Carlos Soares has sold enough flooring to furnish all the residences, businesses and public facilities in a medium-sized city since starting Divine Flooring in 1999. 

But now the Calgary entrepreneur will expand into manufacturing luxury flooring using a key Alberta hydrocarbon that will create a more sustainable product and reduce reliance on imports. 

“People walk on luxury vinyl floors every day in their homes, malls, stores, hotels— it is the fastest growing category in our industry over the past decade,” says Soares, whose business employs 165 people and 250 contractors in Calgary, Edmonton, Vancouver and Chicago.  

“Billions of square feet of new floor coverings are manufactured and installed every year around the world.” 

While luxury vinyl products mimic the look of natural woods, they generally contain polyvinyl chlorides or PVCs, a synthetic plastic polymer used to create flexibility and durability.  

PVCs are difficult to recycle and take a lot of energy to produce. Most PVC production is in Asia, with roughly half of the world’s capacity in China. 

Soares has discovered a more environmentally friendly alternative to PVCs produced at the Heartland Polymers plant near Edmonton. 

Opened by Inter Pipeline Ltd. in July 2022, the facility produces polypropylene plastic pellets directly from locally sourced propane, a first of its kind in North America. Polypropylene is one of the world’s most widely used recyclable plastics.  

By converting about 22,000 barrels per day of propane into polypropylene instead of using it as fuel, Heartland says it cuts up to one million tonnes of greenhouse gas emissions annually — the equivalent of about 217,000 cars. 

“Polypropylene is our secret sauce. It can do all the things PVCs do,” says Soares.  

“But it is made in Alberta and it is a low-emission product free of chemicals that make it tough to recycle.” 

Soares and his partners in a venture called PolyCo have started construction on a $45 million facility in Balzac, about 25 kilometres north of downtown Calgary, to manufacture luxury flooring using Heartland polypropylene.  

A second-generation Canadian and entrepreneur, he wants to give back to the place where he grew up in a meaningful way. 

“My grandparents moved to Canada from Portugal in 1967 and this country has given our family so much. My father started his own welding shop in 1974 and ran it for years with old-school values. He always taught me to do the right thing and don’t compromise on quality,” he says.  

“That’s what we want to do with this proposal. We are putting more Canadians to work to make a more sustainable product and strengthen our local economy.” 

Carlos Soares, president of Divine Flooring. Photo for the Canadian Energy Centre

Production at the plant is scheduled to start in the third quarter of 2027. It will employ 100 people when it reaches full capacity, initially producing 28 million square feet of flooring every year. A second phase will eventually bring the plant’s total capacity to 50 million square feet annually. 

The plant will be a “zero waste” facility, where all the dust and trimmings from the process will be swept up and put back into future production. 

In July, Emissions Reduction Alberta awarded the project $5 million through its Advanced Materials Challenge, a competition funding innovative low-emission products in the province. 

The funding is part of $49 million in ERA grants to 18 projects, determined after independent review by a team of experts in science, engineering, business development, commercialization, financing and greenhouse gas quantification.

Together, the projects have a total estimated value of $198 million.  

ERA’s goal is to accelerate projects that can improve the economy and the environment, says Justin Riemer, the agency’s CEO.  

“In the case of the PolyCo project, it highlights how to better utilize the supply chain we have here in Alberta. Everything this plant will need to source is literally within a three-hour drive,” he says.   

ERA has provided more than $1 billion in grants to more than 300 projects valued at $7 billion in 16 years across the province. 

“Of all the completed projects who’ve received funding, 50 per cent have been commercialized, which is a much better success rate than venture capital gets,” says Riemer, who has led ERA for three years.  

“It’s important to have this funding available because a lot of financial infrastructure in this country is risk-adverse to trialing and commercializing innovation technology.” 

The agency’s grants are financed through Alberta’s Technology Innovation and Emissions Reduction (TIER) fund, which collects contributions from the oil and gas sector under the province’s carbon pricing and trading system. 

“ERA receives about 10 per cent of the TIER contributions,” Riemer says.   

“Through these competitions, we have managed to see successful commercialization of technologies across a broad array of sectors beyond oil and gas including forestry, agriculture, power generation, critical minerals and even nuclear.”  

For Soares, the vote of confidence given by the agency in the proposal was crucial. 

“This ERA grant is huge for this project to go ahead but so was the decision. It gives us the confidence the government is behind the project and wants to see it materialize,” he says.  

“They are serious about real ideas that can produce sustainable and affordable products right here.” 

Soares is unapologetic in having his project funded by carbon levies collected from oil and gas. 

“We produce oil and gas more responsibly than anywhere in the world in Alberta and I’m proud of that even though I don’t work directly in the industry,” he says.  

“The fact that oil and gas contribute to grants that help create more sustainable products and technologies demonstrates the province’s commitment to doing things better.” 

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Dow Chemical’s Nov. 28 announcement confirming it will invest $8.8 billion to build a net zero petrochemical complex near Edmonton was close to a decade in the making for Fort Saskatchewan Mayor Gale Katchur. 

“Now that they’ve finally announced the project, I’m one of the happiest mayors around,” says Katchur, who was first elected in October 2010. 

“What Dow is building will inspire other industries with innovation and technology like this. Dow has been a cornerstone for our community for the past 60 years. This investment ensures they are going to be around for a lot longer.” 

The project, which has support from the municipal, provincial and federal governments, will increase Dow’s production of polyethylene, the most widely used plastic in the world. 

Welcomed by the community 

By capturing and storing carbon dioxide emissions and generating hydrogen on-site, the complex will be the world’s first ethylene cracker with net zero emissions from operations.  

“I remember speaking to Dow executives during their regional visit some years back. They were curious about potential public concerns, given the visibility of their visit and the nature of their business,” Katchur says. 

“My response was clear: the primary concern in our community is the pace of progress. People here recognize and appreciate the petrochemical industry. We understand the benefits that it brings.” 

Competitive advantages 

Katchur’s joy is shared by Mark Plamondon, executive director of Alberta’s Industrial Heartland Association, who sees the Michigan-based multinational’s decision as an endorsement of the region’s competitive advantages. 

“Dow is a global company and could put their capital anywhere in the world,” says Plamondon, whose group attracts global investment in heavy industry to the 582-square-kilometre region northeast of Edmonton.  

“What this demonstrates is Dow can meet both their economic and environmental goals by investing in this region. That sends a real message.” 

Bob Masterson, CEO of the Chemistry Industry Association of Canada, sees Dow’s decision to build the facility as a signal of where the industry will make large investments in the future. 

“In the short term, you are looking at the province’s largest construction project requiring more than 7,000 high-skill, high-paying jobs for the next seven to 10 years,” says Masterson, whose Ottawa-based group represents chemistry and plastics producers across Canada.  

Alberta a top destination for low carbon chemical production 

“What Dow’s decision really says is Alberta is a top destination for the chemistry industry to invest. One of the top chemical producers in the world is making this investment in Canada,” he says. 

“When you look at the bigger picture, the only real rival for low-carbon investment of this kind is the U.S. Gulf Coast, where you have the same access to natural gas liquids as a feedstock and supportive public policy environment.” 

The Industrial Heartland region is particularly attractive for companies looking to invest in low-carbon products, Masterson says. 

“Alberta has an abundant low-carbon feedstock in natural gas liquids to produce hydrogen and the geological space to sequester carbon. These natural assets can encourage investment and support low-carbon chemistry industry,” he says.  

“One of the largest petrochemical companies on the planet believes it can build a low-carbon chemistry plant based on these assets. Other companies will see they can generate and extract that value out of those resources in a very sustainable and responsible manner.” 

Filling space on the Alberta Carbon Trunk Line 

In addition to geological and natural resources, the region already possesses critical infrastructure to woo investment in low-carbon production, such as the Alberta Carbon Trunk Line (ACTL), the world’s largest CO2 pipeline.  

Dow has signed an agreement with ACTL owner Wolf Midstream to utilize space on the system.  

ACTL is the foundation of a hub that captures CO2 from an oil refinery and fertilizer plant and moves it for permanent storage in a nearby depleted oil field.  

The pipeline currently transports 1.6 million tonnes of CO2 per year but is built to transport 14.6 million tonnes of CO2 per year.  

“The infrastructure is in place already. The trunk line has plenty of surplus capacity to transport additional emissions,” Plamondon says.  

“That just adds to the value proposition for potential facilities that are moving to low-carbon production.” 

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There is no better excuse for a barbecue than the combination of sunshine and holidays. 

We often take the impact oil and gas, and petrochemical-based products have on this favourite summertime activity for granted.  

The following photo essay explores how involved oil and gas is in executing the perfect summer BBQ.  

The first ingredient for a successful summer gathering is guests! How will they get there and what are they wearing?  

According to IHS Markit, nearly 12 per cent of new vehicles registered in Canada in 2021 were some form of electric vehicle. Therefore, most of your friends and family are still arriving by gasoline powered vehicle, maybe even by public transport. 

Not only will your guests be transported by them, they’ll also be clothed in petroleum products. Polyester and nylon are the first and second most-used manufactured fibres in apparel. These materials are made from petroleum-based polymers, more commonly known as plastic.  

What request do you often hear immediately upon arrival at any gathering – “Can I get you anything to drink?” Alternatively, you may be given directions to grab a refreshment from a nearby cooler. The container for keeping your beverage fresh and frosty is either powered by oil and gas or made from petrochemicals.  

A cooler’s shell is rigid plastic, polypropylene, while its insulation is made of polystyrene – a synthetic resin obtained by reacting ethylene, sourced from natural gas and/or petroleum, with the hydrocarbon benzene and often blended further with other polymers.  

After initial greetings and mingling are taken care of, the designated barbecue chef fires up the grill. Whether it is natural gas- or propane-powered, its sole function depends on oil and gas products.  

Hot off the grill, the food on your plate was transported a great distance to your local grocery store by large, fuel-powered trucks, and perhaps driven the short distance home in Canada’s number one selling vehicle: the gasoline powered Ford F-150.  

But the oil and gas sector’s contribution to the items that are about to satisfy your appetite doesn’t stop with transportation, its feedstocks are also a key ingredient in the fertilizers that allow food production to keep pace with global population. 

Taking a seat to enjoy your meal and enjoy some good conversation? The composition of the lawn chair you’re sitting on can be attributed to nylon, polyester and plastic. Need to retreat under a tent or awning during a quick rain shower? That too is made from oil and gas and petrochemical-based products.  

Utensils, plates, those red cups we all know and love – they’re also made from polystyrene.  

Playing giant connect-four? Throwing or kicking a ball around? Your go-to backyard games also rely on petrochemical-based materials.

So the next time you are enjoying a warm summer barbecue, surrounded by food, friends and family, drink in the scenery and acknowledge how oil and gas and petrochemical products made your evening possible. 

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The grass has finally turned green, and parents are setting up their folding chairs on sidelines across the country as spring and summer sports kick-off. 

Many families introduce their children to sport through soccer, not only for the benefits of teamwork and play, but because the equipment requirements are less intensive than hockey or baseball. 

But have you ever considered what a soccer field would look like without contributions from oil and gas? 

The following is a list of common soccer equipment that is made of petrochemical-based materials such as butyl, polypropylene and polyethylene, products made possible by oil and gas and plastics. It may surprise you to learn how dependent their existence is on oil and gas. 

• Soccer ball 
• Astroturf  
• Fertilizer  
• Cleats 
• Net 
• Pylons  
• Gloves 
• Jersey  
• Socks 
• Shin guards 
• Mouth guard 
• Bag 
• Water bottles 
• Tupperware (what are sports without snacks?)  
• Minivans 

The same can be said for many other spring and summer sports; tennis, baseball, cycling or kayaking, to name a few.  

Sports equipment relies heavily on chemistry to help athletes reach peak performance and provide critical safety and protective functions. 

Next time you’re enjoying a hot chocolate from the spectator’s seat, take a good look around and complete a quick tally of items that require oil and gas, either for their production and composition, or delivery, and you may be surprised at how many outdoor hobbies would be non-existent without contributions from Canada’s oil and gas industry.  

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It’s 6 a.m. on a Saturday morning – you wouldn’t usually be up so early on a weekend, but the mountains are calling, and your alarm clock is begging you to answer them. 

A fresh pot of coffee waits for you in the kitchen as you quickly fry up an egg and toast some bread as you check hill conditions on your phone before warming up the car, loading your gear, and hitting the road.  

The sun peaks over the mountains to light your way to the hill. The parking lot is beginning to fill with other early risers, and you are eager to avoid a long line at the gondola.  

You hustle to bundle up in warm fleece layers, boots, and a jacket, grab your skis, goggles, poles, helmet, and extra wax before riding the lift to the resort – if you’re lucky, that chairlift may even be heated.  

With temperatures hovering above zero degrees, it’s the perfect day to fly down a mountain on one or two sticks, then head home to curl up on the couch in front of your TV and gas fireplace to cheer on the nation’s athletes as they compete on the world stage.  

These cold weather pastimes are made possible by petrochemical-based materials; products made from oil and gas and plastics. 

The Chemistry Industry Association of Canada estimates 70,000 products used by Canadians every day are made from plastics.  

Whether it’s a leisurely skate, or showing off aerial acrobatics in the snowboard park, the various outdoor sports Canadians indulge in during winter would look a lot different without these products.  

Sports equipment relies heavily on chemistry to help athletes reach peak performance and provide critical safety and protective functions: 

• Lubricants and waxes allow snowboards and skis to carve effortlessly through powder and glide over icy conditions.  
• Polycarbonate lenses and visors have built-in UV resistance and deflect harsh glare off the bright snow, are thin and lightweight, and have high impact resistance. 
• Helmets are made from polycarbonate: both their hard outer protective shells, and the soft inner padding.   
• Flexible spandex gear for downhill skiers, speed skaters, and curlers is made from polyurethane, as are nylon and polyester for your everyday winter jacket.  
• Made from organic polymers, carbon fiber’s high-strength and lightweight properties, combined with its versatility and durability make it the chosen material for high performance skis, snowboards, hockey sticks, even fabric.  

If enjoying winter sports from the comfort of your own home or in the stands is more your style, even spectator sports depend on oil and gas. The power to keep the lights on and heat the arena, as well as the fuel to transport athletes to competitions around the globe, and the materials used to manufacture your tablet or television are all a result of oil and gas activity.  

Beyond the fuels that heat our homes and make things go, petrochemical products from Canadian oil and gas drive the $35 billion Canadian plastics industry that employs nearly 100,000 people in businesses that make and recycle plastic.   

Canadian producers have set goals to make this $85 billion industry a circular economy by advancing technologies to allow for 100 per cent of plastic packaging to be recoverable and recyclable by 2030. 

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Modern medicine relies on petroleum not only to power hospitals and transport patients, but to manufacture equipment and pharmaceuticals as well.

Reduced availability of petroleum supply would severely impact the healthcare system, according to a 2011 study published in the American Journal of Public Health (AJPH). 

The authors state that several others “have highlighted health care’s exposure to declines in petroleum production, but the issue has received little attention from economists or policymakers, and little has been done to further assess and manage the potential risk.”  

Ten years later, it is difficult to find any updated research associated with these risks, which is why it is important to acknowledge the major contributions of oil and gas products to the healthcare sector.  

How are petroleum-based products being used in healthcare? Here is a breakdown: 

Power 

Energy consumption in hospitals is largely due to space heating and cooling, steam production, ventilation, high powered lighting, equipment usage, hot water, and cooking.  

According to a 2018 energy retrofit guideline, natural gas provides approximately two-thirds of the typical Canadian hospital’s energy requirements.   

The remainder is fulfilled by electricity, which can be generated from natural gas, coal, hydro, wind, solar, biomass or nuclear sources.  

Transportation 

STARS air ambulance responded to 1,255 events for the 2019/2020 reporting year, and more than 500 ambulance vehicles respond to over 550,000 medical events each year in Alberta alone. 

In Ontario, non-profit air ambulance service Ornge sent helicopters and fixed wing aircraft on more than 8,000 missions last year, travelling over 17 million kilometres to ensure life-saving care for critical patients. 

Ambulances run on gasoline and diesel and helicopters run on aviation fuel. Although distances traveled and fuel used are not routinely tracked, these transport services are fuel intensive and dependent.  

Personal Protection Equipment (PPE) 

While donning PPE is common practice in healthcare centres, demand for the equipment increased significantly with the onset of the Covid-19 pandemic. The introduction of high-traffic testing centres and new safety procedures within hospitals require healthcare workers to put on a new gown each time they enter a room to attend to a patient.  

In many cases, PPE is produced using petrochemicals, including gloves, respirators, goggles, gowns, and face shields.

N95 mask infographic. Photo courtesy CAPP

Most of the main components of an N-95 mask are made from petroleum products such as polyethylene and polypropylene, polymers derived from natural gas and produced during the petroleum refining process.  

Much like N-95 respirators, the protective isolation gowns worn by medical professionals and visitors in hospital are manufactured according to specific standards and are made of basic synthetic fibers from polypropylene, polyester, and polyethylene, which offer increased protection from liquid penetration, like plastic films.  

Medical Equipment 

Virtually any piece of medical equipment that contains plastic is made possible by oil and gas. The availability of these plastic devices has become linked to high quality medical care, and therefore patient health. 

Pharmaceuticals 

According to the AJPH study, “approximately 3% of petroleum production is used for pharmaceutical manufacture, but nearly 99% of pharmaceutical feedstocks and reagents are derived from petrochemicals.”  

The chemical reactions that result in these feedstocks that produce aspirin, penicillin and more involve the use of organic molecules found in petroleum.  

In addition, polymers are used to make pill capsules and coatings – including that time-release coating on your extra strength Tylenol.  

Packaging is also made from plastics and keeps medication sterile, child-resistant, and safe from accidental breakage. 

Canadian Plastics  

The Chemistry Industry Association of Canada estimates 70,000 products used by Canadians every day are made from plastics.  

Canada’s plastics industry is committed to solving the plastic waste problem and has set a goal to make 100 per cent of plastic packaging recyclable or recoverable by 2030.  

The production of highly recyclable plastics such as polyethylene is imperative to meeting this goal.   

Through innovation and technology, the petrochemical industry is transitioning towards a “circular economy” where materials are reused and recycled in a closed and sustainable loop.   

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