Main content | back to top
Waterton Gas Complex
Shell's Waterton Complex is located in southern Alberta about 30 kilometres southwest of Pincher Creek. The Waterton Complex was constructed to process sour natural gas from the Waterton field discovered by Shell in 1957.
Plant Profile
Location: About 30 kilometres southwest of Pincher Creek, in southern Alberta.
Employees: Approximately 150 - about 100 work directly for Shell and the remainder are employed by contractors.
License Capacity: The plant is capable of processing 5 million cubic metres of raw gas daily.
Actual Production: 4.5 million cubic metres/day
Products: sales gas (methane), natural gas liquids (propane, butane and ethane), condensate and sulphur.
The Waterton Complex, owned and operated by Shell, was constructed to process sour natural gas from the Waterton field.
Construction of the original plant began in 1960. The plant began operating in January 1962. Since then, the plant has undergone a number of expansions to increase its overall capacity and to improve its efficiency in reducing emissions.
Between Shell and other companies, there are more than 75 producing wells in the Waterton gas field.Contact Information Contact Information
Complex admin office: 403-627-7200 business hours Contact Shell Helps for other inquiries: 1-800-661-1600 Monday to Friday 6:00am - 6:00pm MST Report an emergency: 403-627-4200 24 hours Operations and Products
The plant processes about 5 million cubic metres of raw gas daily into products including Natural Gas (Methane), Natural Gas Liquids, Condensate and Sulphur.
- Methane (sales gas): 3.5 million cubic metres a day
Methane is shipped by pipeline to markets in Eastern Canada and the United States. It is used primarily for heating and electrical generation.
- Natural Gas Liquids (NGLs): 900 cubic metres a day
Propane Volumes per day = 300 cubic metres
Propane is sold to domestic and United States distributors for heating, crop drying, auto fuel and petrochemical feedstock.
Butane Volumes per day = 200 cubic metres
Butane is shipped to refineries where is used as a gasoline blending component and as a fuel in products such as butane lighters and curling irons.
Ethane Volumes per day = 400 cubic metres
Ethane is shipped by pipeline to petrochemical plants where it is used as a "building block" for a variety of chemicals and plastics.
- Condensate: Volumes per day = 400 cubic metres
Condensate is a petroleum liquid similar to unrefined gasoline. It is shipped by pipeline to refineries as a feedstock to convert crude oil into various finished petroleum products, or for use as a diluent that thins heavy crude oil so that it will pump or move down a pipeline.
- Sulphur: Volumes per day = 1450 tonnes
Sulphur is transported by rail to Vancouver for shipment to international markets, where it is used to manufacture fertilizer, paper, sugar, drugs, matches and other products.
- Methane (sales gas): 3.5 million cubic metres a day
Process
Shell’s Waterton natural gas is sour because it contains hydrogen sulphide, a potentially dangerous substance which must be handled with care to prevent harm to people or the environment.
A pipeline from each well forms part of a gathering system which feeds raw sour gas and the associated liquids to the plant. Gas flows to the plant because of the natural underground pressure of the reservoir or it may be assisted by compressors.
When the sour natural gas first enters the plant, vapour and liquids are separated in a large vessel called an inlet separator. Some light hydrocarbons remain suspended in the liquid. Heat removes these gases so the liquid can be handled safely.
Heavy hydrocarbons are removed from the gas by passing the stream, under pressure, through a light oil. The oil is then distilled to remove these hydrocarbons. The heavy hydrocarbons are combined with liquids from the inlet separator and sent to storage.
At this point, the gas still contains three components which must be removed before it can be sold: hydrogen sulphide, carbon dioxide and water.
Hydrogen sulphide and carbon dioxide are removed by passing the gas through a chemical solution that 'sweetens' the gas. Water and natural gas liquids (NGLs) such as ethane, propane and butane are extracted as separate products before the gas leaves the plant by dehydrating and subsequently cooling the gas.
The sweetening solution is distilled to recover the hydrogen sulphide. Ninety-seven per cent of the hydrogen sulphide is reduced to elemental sulphur by combining the gas with oxygen and burning it.
To achieve the 98.7 per cent recovery rate required by government regulations, the Waterton Complex uses the Super Claus Tail Gas Treating Process.
Safety
No job is more important than ensuring the safety of our neighbours, contractors and employees and protecting the environment. All Waterton employees are trained in safe work procedures and a response system is in place in the unlikely event of an emergency.
Workplace Safety
Safety is always our first priority. We aim to have zero fatalities and to prevent incidents like spills, fires and accidents. We are working to ensure compliance with our safety procedures and tackling the cultural issues that can lead to unsafe behaviour.
The Waterton Complex has won both the Canadian Gas Processors Association and Alberta Petrochemical Safety Council Large Plant Safety Awards.
Emergency Response System
In the unlikely event of an emergency, our response procedures are designed to protect the safety of the public living in the vicinity of our facilities. The Complex emergency procedures manual outlines step-by-step emergency response action. Complex employees are trained to handle emergencies should any arise. Staff maintain a high degree of emergency preparedness by conducting regular simulated exercises.
To report an unusual odour, spill or other emergency to the Waterton Complex please call (403) 627-4200 (24 hours).