Higher Value Use of Low Grade Heat

Transcription

1 igher Value Use of Low Grade eat SOLUTION DESCRIPTION: Technologies that create value from excess low grade heat resulting from Steam Assisted Gravity Drainage (SAGD) oil sands production and/or related surface facility operations. CALLENGE SPONSOR: COSIA s GG EPA is sponsoring this challenge. Our aspiration is to produce our oil with lower greenhouse gas emissions than other sources of oil. CREATED: March 2015 All projects are evaluated and actioned as they are received. COSIA has four Environmental Priority Areas (EPAs): Water, Land, Tailings, and Greenhouse Gases (GGs). For more information on this COSIA Challenge please visit Canada s Oil Sands Innovation Alliance (COSIA) accelerates the pace of environmental performance improvement in Canada s oil sands through collaborative action and innovation. COSIA Members represent more than 90 per cent of oil sands production. We bring together innovators and leading thinkers from industry, government, academia and the wider public to identify and advance new transformative technologies. Challenges are one way we articulate an actionable innovation need, bringing global innovation capacity to bear on global environmental challenges. 1

2 WAT TO SUBMIT TO COSIA COSIA requires sufficient non-confidential, nonproprietary information to properly evaluate the technology. Some items that will be especially important to present in your submission are: Concept and basic unit operations Technical justification for the approach (e.g. laboratory batch or continuous experiments; pilot or demo plants; process modeling; literature precedent) Describe quantities and qualities of utilities and consumables that are required Energy inputs quantity and type(s) Capital and operating cost estimates if available based on described capacity targets 3rd party verified comparison of your proposed technology against an MEA baseline. 3rd party verifiers should be reputable, independent engineering companies if possible Basis of cost estimation, including estimation scope, contingency, etc. IP status of your proposed technology What operating environment restrictions might your technology face: Explosive atmospheres Severe weather Power fluctuations FUNDING, FINANCIALS, AND INTELLECTUAL PROPERTY COSIA Members are committed to identifying emerging technologies and funding the development of the technologies to the point of commercialization, while protecting the Intellectual Property (IP) rights of the owner of the technology. Successful proposals can receive funding from COSIA members to develop and demonstrate the technology in an oil sands application. Multiple technologies may be funded, at the discretion of the Members. OW TO SUBMIT TO COSIA Submit a summary of your solution using COSIA s Environmental Technology Assessment Portal (E- TAP) Process, available at: Please note: ETAP is a staged submission process. The initial submission requires only a brief description and limited technical information. Upon review by COSIA, additional information may be requested. Instructions for submission are provided on the ETAP site. All information provided is non-confidential. COSIA will respond to all submissions. 2

3 #0012: igher Value Use of Low Grade eat DETAILED SOLUTION DESCRIPTION The COSIA GG Environmental Priority Area Steering Committee seeking leading edge technologies that create value from excess low grade heat resulting from Steam Assisted Gravity Drainage (SAGD) oil sands production and/or related surface facility operations. The successful technology will: Be implementable within a SAGD oil sands Central Processing Facility (CPF) and/or with SAGD well bores Upgrade low grade heat (<60-80 C) to higher value heat (>130 C) OR convert low grade heat to electricity at >10% efficiency Function successfully in existing SAGD oil sands operations with high reliability Require lower energy inputs than the higher heat value or electricity produced Break even over installation and capital costs in less than 4 years Technologies at all stages of technical maturity are of interest BACKGROUND The most common recovery process employed for producing from oil sands reservoirs is known as SAGD. In this process, steam is generated at a Central Processing Facility (CPF), transported to well pads, and injected below ground into a horizontal well bore within the reservoir. The heat supplied by the steam warms the heavy oil in the reservoir allowing it to flow via gravity drainage into a second underlying wellbore that captures the oil/water mixture and produces it to the surface. Once at the surface, the mixture of oil and water is cooled from C down to around 800 C prior to separation. Once separated, the produced water is treated and recycled for steam generation. The resulting oil is treated and delivered into a pipeline for shipping. This cooling process generates significant amounts of low grade heat at C. COSIA would like to identify technologies that can create value from this by-product by converting it to higher value heat for use either within the CPF or SAGD wellbores, or by converting it to electricity at >10% efficiency rate. Existing technologies to upgrade waste heat are not widely used due to associated high capital expenses. APPROACES NOT OF INTEREST The following approaches are not of interest: Organic Rankine Cycle ADDITIONAL INFORMATION Some items that will be especially important to present in your response are: Basic unit operations Provide reasons why you believe your approach will work (ie glassware experiments, process modeling, literature precedent) Describe utilities that might be required Capital and operating cost estimates if available based on described capacity targets IP status What operating environment restrictions might your technology face? Explosive atmospheres Severe weather Power fluctuations Power generation: E = (V-EC)/Q eat pump: COP = V/EC 3

4 #0012: igher Value Use of Low Grade eat E = Efficiency COP = Coefficient of Performance V = igher Value eat, GJ (electricity produced) EC = Energy Consumed, GJ (to produce V) Q = total waste heat available, GJ 4

5 COSIA SAGD TEMPLATE Base Case Mechanical Lift kpa Diluent Warm Lime Softening - OTSG 27,765 BPSD 10,210 BPSD 3, m 3 /d API Oil Treating Diluent lost to Fuel 42 BPSD 8,783 BPSD 7 m 3 /d Well Pad Facilities Water lost to Dilbit 13 BPSD Air Cooler Vapour Recovery 2 m 3 /d Dilbit 51,941 BPSD Preflash Fluid Water Knock-Out Treaters CPF Dilbit 8,258 m 3 /d PADS Emulsion Vessel 1 Vessel 2 x Mechanical 16.1 API 21.3 API 122,948 BPSD 19,547 m 3 /d Recycled Recovered Diluent Sour CPF Produced Gas Chemicals Chemicals 0 BPSD 1.85 MMSCFD 0 m 3 /d 52,283 Sm 3 /d Produced Gas 0.21 Sulfur (metric t/d) Composition Reservoir Mol% Composition (Dry Basis) CO Mol% Mol% SOR: 3.00 (wet) N2 1.3 Mol% CO Mol% GOR: S 0.13 Mol% N2 0.9 Mol% C Mol% 2S 0.3 Mol% Bitumen C Mol% De-Oiling C Mol% 33,000 BPSD C Mol% C2 1.4 Mol% 5,247 m 3 /d C4 0.3 Mol% C3 2.0 Mol% 7.08 API C Mol% IGF/ISF/ORF Units Skim Tank C4 0.3 Mol% 5.05 % Sulfur (comp at test separator) De-oiled Water 1 Train Produced Water C Mol% 589,560 kg/h 591,682 kg/h Produced Water 14,175 m 3 /d 14,234 m 3 /d 589,710 kg/h 1,492 mg/l TDS 1,492 mg/l TDS 14,182 m 3 /d 188 mg/l Silica 188 mg/l Silica 1,492 mg/l TDS 14 mg/l ardness 14 mg/l ardness 188 mg/l Silica 300 mg/l TOC 300 mg/l TOC mg/l ardness mg/l TOC Produced Gas Water Treatment 0.93 MMSCFD Chemicals Blowdown to WLS Summary Table 26,233 Sm 3 /d Lime 363 kg/h 117,811 kg/h MU TDS (ppm) 7,172 MagOx 96 kg/h 2,829 m 3 /d PW TDS (ppm) 1,492 Electricity (ESP) Soda ash 37 kg/h 28,493 mg/l TDS PW TOC (ppm) MW PW WLS Afterfilters 158 mg/l Silica LP Flash BD (%) 8% Tank 1 x WLS Treater WAC Polishers BFW 0 mg/l ardness BD Recycle (%) 60% Steam WLS Feed WLS Overflow 3 x WAC Units Tank 2,346 mg/l TOC TDS to Boiler (ppm) 6, ,220 kg/h 856,388 kg/h 855,905 kg/h 2 x Polishers Boiler TOC (ppm) ,757 m 3 /d CWE 20,587 m 3 /d 20,576 m 3 /d MU Flowrate (kg/h) 149,027 6,160 mg/l TDS 6,062 mg/l TDS Backwash Service Water WLS Sludge (kg/d) 23, mg/l Silica 34 mg/l Silica 4,280 kg/h Disposal Type (L,S) L 10 mg/l ardness 3 mg/l ardness 103 m 3 /d Disposal Rate (kg/h) 63, mg/l TOC 515 mg/l TOC Disposal Solids (kg/d) 51,662 Water Losses to Reservoir: Clarifier Waste Regeneration 65,522 kg/h 980 kg/h (dry basis) Waste to Disposal Water Balance 1,576 m 3 /d 259 m 3 /d Stream Flow Flow TDS Silica ardness 10 % Losses 22,945 mg/l TOC kg/h m 3 /d ppm ppm ppm Steam to reservoir 655,220 15, Losses to reservoir 65,522 1, Produced Water 591,682 14,234 1, Losses to production De-oiled Water 589,560 14,175 1, Steam Generation P Steam Make-up Water 149,027 3,584 7, % Quality Efficiency 91.5 % (LV) BFW Supernatant Flue Gas (includes Glycol eater) 655,220 kg/h Duty (abs) 1,437 GJ/h 851,624 kg/h WLS Feed 856,388 20,587 6, CO2 2,191 metric t/d 15,757 m 3 /d CWE 1,362 MMBTU/h 20,474 m 3 /d WLS Overflow 855,905 20,576 6, Make-up Water Ion SO metric t/d 10.0 MPag Duty (fired) 1,570 GJ/h (LV) 6,059 mg/l TDS Clarifier Waste to Land ,027 kg/h Exchange NOx 0.38 metric t/d 1,488 MMBTU/h (LV) 34 mg/l Silica Blowdown to Disposal 63,435 1,523 28, ,584 m 3 /d NOx emission: 9.66 g/gj Utility Steam 0 mg/l ardness LP Steam to WT ,172 mg/l TDS Energy 101 GJ/h (LV) 35.0 GJ/h Wet Steam OTSG 170 C 515 mg/l TOC LP Steam to eader 15, , mg/l Silica Flow Rate 462 MMSCFD 15,133 kg/hr PS 77 % Quality 6 x OTSG Boilers Service Water 4, , mg/l ardness O2 in Fuel Gas 2.1% Wt% 851,624 kg/h Radiation Losses BFW Pump (LP&P) Power Treated Produced Gas BFW 851,624 20,474 6, mg/l TOC 20,474 m 3 /d CWE 32.1 GJ/hr 5.5 MW 1.85 MMSCFD Method 1 Water Recycle: 86 % 92 kgmol/hr Emissions Summary LP Steam 679,396 kj/kgmol (LV) Source SO2 S CO2 NOx Flash Air Blower 63 GJ/h metric t/d metric t/d metric t/d metric t/d 3.7 MW OTSG Flue Gas Recovered Sulfur Natural Gas to CPF 32.8 GJ/hr Blowdown to Disposal MMSCFD Glycol eater 63,435 kg/h 1,859 kgmol/hr 0.81 MMSCFD 1,523 m 3 /d 810,745 kj/kgmol (LV) 40 Kgmol/hr Natural Gas (Total) 28,472 mg/l TDS 1,508 GJ/h MMSCFD 2153 kg/h solids 1,900 kgmol/hr

6 ENERGY FLOW DIAGRAM Base Case: WLS - OTSG Glycol Air Cooler 125 GJ/h Diluent Total Air Cooler eat Released to Atmosphere Glycol Return 50 C 5.8 C GJ/hr 71 C 40 C Produced Gas Cooler (relative to ambient air) 2.4 GJ/h 4.41 GJ/h 1.2 GJ/h 128 C 55 C 55 C Produced Gas Emulsion / BFW Exchanger Sales Oil Coolers eat Exchangers Legend Preflash Emulsion 137 GJ/h Vapor 43.9 GJ/h Dilbit PADS Vessel 175 C 133 C Oil Treating Recovery 131 C 50 C Process to Process C 129 C 129 C 106 C ot Glycol 144 C Skim Tank Produced Water Cooler C Cold Glycol 13.4 GJ/h PW / BFW Exchanger 85 C 90.3 C 85 GJ/h Direct Contact/Quench C 97.2 C 106 C Reservoir Make-up Water eater Exchangers Duty 22 GJ/h GJ/h Make-up Water Emulsion / BFW C 40 C 5 C Produced Water Glycol Cooler GJ/h PW / BFW Exchanger 84.5 De-Oiling / Water Treatment PW / MU water exchanger Produced Gas Air Cooler (s) 3.5 Air Glycol eater 2 Diluent Glcyol eater 4.4 BFW 82 C 13 GJ/h Sales Oil Coolers C Make-up Water Glycol eater 21.8 PW / MU water exchanger 18.1 Blowdown Glycol Cooler 79.3 Stack Losses BFW Preheaters 86.7 Stack GJ/hr OTSG Air Glycol eaters (two services) 22.7 BD Water to Disposal 80 C Air Glycol Preheater 195 C (LV basis) OTSG Air Preheater (Flue Gas) N/A Water eat to Earth 80 C 9.16 GJ/h Forced Draft Fan Utility Coolers GJ/hr Blowdown Cooler Air 20 C Fan 33 C Glycol Air Cooler C (based on 5 C Ground Temp) 79.3 GJ/h 5 C Electrical Loads Power Equivalent eat P Steam MW GJ/h 310 C BFW P BFW Pump C LP BFW Pump Downhole Pumps Radiation Losses Pad Auxiliaries PS 310 C 32.1 GJ/hr Forced Draft Fan Utility Steam (relative to ambient) Misc Users ,133 kg/h OTSG VRU Compressors BFW Preheaters WLS/Evaporator C 86.7 GJ/h Glycol System LP Steam Total Flash 220 C Direct CO2 Generation 2,191 MT/day kg/m3 Bitumen 35.0 GJ/h Indirect CO2 Generation 328 MT/day 62.5 kg/m3 Bitumen Total CO2 Emissions 2,519 MT/day kg/m3 Bitumen 55 C Assumes electricity grid CO2 emissivity of 763 kg CO2eq / MW-hr Combustion Air Direct Emissions from Combustion only 30 GJ/hr (LV) C Glycol eater Natural Gas Glycol eater 1.16 GJ/h Inputs Energy P BFW Pump GJ/h 146 C Natural Gas 1538 Electrical Power Produced Gas 51.1 C 40 C 63 GJ/h (LV) Total C 1.8 GJ/h 11.4 GJ/h Natural Gas Tracing & Utility eat Input (LV) C Building eat Coolers 1538 GJ/h

7 Ore Grade Fine Contents Waste to Ore COSIA Mining & Extraction: igh Grade - Paraffinic Froth Treatment - Energy Flow Processing Plant 78 C Legend 50 C Bitumen Mine Face 5 C Ore Preparation 50 C Primary Extraction Water Truck and Shovel 50 C 50 C Stripping Steam Steam 70 GJ/h Fuel gas Diesel ydrotransport Pump Solvent 515 GJ/h Tailing Deaerated Froth Pump Abbreviations BFW Boiler Feed Water CW Cooling Water CWR Cooling Water Return CWR PSC Tailing Pump FSU Froth Settling Unit GTG Gas Turbine Generator CW V igh eating Value 225 C RSG eat Recovery Steam Generator LPS Low Pressure Steam MPS Medium Pressure Steam PSC Primary Separation Cell Make Up Solvent Solvent Storage FSU C PW Process Water 20 C SRU 215 C SRU Solvent Recovery Unit SRU/MPS Exchanger Duty TSRU Tailing Solvent Recovery Unit Strippingg Steam 199 GJ/h 76 GJ/h Energy Output Summary Input (GJ/h) Output (GJ/h) 99 C Cogen GTG 1,547 Electricity 457 RSG 672 BFW Preheating Steam C 38 C Cogen Losses 333 Bitumen Cooler Duty 200,000 bbl/d Subtotal - Cogen 2,220 2, GJ/h Boilers 751 Steam 687 CW CWR Boiler Losses 64 Subtotal - Boilers Total 751 2, ,971 TSRU 90 C Strippingg Steam Flue Gas - Based on Stochiometric Combustion CW CWR 89 GJ/h Natural Gas V Tailing Pond Excess 13% O2 Excess O2 Cogen Flue Gas TSRU Tailing Pump CO2 in Flue Gas from Cogen CW (Cold) CWR (Warm) 2O in Flue Gas from Cogen 30 C 60 C Boiler Flue Gas Reclaimed Water 25 C CO2 in Flue Gas from Boilers 2O in Flue Gas from Boilers Flue Gas Temperature - Acid Dew Point Limit Condensate 186 C Flue Gas - Max. without Economizer 40 MJ/m3 179 % 13 % 2,660 e3m3/h 4% vol.% 7% vol.% 380 e3m3/h 9% vol.% 17% vol.% 121 C 274 C Make Up Water Raw Water Pond Recycled Water 49 C 56 C 78 C ot Water Tank Exchanger & Cooler 25 C 25 C Pond 25 C 78 C Process Water / Cooling Water PW/CW Exchanger Duty PW/Condensate PW/LPS Process Water / Condensate 1,108 GJ/h Exchanger Duty 301 GJ/h Exchanger Duty Process Water / LPS 1,051 GJ/h SRU Feed / MPS 57 C Cooler 25 C Warm Water Tank 50 C Energy Consumption Summary GJ/h e3m3/d 99 C GTG 1, RSG Natural Gas Cogen Losses Building eating and Flare C 333 GJ/h Boilers Diesel C Boiler Losses Energy Intensity (GJ per bbl of bitumen produced) 0.49 GJ/bbl MPS Output 64 GJ/h Electricity Generated 3,044 MW/d Cogen Facility 85% Efficiency 434 GJ/h Electricity Consumed 3,142 MW/d Cogen Energy Output Auxillary Boiler 687 GJ/h MPS Electricity 457 GJ/h Electricity GG Emissions Summary 127 MW 633 GJ/h BFW Preheating Stationary Combustion & Flaring 4,137 t CO2e/d 797 GJ/h Steam Mobile Equipment 892 t CO2e/d GTG Duct burner RSG 797 GJ/h LPS Output Fugitive Mine kg CO2e/m2/d 1,051 GJ/h Fugitive Pond kg CO2e/m2/d GTG Duct Burner RSG Flue Gas LPS Total Cogen Emissons (Gt) 2,569 t CO2e/d Natural Gas Required 1,547 GJ/h 672 GJ/h 2,660 e3m3/h Boilers Boilers Flue Gas Deemed emissions from eat by Cogen (D ) 2,069 t CO2e/d 3,575 GJ/h V 38,678 m3/h 16,812 m3/h 4% CO2 vol.% 751 GJ/h 380 e3m3/h Deemed emissions from Electricity by Cogen (D E ) 500 t CO2e/d 89,376 m3/h 2 Unit 2 Unit 7% 2O vol.% 18,780 m3/h 9% CO2 vol.% MPS LPS 2,145 e3m3/sd C 91.5% Efficiency 17% 2O vol.% 100 % Quality 90 % Quality Project: Static Oil Sands Mine and Extraction Reference Facility 6 unit C 225 C 210 C Case: Paranffic - igh Grade Revision: V Natural Gas 2,100 kpag 1,050 kpag Owner: COSIA 25 C 604 GJ/h 102 T/h Stripping Steam 511 T/h Date: 04-Oct-15 Space eating 53 T/h Processing eating Energy / eat Flow Purge Gas to Flare igh Temperature Extraction, igh Grade, Summer Condition 25 C 78 C Duty (GJ/h) 1, , This is a generic and hypothetical mine and extraction facility developed by COSIA. While representative, it is not based on any one facility. Recovery and solvent loss is based on Alberta Energy Regulator requirements.

8 Ore Grade Fine Contents Waste to Ore COSIA Mining & Extraction igh Grade - Paraffinic Froth Treatment - Material Flow Ore Preparation: Conditioning, Crushing and Conveying Mine Face 13,142 T/h Crusher Conveyor Feed Rotary Breaker Truck and Shovel 5 C System 50 C Rejects Bitumen 12 Bitumen 3 Water 3 Water 6 Solids 85.3 Solids T/h ot Process Water 80 C 5,918 T/h Gland Cooling Water 244 T/h 441 T/h Breaker Rejects Warm Dilution Water 45 C 4,396 T/h 18,888 T/h SG Primary Extraction 50 C Vent to atmosphere 6 T/h Caustic Stripping Steam 30 T/h Deaerator C PSC NaO Flotation Froth Deaerated Froth 77 C Middlings 2,443 T/h Flotation & Cyclone Bitumen 60 Water 28 Middlings Displacement Cooling Water 5,769 T/h Solids 12 PSC Tailing 26,634 T/h Bitumen 0.3 Secondary Extraction- Froth Treatment Water 60 Solids 40 Make Up Solvent 4 T/h Solvent - Bitumen to SRU 3,546 T/h Bitumen 38 Gland Cooling Water 61 T/h FSU C Solvent to Bitumen 1.65 wt/wt SRU 215 C Bitumen 10.4 Solvent Make up Water 62 Stripping Steam 33 T/h Legend 20 C Solids 23 Bitumen Water Recovered Solvent Tailing to TSRU 1,217 T/h Steam 2,255 T/h SRU Recovered Water 34 T/h Fuel gas TSRU 90 C Solvent Loss : Bitumen Gland Cooling Water 143 T/h Solvent 0.3 % vol./vol. TSRU Tailing Tailing 1,382 T/h Stripping Steam 39 T/h Bitumen 7 % Abbreviations Water 70 % BFW Boiler Feed Water Solids 21 % FSU Froth Settling Unit Bitumen GTG Gas Turbine Generator 51 T/h V igher eating Value 2,204 T/h RSG eat Recovery Steam Generator LPS Low Pressure Steam 200,000 bbl/sd MPS Medium Pressure Steam Bitumen 99.9 % PSC Primary Separation Cell 16,531 T/h Tailing Asphaltene 12.0 % SG Specific Gravity Recycled Water Reclaimed Water 14,051 T/h Tailing Pond Solids + Water 0.1 % SRU Solvent Recovery Unit 25 C 85 % Process Water Recycled Asphaltene Rejection 7.6 % TDS Total Dissolved Solids TOC Total organic carbon TSRU Tailing Solvent Recovery Unit 2,480 T/h Losses 33 T/h Bitumen Recovery Summary Utilities Ore Preparation Raw Water Pond 241 T/h 479 T/h Recovered MPS Primary Extraction Water treatment Condensate GTG 100 % Quality Froth Treatment (without rejected asphaltenes) 1,547 GJ/h 225 C Total Bitumen Recovery 38,678 m3/h 2,100 kpag Asphaltenes Rejection 2,721 T/h 127 MW 102 T/h Stripping Steam Total Bitumen Recovery (with rejected asphaltenes) 2 Unit 53 T/h Processing eating Duct Burner MPS LPS Water Summary (T/) Make-up Water BFW 672 GJ/h RSG 2 Unit 90 % Quality Cooling Water Process Water 25 C 241 T/h 16,812 m3/h Cogen Efficiency 85 % 210 C eated Water 6,059 mg/l TDS 2 Unit 1,050 kpag Reclaimed Water Make-up Water 34 mg/l Silica GTG Duct Burner RSG 511 T/h Raw Water 6,059 mg/l TDS 0 mg/l ardness BFW 7 mg/l Silica 515 mg/l TOC LPS Utility Steam Boiler Blowdown mg/l ardness Make-Up Water 6 mg/l TOC Recovered Condensate 479 T/h Boilers LPS Condensate Return Fresh Water : Bitumen 751 GJ/h 2.03 vol./vol. Natural Gas Required Space eating 18,780 m3/h Project: A Static Oil Sands Mine and Extraction Reference Facility 3,575 GJ/h V Purge Gas to Flare 91.5 % Efficiency Case: Paraffinic - igh Grade Revision: V ,376 m3/h 6 unit Owner: COSIA Natural Gas 2,145 e3m3/sd 604 GJ/h Auxilary Boiler Date: 04-Oct C Boiler Blowdown Material Flow 21 T/h igh Temperature Extraction, igh Grade, Summer Condition 99.0% 94.6% 98.4% 92.2% 7.6% 85.1% 6,217 10,314 14,051 2, , This is a generic and hypothetical mine and extraction facility developed by COSIA. While representative, it is not based on any one facility. Recovery and solvent loss is based on Alberta Energy Regulator requirements.

9 Ore Grade Fine Contents Waste to Ore COSIA Mining & Extraction: igh Grade - Naphthenic Froth Treatment - Energy Flow Processing Plant 80 C 45 C Mine Face 1 C Ore Preparation 45 C Primary Extraction Truck and Shovel 50 C 50 C Stripping Steam Legend 78 GJ/h Bitumen Diesel ydrotransport Pump Water 478 GJ/h Steam Fuel gas Deaerated Froth Pump Diluent Tailing Abbreviations PSC Tailing Pump BFW Boiler Feed Water CW Cooling Water CWR Cooling Water Return 225 C GTG Gas Turbine Generatior V igh eating Value RSG eat Recovery Steam Generator LPS Low Pressure Steam Diluent Diluent Storage 48 C Inclined Plate MPS Medium Pressure Steam 48 C Separator 84 C NRU Naphtha Recovery Unit Diluent Feed / MPS PSC Primary Separation Cell Exchanger Duty PW Process Water 199 GJ/h Centrifuge 84 C Energy Output Summary Input (GJ/h) Output (GJ/h) Cogen GTG 1,547 Electricity 457 RSG 672 BFW Preheating 386 Steam 1,044 Diluted 84 C Bitumen Cogen Losses 333 Subtotal - Cogen 2,220 2, C Boilers 291 Steam ,000 bbl of Bitumen/d Boiler Losses 25 Subtotal - Boilers Total 291 2, ,511 NRU Stripping Steam 112 GJ/h Flue Gas Tailing Pond Natural Gas V Excess 13% O2 in Cogen Excess O % 13% MJ/m3 % % NRU Tailing Pump Cogen Flue Gas 2,660 e3m3/h CW (Cold) CWR (Warm) CO2 in Flue Gas from Cogen 4% vol.% 30 C 60 C 2O in Flue Gas from Cogen 7% vol.% Reclaimed Water 10 C Boiler Flue Gas CO2 in Flue Gas from Boilers 2O in Flue Gas from Boilers 147 9% 17% e3m3/h vol.% vol.% Condensate 186 C Flue Gas Temperature - Acid Dew Point Limit Flue Gas - Max. without Economizer C C Make Up Water Raw Water Pond Recycled Water 10 C 53 C 59 C 80 C ot Water Tank 10 C 10 C Pond 10 C 80 C Exchanger PW/CW Exchanger Duty PW/Condensate PW/LPS Process Water / Cooling Water 1,879 GJ/h Exchanger Duty 255 GJ/h Exchanger Duty Process Water / Condensate 921 GJ/h Process Water / LPS 62 C Diluent Feed / MPS 10 C Warm Water Tank 45 C Energy Consumption Summary 99 C GTG 10 C RSG Natural Gas Cogen Losses Building eating and Flare 68 C 333 GJ/h Boilers Diesel 51 C Boiler Losses Energy Intensity (GJ / bbl bitumen produced) MPS Output 25 GJ/h Electricity Generated Cogen Facility 85% Efficiency 389 GJ/h Electricity Consumed Cogen Energy Output Auxilary Boiler 266 GJ/h MPS Electricity 457 GJ/h Electricity GG Emissions Summary 127 MW 386 GJ/h BFW Preheating Stationary Combustion & Flaring 1,044 GJ/h Steam Mobile Equipment 1,044 3,329 t CO2e/d 827 t CO2e/d GTG Duct burner RSG GJ/h LPS Output Fugitive Mine kg CO2e/m2/d 921 GJ/h Fugitive Pond kg CO2e/m2/d GTG Duct Burner RSG Flue Gas LPS Total Cogen Emissons (Gt) 2,569 t CO2e/d Natural Gas Required 1,547 GJ/h 672 GJ/h 2,660 e3m3/h Boilers Boilers Flue Gas Deemed emissions from eat by Cogen (D ) 2,069 t CO2e/d 2,876 GJ/h V 38,678 m3/h 16,812 m3/h 4% CO2 vol.% 291 GJ/h 147 e3m3/h Deemed emissions from Electricity by Cogen (D E ) 500 t CO2e/d 71,909 m3/h 2 Unit 2 Unit 7% 2O vol.% 7,273 m3/h 9% CO2 vol.% MPS LPS 1,726 e3m3/sd C 91.5% Efficiency 17% 2O vol.% 100 % Quality 90 % Quality Project: Static Reference Oil Sands Mine and Extraction Reference Facility 4 unit C 225 C 210 C Case: Naphthenic - igh Grade Revision: V 1.6 Natural Gas 2,100 kpag 1,050 kpag Owner: COSIA 10 C 366 GJ/h 68 T/h Stripping Steam 448 T/h Date: 04-Oct-15 Space eating 104 T/h Processing eating Energy / eat Flow Purge Gas to Flare igh Temperature Extraction, igh Grade, Average Condition 80 C Duty (GJ/h) 1, GJ/h e3m3/d 1, GJ/bbl 3,044 MW/d 3,600 MW/d This is a generic and hypothetical mine and extraction facility developed by COSIA. While representative, it is not based on any one facility. Recovery and solvent loss is based on Alberta Energy Regulator requirements.

10 Ore Grade Fine Contents Waste to Ore COSIA Mining & Extraction: igh Grade - Naphthenic Froth Treatment - Material Flow Ore Preparation: Conditioning, Crushing and Conveying Mine Face 12,187 T/h Crusher Conveyor Feed Rotary Breaker Truck and Shovel 1 C System 50 C Rejects Bitumen 12 Bitumen 4 Water 3 Water 6 Solids 85.6 Solids T/h ot Process Water 80 C 5,045 T/h Gland Cooling Water 227 T/h 412 T/h Breaker Rejects Warm Dilution Water 45 C 3,514 T/h 17,072 T/h Primary Extraction 50 C Caustic Stripping Steam 28 T/h Deaerator C NaO Flotation Froth Deaerated Froth 77 C 2,357 T/h Flotation & Cyclone Bitumen 58 Water 32 Middlings Displacement Cooling Water 5,372 T/h Solids 10 Middlings Primary Separation Cell Vent to atmosphere 6 T/h PSC Tailing 23,623 T/h Bitumen 0.1 Secondary Extraction- Froth Treatment Water 58 Solids 42 Diluent 955 T/h 1,354 T/h IPS Centrifuge Warm Water 19 T/h Inclined Plate 1,354 T/h 928 T/h Separator 84 C 59 Bitumen 58 Bitumen 1.5 Water 3 Water Diluent 0 Solids 1 Solids 48 C 0.7 wt/wt Diluent : Bitumen 0.7 wt/wt Diluent : Bitumen Diluent:Bitumen 0.7 wt / wt Diluent Loss:Bitumen 0.4 vol. / vol. Centrifuge 84 C 1,977 T/h 28 Bitumen Legend 38 Water Bitumen 12 Solids Water Steam 70 T/h NRU Tailing 1049 T/h Fuel Gas NRU 1,019 T/h 2 Bitumen Diluent Stripping Steam 40 T/h 2 Bitumen 69.8 Water Diluted Tailing 76 Water 21 Solids Bitumen 22 Solids 7 Diluent Abbreviations 0.4 Diluent BFW Boiler Feed Water 1,339 T/h Bitumen GTG Gas Turbine Generatior 200,000 bbl Bitumen V igh eating Value 14,178 T/h Tailing 881 T/h Diluent RSG eat Recovery Steam Generator Recycled Water Reclaimed Water 12,051 T/h Tailing Pond 0.7 wt / wt Diluent :Bitumen LPS Low Pressure Steam 10 C 85 % Process Water Recycled 1 vol / vol Diluent : Bitumen MPS Medium Pressure Steam 17 Asphaltene in Bitumen NRU Naphtha Recovery Unit 3 Solids + Water PSC Primary Separation Cell 2,127 T/h Losses 31 T/h Bitumen Recovery Summary Utilities Ore Preparation Raw Water Pond 202 T/h 470 T/h Recovered MPS Primary Extraction Water treatment Condensate GTG 100 % Quality Froth Treatment (without rejected asphaltenes) 1,547 GJ/h 2,100 kpag Total Bitumen Recovery 38,678 m3/h 225 C Asphaltenes Rejection 2,328 T/h 127 MW 68 T/h Stripping Steam Total Bitumen Recovery (with rejected asphaltenes) BFW 2 Unit 104 T/h Process eating 202 T/h Duct Burner MPS LPS Utility Steam Water Summary (T/) Make-up Water 6,059 mg/l TDS 672 GJ/h RSG 2 Unit 90 % Quality Cooling Water Process Water 10 C 34 mg/l Silica 16,812 m3/h Efficiency 85 % 1,050 kpag eated Water 0 mg/l ardness 2 Unit 210 C Reclaimed Water Make-up Water 515 mg/l TOC GTG Duct Burner RSG 448 T/h Raw Water 6,059 mg/l TDS BFW 7 mg/l Silica Boiler Blowdown mg/l ardness Make-Up Water 6 mg/l TOC Recovered Condensate 470 T/h Boilers LPS Condensate Return Fresh Water : Bitumen 291 GJ/h 1.8 vol./vol. Natural Gas Required Space eating 7,273 m3/h Project: Static Oil Sands Mine and Extraction Reference Facility 2,876 GJ/h Purge Gas to Flare 91.5 % Efficiency Case: Naphthenic - igh Grade Revision: V ,909 m3/h 366 GJ/h 4 unit Owner: COSIA Natural Gas 1,726 e3m3/sd Auxilary Boiler Date: 27-Sep-15 Boiler Blowdown Material Flow 20 T/h igh Temperature Extraction, igh Grade, Average Condition 928 T/h 98.9% 98.0% 98.2% 95.2% 0.0% 95.2% 5,599 8,579 12,051 2, , This is a generic and hypothetical mine and extraction facility developed by COSIA. While representative, it is not based on any one facility. Recovery and solvent loss is based on Alberta Energy Regulator requirements.