were also soaring.
These realities nullified earlier cost estimates. Horizon’s first phase wound up at $9.7 billion—nearly twice its original budget. It’s hardly the worst example, though. In September, Petro-Canada (TSX: PCA) and its partners, Teck Cominco (TSX: TCK.B) and UTS Energy (TSX: UTS), revealed that estimated costs for their Fort Hills mining project climbed by more than 50% in just 15 months, to about $21 billion. Strategy West president Bob Dunbar calculates that Suncor Energy’s Millennium project, completed in 2001, cost between $30,000 and $35,000 for each daily barrel of capacity. For Horizon, the figure is $80,000. And Fort Hills? Try $170,000. “We’ve really seen a huge run-up in costs,” Dunbar says.
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The industry finally blinked when oil prices collapsed, forcing a sudden surge in project cancellations and deferrals in recent months. Suncor in October slashed capital spending plans for next year. The following month, CNRL cut its budget and delayed expansion at Horizon. Royal Dutch Shell postponed its Carmon Creek project. Petro-Canada and its partners put off the decision about whether to proceed with Fort Hills. And so on.
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