Scovan Innovations: HipVap IFSG Commercial Pilot Demonstration 

A CRIN and Alberta Innovates-supported Scovan project demonstrated that untreated, produced water can economically be used directly in steam generation with minimal treatment, significantly reducing water treatment costs, freshwater consumption, and waste disposal needs.

The HipVap Integrated Fired Steam Generation (IFSG) Commercial Pilot Demonstration achieved reductions in CO₂ emissions relative to alternative technologies, proving a cost-effective alternative for smaller-scale SAGD operations.

Launched in January 2021, the project set out to accelerate HipVap’s Technology Readiness Level (TRL) from 6 to 8 by demonstrating its performance in a live SAGD environment. The HipVap unit was installed and operated at a SAGD facility near Bonnyville, Alberta. The collaborative project ultimately resulted in the creation of five new partnerships, including three industry partners. Notably, during the execution of this project, Scovan scaled its operations and grew from a team of nine employees in 2021 to 189 employees by the end of 2024, of which, the CRIN and Alberta Innovates-supported pilot project accounted for 52 full-time equivalent positions. Scovan estimates this technology will lead to the creation of nearly 2,800 new full-time jobs by 2033.

Looking ahead, Scovan is pursuing its first commercial HipVap development with new potential clients. At the same time, the team is exploring the next demo location to pilot HipVap to demonstrate more of the technology’s capabilities and further solidify its market presence.

HipVap is an efficient, low-emission steam generation system for SAGD operations that uses untreated produced water that reduces both upfront capital cost and ongoing operational cost, while also reducing environmental impact relative to typical steam generation technologies. This is achieved by designing an indirect-fired system using hot oil as the heating medium, which enables low-quality water usage, reduced carbon footprint, minimized blowdown (10%), and improved energy efficiency. The integration of AI and machine learning further optimize chemical dosing, manage fouling, and predict maintenance.

The project, which concluded in December 2024, successfully demonstrated that HipVap could achieve 90% produced water conversion to steam without conventional water treatment, operate for extended and predictable periods of time between cleaning procedures, optimize chemical injection using AI to reduce scaling maintenance frequency, and improve system reliability by using predictive maintenance.

HipVap’s success has paved the way for more sustainable steam generation solutions in the oil sands sector. The technology has the potential to reduce the industry's reliance on traditional water treatment processes. Its modular design also allows for easier deployment in smaller SAGD operations, expanding accessibility to cleaner steam solutions.

HipVap’s main industry and environmental impacts are improved project economics, water management through reduced reliance on freshwater, emissions reduction, accelerated AI adoption in SAGD, and scalability.