Canadian Oil Sands Trust 2006 Annual Report
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Management's Discussion and Analysis

Review of Consolidated Results

Operating Costs

The following table breaks down unit operating costs into its major components and shows bitumen costs on both a per barrel of bitumen and per barrel of SSB produced basis. This allows investors to better compare Syncrude’s unit costs to other oil sands producers.

  2006 2005
  $ per bbl
Bitumen
$ per bbl
SSB
$ per bbl
Bitumen
$ per bbl
SSB
Bitumen Costs1        
Overburden removal 2.09    1.82   
Bitumen production 7.50    7.39   
Purchased energy2 2.64    3.18   
  12.23  14.47  12.39  14.95 
Upgrading Costs3        
Bitumen processing and upgrading   4.89    3.93 
Turnaround and catalysts   2.20    2.53 
Purchased energy2   2.98    3.25 
    10.07    9.71 
Other and research   1.92    1.93 
Change in treated and untreated inventory   0.25    (0.46)
Total Syncrude operating costs   26.71    26.13 
Canadian Oil Sands adjustments4   0.36    0.21 
Total operating costs   27.07    26.34 
Syncrude production volumes (thousands of barrels per day) 305  258  258  214 
   
  1. Bitumen costs relate to the removal of overburden, oil sands mining, bitumen extraction and tailings dyke construction and disposal costs. The costs are expressed on a per barrel of bitumen production basis and converted to a per barrel of SSB based on the current period’s production of SSB. The cost difference reflects the yield of SSB from processing and upgrading as well as changes in bitumen and treated and untreated inventory. All overburden stripping costs are expensed in the period incurred.
  2. Natural gas costs averaged $6.26 per GJ and $8.40 per GJ in 2006 and 2005, respectively.
  3. Upgrading costs include the production and ongoing maintenance costs associated with processing and upgrading of bitumen to SSB. It also includes the costs of major refining equipment turnarounds and catalyst replacement, which are expensed.
  4. Canadian Oil Sands’ adjustments mainly pertain to Syncrude-related pension costs, property insurance costs, site restoration costs, as well as the inventory impact of moving from production to sales as Syncrude reports per barrel costs based on production volumes and we report based on sales volumes.

The operating cost table indicates the most significant changes in 2006 over 2005 resulted from the increases in bitumen processing and upgrading costs, including the amounts from the change in treated and untreated inventory, partially offset by reduced purchased energy costs in the bitumen and upgrading areas of the operation. As a result of the new Stage 3 facilities, more infrastructure and a larger workforce were in place in 2006 than 2005. However, since production from the new facilities did not come on stream until the last four months of 2006, the per barrel production costs increased. In addition, costs were generally higher in 2006 compared to 2005 due to the inflationary pressures in the Fort McMurray area.

Purchased natural gas is a significant component of the bitumen production and upgrading processes. Year-over-year, the decline in purchased energy costs of approximately $1 per barrel, as shown in the following table, reflects the reduction in natural gas prices of $2.14 per GJ, which more than offset the increase in consumption. The increase in consumption to 0.98 GJs per barrel is attributable to increased bitumen volumes sourced at the Aurora mine, and increased use of purchased natural gas for items such as steam generation during start-up of the Stage 3 facilities, which are highly integrated. Purchased energy consumption per barrel is expected to decline from levels recorded in 2006 once the Stage 3 operations have stabilized but consumption is expected to remain higher than historical norms. We estimate that long-term consumption going forward will be about 0.85 GJs per barrel as additional hydrogen, which is derived from natural gas, will eventually be used to increase product quality from SSB to “Syncrude™ Sweet Premium” (“SSP”) and as bitumen is increasingly sourced from the Aurora mine. The Aurora mine relies mainly on purchased natural gas for its energy needs as process heat from the upgrader is unavailable due to the mine’s distance from the Mildred Lake plant.

Included in “Other and research” in the operating cost table is the cost of Syncrude’s incentive compensation and employee retention programs. Syncrude’s incentive compensation is based on the market return of some of the Syncrude owners’ units/shares, and therefore, can fluctuate from year-to-year. Such amounts were lower in 2006 than the prior year, reflecting lower performance of the owners’ units/shares relative to 2005. Offsetting this reduction were costs accrued for the new employee retention program Syncrude introduced in 2006. Many oil sands operators have introduced similar programs, which are designed to retain experienced employees in the competitive Fort McMurray labour market.

($ per bbl of SSB) 2006 2005 Change % Change
Production costs 20.97  19.25  1.72 
Purchased energy 6.10  7.09  (0.99) (14)
Total operating costs 27.07  26.34  0.73 
         
(GJs per bbl of SSB)     Change % Change
Purchased energy consumption 0.98  0.84  0.14  17 
   

 

PURCHASED ENERGY COSTS
($ per bbl, before hedging)

Purchased Energy Costs

Production Costs


PRODUCTION COSTS
($ per bbl)

   
Revenues, after Crude Oil Purchases, Transportation and Marketing Expense
 
Non-Production Costs