The oil sands, also known as bituminous sands, are a naturally occurring mixture of sand, clay, water, and a dense, highly viscous form of petroleum called bitumen. These deposits represent one of the world’s largest reserves of oil, with the largest known concentration found in Alberta, Canada. Unlike conventional crude oil, bitumen is too thick to flow easily at normal temperatures, requiring specialized processes for both extraction and preparation before it can be used. The ultimate purpose of this resource is to create a wide array of products, ranging from fuels that power transportation to materials used in manufacturing and infrastructure.
From Bitumen to Refinery Input
The raw bitumen extracted from the oil sands is too heavy and sticky to be processed directly by most refineries or transported efficiently through pipelines. This preparation process involves either “upgrading” the bitumen or “diluting” it to reduce its viscosity and density.
Upgrading involves complex chemical treatments that break the large, heavy hydrocarbon molecules of bitumen into smaller, lighter fractions through processes like coking or hydrocracking. This produces Synthetic Crude Oil (SCO), a lighter, less viscous product that can be processed by conventional refineries just like typical crude oil.
Alternatively, raw bitumen can be blended with lighter hydrocarbon liquids, called diluents, to create a mixture known as Diluted Bitumen, or “DilBit”. DilBit has a low enough viscosity to be shipped via pipeline to refineries configured to handle heavier crude oils.
Whether converted into SCO or blended into DilBit, the prepared oil is then ready to be fed into a refinery, where it is separated and converted into various petroleum products.
The Dominant Role in Transportation Fuels
The largest volume application for products derived from oil sands is in fueling the global transportation sector. Once the SCO or DilBit is refined, it is separated into different fractions based on molecular size and boiling point, with the lighter fractions being ideal for internal combustion engines. The high energy density of these petroleum products makes them particularly well-suited for powering vehicles that require significant range and power.
Gasoline, which is used to power spark-ignition engines in most passenger cars, is a primary output of the refining process. Diesel fuel, which is a heavier fraction, is produced for compression-ignition engines that power trucks, buses, locomotives, and heavy machinery. Diesel is valued for its superior energy density and efficiency in these applications, supporting commercial transport and industrial operations worldwide.
Aviation fuels, including jet fuel, are also manufactured from the refined fractions of oil sands-derived crude. The vast majority of oil sands output, like most crude oil globally, is channeled into this energy sector.
Non-Combustion Applications: Asphalt and Infrastructure
While most of the oil is refined into fuels, the heaviest residual fractions of the bitumen are utilized for non-combustion purposes, primarily in construction and infrastructure. The intrinsic physical properties of the original bitumen, such as its high viscosity and water resistance, are what make it a valuable material for these applications. This use relies on the material’s structural integrity rather than its energy content.
The most recognized non-fuel use is in the production of asphalt binder, the “glue” that holds road surfaces together. Bitumen is blended with aggregate materials like crushed stone and sand to create asphalt concrete, which is used to pave roughly 65% of the world’s roads. Bitumen from oil sands is often noted for its low wax content, a characteristic that can contribute to the production of high-quality, durable asphalt binders.
Beyond road surfaces, the material is also used in various waterproofing and sealing applications. Roofing shingles, sealants, and membranes all rely on the dense, water-resistant nature of bitumen to protect buildings and structures from moisture. This infrastructure application allows the heaviest components of the resource to be put to direct, structural use without being chemically converted into lighter fractions.
Feedstock for Petrochemicals and Manufacturing
A smaller, yet still globally significant, portion of the refined oil sands product is directed toward the petrochemical industry, where it serves as a foundational chemical feedstock. The lighter fractions that emerge from the upgrading and refining processes, such as naphtha and gas oils, are not always converted into fuels. Instead, they are used as raw materials in chemical manufacturing plants.
These refined components are subjected to high-temperature processes, such as steam cracking, to produce basic chemical building blocks like ethylene, propylene, and benzene. These primary petrochemicals are then polymerized or reacted further to create a multitude of synthetic materials. The resulting products include plastics like polyethylene and polypropylene, which are ubiquitous in consumer goods, packaging, and durable manufactured items.
Oil sands-derived inputs also contribute to the creation of solvents, fertilizers, and a variety of other industrial chemicals.