Post on 26-Jul-2020
transcript
Development of a Static Oil Sands Mine andExtraction Reference Facility
PRESENTED TO
Tetra Tech Canada Inc.Riverbend Atrium One, 115, 200 Rivercrest Drive SE
Calgary, AB T2C 2X5 CANADA
Tel 403.203.3355 Fax 403.203.3301
Canada’s Oil Sands Innovation Alliance
JANUARY 12, 2017
ISSUED FOR USE_REVISION 1
FILE: 704-ENV.CENV03071
Development of a Static Oil Sands Mine and Extraction Reference Facility_Rev1.docx
This page intentionally left blank.
DEVELOPMENT OF A STATIC OIL SANDS MINE AND EXTRACTION REFERENCE FACILITY
FILE: 704-ENV.CENV03071 | JANUARY 12, 2017 | ISSUED FOR USE_REVISION 1
i
Development of a Static Oil Sands Mine and Extraction Reference Facility_Rev1.docx
TABLE OF CONTENTS
1.0 INTRODUCTION.......................................................................................................................... 1
2.0 SCOPE......................................................................................................................................... 1
3.0 APPROACH................................................................................................................................. 2
3.1 Cogeneration .........................................................................................................................................3
3.2 Steps......................................................................................................................................................3
4.0 PARAFFINIC FROTH TREATMENT............................................................................................ 4
4.1 Paraffinic Material Flow .........................................................................................................................4
4.2 Paraffinic Energy Flow...........................................................................................................................5
5.0 NAPHTHENIC FROTH TREATMENT.......................................................................................... 5
5.1 Naphthenic Material Flow ......................................................................................................................5
5.2 Naphthenic Energy Flow........................................................................................................................6
6.0 GHG EMISSIONS CALCULATIONS............................................................................................ 6
7.0 FLOW DIAGRAMS ...................................................................................................................... 7
8.0 CLOSURE.................................................................................................................................... 8
LIST OF TABLES IN TEXT
Table 1: Project Team........................................................................................................................... 2
Table 2: Key Assumptions .................................................................................................................... 2
Table 3: Natural Gas Requirement (GJ/h Lower Heating Value – LHV) per Train ................................. 3
Table 4: Major Equipment Size ............................................................................................................. 3
Table 5: Key Parameters for PFT Material Flow.................................................................................... 4
Table 6: Key Parameters for NFT Material Flow ................................................................................... 5
Table 7: Supply Conditions for NFT Material Flow ................................................................................ 6
Table 8: Fugitive Emissions from Mine Face......................................................................................... 6
Table 9: Fugitive Emissions from Tailings Ponds by Paraffinic Froth Treatment Process...................... 6
Table 10: Fugitive Emissions from Tailings Ponds by Naphthenic Froth Treatment Process................. 7
DEVELOPMENT OF A STATIC OIL SANDS MINE AND EXTRACTION REFERENCE FACILITY
FILE: 704-ENV.CENV03071 | JANUARY 12, 2017 | ISSUED FOR USE_REVISION 1
ii
Development of a Static Oil Sands Mine and Extraction Reference Facility_Rev1.docx
APPENDIX SECTIONS
APPENDICES
Appendix A
Appendix B
Material and Energy Flow Diagrams
Tetra Tech’s General Conditions
DEVELOPMENT OF A STATIC OIL SANDS MINE AND EXTRACTION REFERENCE FACILITY
FILE: 704-ENV.CENV03071 | JANUARY 12, 2017 | ISSUED FOR USE_REVISION 1
iii
Development of a Static Oil Sands Mine and Extraction Reference Facility_Rev1.docx
LIMITATIONS OF REPORT
This report and its contents are intended for the sole use of Canada’s Oil Sands Innovation Alliance and their agents. Tetra Tech
Canada Inc. (Tetra Tech) does not accept any responsibility for the accuracy of any of the data, the analysis, or the
recommendations contained or referenced in the report when the report is used or relied upon by any Party other than Canada’s
Oil Sands Innovation Alliance, or for any Project other than the proposed development at the subject site. Any such unauthorized
use of this report is at the sole risk of the user. Use of this report is subject to the terms and conditions stated in Tetra Tech
Canada Inc.’s Services Agreement. Tetra Tech’s General Conditions are provided in Appendix B of this report.
DEVELOPMENT OF A STATIC OIL SANDS MINE AND EXTRACTION REFERENCE FACILITY
FILE: 704-ENV.CENV03071 | JANUARY 12, 2017 | ISSUED FOR USE_REVISION 1
1
Development of a Static Oil Sands Mine and Extraction Reference Facility_Rev1.docx
1.0 INTRODUCTION
Tetra Tech Canada Inc. (Tetra Tech) was contracted by Canada’s Oil Sands Innovation Alliance (COSIA) to develop
a static block mass and energy flow for a typical oil sands mine (Tetra Tech File No.
704-ENVONG03396-01). The objective of this project was to create Excel spreadsheet block flow diagrams for
material and heat / energy for four scenarios. These diagrams will facilitate the evaluation of greenhouse gas (GHG)
reduction opportunities by providing a common basis of understanding for prospective technology developers. This
allows them to better frame and quantify the GHG reduction benefits of their technologies. The block material and
heat / energy diagrams are in a similar format as that used for the production of the COSIA Steam Assisted Gravity
Drainage (SAGD) templates.
This report was prepared for COSIA following the development of the flow diagrams to explain the process used to
develop them and their intended use. The report provides a summary of the scope of the project, the objectives and
the deliverables. A discussion of the methods used and the rationale for their selection is provided. Details regarding
the differences associated with Paraffinic Froth Treatment (PFT) and Naphthenic Froth Treatment (NFT) are
outlined and the GHG emissions calculation process is explained. The report concludes with a description of the
flow diagrams and the assumptions used to prepare them.
2.0 SCOPE
The objective of this project was to create four pairs of Excel spreadsheet block flow diagrams for material and
heat / energy for four scenarios considering PFT and NFT. The specific flow diagrams included:
PFT:
− High grade material and heat/energy flow diagrams in summer condition
− Low grade material and heat/energy flow diagrams in winter condition
NFT:
− High grade material and heat/energy flow diagrams
− Low grade material and heat/energy flow diagrams
The reference oil sands mine and extraction reference facility (hereafter called reference facility) is a fictitious
stand-alone mine excluding integration with either an upgrader or adjacent in situ operations. The reference facility
is based on a fixed size of 200,000 bbl/d neat bitumen.
All assumptions for the development of the reference oil sands mine were discussed with and agreed by Tetra Tech
and COSIA.
The project team to complete the four pairs of Excel spreadsheet block flow diagrams is presented in Table 1.
DEVELOPMENT OF A STATIC OIL SANDS MINE AND EXTRACTION REFERENCE FACILITY
FILE: 704-ENV.CENV03071 | JANUARY 12, 2017 | ISSUED FOR USE_REVISION 1
2
Development of a Static Oil Sands Mine and Extraction Reference Facility_Rev1.docx
Table 1: Project Team
Team Member Role
Nelson Lee, M.A.S., P.Eng. Project Manager
Ross Huddleston, M.E.Des. Senior Reviewer
Doug Cox, P.Eng. Senior Technical Advisor
Bruno Dion, P.Eng. Process Engineer
Min Si, M.N.R.M., GHG-V GHG Analyst
Judy Tai, M.A.S., P.Eng. GHG Analyst
3.0 APPROACH
Tetra Tech developed the material and energy flow diagrams for both high grade and low grade ore by PFT and
NFT processes based on publicly available information, mainly environmental impact assessment (EIA) studies.
Key assumptions for the reference facility are presented in Table 2.
Table 2: Key Assumptions
Parameter Reference Facility Source
Bitumen Density 1.007 t/m3 Teck Frontier 2015 Update
Solvent Density (PFT) 0.624 t/m3 Teck Frontier 2015 Update,
isopentane at 20°C
Diluent Density (NFT) 0.665 t/m3 Engineering Toolbox, Naphtha
Natural Gas HHV 40 MJ/m3 Fortis BC
Natural Gas LHV to HHV 1.1 Industrial Practice
Electric Energy Conversion 3.6 GJ/MWh
Solvent/Diluent Losses:
Bitumen producedLess than 0.4 % vol./vol. AER Directives
Solvent : Bitumen ratio – PFT 1.65 wt./wt. Industrial Practice
Diluent : Bitumen ratio – NFT 0.7 wt./wt. Industrial Practice
The major equipment for the PFT and NFT processes included two units of Gas Turbine Generation (GTG), two
units of Heat Recovery Steam Generators (HRSG) with duct burners, and auxiliary boilers. The natural gas
requirement for GTG and HRSG were sourced from the Imperial Oil Kearl Lake EIA and presented in Table 3.
DEVELOPMENT OF A STATIC OIL SANDS MINE AND EXTRACTION REFERENCE FACILITY
FILE: 704-ENV.CENV03071 | JANUARY 12, 2017 | ISSUED FOR USE_REVISION 1
3
Development of a Static Oil Sands Mine and Extraction Reference Facility_Rev1.docx
Table 3: Natural Gas Requirement (GJ/h Lower Heating Value – LHV) per Train
Scenario GTG HRSG
High Grade 865 376
Low Grade 1,032 471
Note: Kearl EIA, one train is 123,000 bbl/d for high grade and 100,000 bbl/d for low grade
Approximate size per unit for each equipment configuration was also sourced from the Kearl Lake EIA and
presented in Table 4.
Table 4: Major Equipment Size
Equipment Approx. Size per Unit
GTG 85 MW
HRSG 292 MW
3.1 COGENERATION
The GHG credit for cogeneration was calculated as directed by COSIA (Personal Communication, Matt McCulloch,
August 12, 2016). The following approach was used:
Allocation to thermal output based on steam generation (assuming an 80% efficient boiler under Specified Gas
Emitters Regulation (SGER) to allocate emissions to the thermal output of cogeneration units.
Allocation to electrical output based on the difference between the cogeneration unit emissions (Gt as reported
under the SGER) and the deemed emissions from heat (Dh).
3.2 STEPS
The following steps were used to develop the flow diagrams.
1. Review of the publicly available information, including EIA studies, Alberta Energy Regulator (AER) reports,
SGER reports, etc.
2. Develop material balance sheets and energy consumption.
3. Prepare draft material flow and energy flow diagrams.
4. Review and comment on the draft diagrams by COSIA’s members.
5. Incorporate COSIA member’s comments and revision of the flow diagrams.
6. Final review of the revised diagrams by COSIA members and agreement to issue final flow diagrams.
7. Final review of flow diagrams issued to COSIA.
DEVELOPMENT OF A STATIC OIL SANDS MINE AND EXTRACTION REFERENCE FACILITY
FILE: 704-ENV.CENV03071 | JANUARY 12, 2017 | ISSUED FOR USE_REVISION 1
4
Development of a Static Oil Sands Mine and Extraction Reference Facility_Rev1.docx
4.0 PARAFFINIC FROTH TREATMENT
The following EIA studies were reviewed by Tetra Tech to guide the development of the flow diagram for PFT.
Teck Frontier
Teck Frontier Project Updates (2015)
Total Joslyn North Mine
Total Joslyn North Mine Updates (2010)
Imperial Kearl Lake
Based on the Scope of Work set out by COSIA, Tetra Tech selected Joslyn North Mine Updates (Joslyn 2010
Update report, 2010) as the basis on which to develop the reference facility. The Joslyn 2010 Update report was
selected because it provided detailed fines content in the material balance sheets.
4.1 PARAFFINIC MATERIAL FLOW
The material flow for the reference facility was developed based on the Joslyn 2010 Update report; Figure 5.3-1 for
high grade summer condition; and Figure 5.3-3 for the low grade winter condition.
Tetra Tech adjusted the two material sheets by:
Removing froth storage;
Removing de-pentanizer and diluent storage;
Prorating the production rate to 200,000 bbl/d; and
Updating the bitumen recovery rate to be consistent with other EIA studies.
Tetra Tech considered the specific parameters for the secondary extraction process based on Tetra Tech’s
knowledge of industrial practices and publicly available information (Table 5).
Table 5: Key Parameters for PFT Material Flow
Parameter Reference Facility
Asphaltene Rejection Approx. 7% *
Asphaltene Content in bitumen product 12%
Solvent Losses: Bitumen Produced 0.3% vol./vol.
Solvent: Bitumen Ratio 1.65% wt./wt.
Water + Solids in Diluted Bitumen Products Less than 0.5%
* expressed as percent of bitumen product
DEVELOPMENT OF A STATIC OIL SANDS MINE AND EXTRACTION REFERENCE FACILITY
FILE: 704-ENV.CENV03071 | JANUARY 12, 2017 | ISSUED FOR USE_REVISION 1
5
Development of a Static Oil Sands Mine and Extraction Reference Facility_Rev1.docx
4.2 PARAFFINIC ENERGY FLOW
To be consistent with material balance, Tetra Tech used the Joslyn 2010 Update report as the basis for natural gas
and diesel requirements (Table 5.4-3), then prorated these requirements to a static 200,000 bbl/d production
volume.
Cooler and exchanger duties (GJ/h) were modeled by Aspen HYSYS based on flow rates and temperature change.
Tetra Tech used the AER ST 39 reports for Kearl, 2014 electricity consumption data to estimate electricity
consumption for the reference facility. June to August was considered as the summer period for high grade ore,
electricity consumption for summer was estimated to be 3,114 MWh/d. January to March was considered as the
winter period for low grade ore, electricity consumption for winter was estimated to be 4,119 MWh/d.
5.0 NAPHTHENIC FROTH TREATMENT
This section provides a description for the development NFT material flow and energy flow diagrams. The following
EIA studies were reviewed by Tetra Tech to guide the development of the flow diagram for PFT.
Syncrude Mildred Lake – 1973
Alsands Oil Sands Mine – 1978
Suncor Steepbank Mine – 1996
Suncor Millennium – 1998
CNRL Horizon – 2002
5.1 NAPHTHENIC MATERIAL FLOW
The naphthenic material flow was developed based on the paraffinic material flow. Ore preparation and primary
extraction were considered to be equivalent for PFT and NFT. Tetra Tech considered the following parameters for
the secondary extraction process based on Tetra Tech’s knowledge of industrial practices and publicly available
information (Table 6).
Table 6: Key Parameters for NFT Material Flow
Parameter Reference Facility
Asphaltene Rejection 0%
Maltene Losses 2%
Diluent Losses: Bitumen Produced Less than 0.4% vol./vol.
Diluent: Bitumen Ratio 0.7% wt./wt.
Water + Solids in Diluted Bitumen Products 3%
Several adjustments were made to the NFT material flow parameters based on information provided by Mr. Oladipo
(Dipo) Omotoso of Suncor (Personal Communication, August 17, 2015).
DEVELOPMENT OF A STATIC OIL SANDS MINE AND EXTRACTION REFERENCE FACILITY
FILE: 704-ENV.CENV03071 | JANUARY 12, 2017 | ISSUED FOR USE_REVISION 1
6
Development of a Static Oil Sands Mine and Extraction Reference Facility_Rev1.docx
5.2 NAPHTHENIC ENERGY FLOW
The Suncor Steepbank and Millennium EIA reports provided thermal energy demand for extraction during average
conditions. The other EIA reports provided combined energy demand including both extraction and upgrading.
As Tetra Tech was not able to separate energy demand between the extraction plant and the upgrader, energy
demand for the NFT process was based on information from the Suncor Steepbank and Millennium EIA reports.
The supply conditions (temperatures) used for the NFT process are provided in Table 7.
Table 7: Supply Conditions for NFT Material Flow
Parameter Supply Conditions
Oil Sands Feed Temperature 1 °C
Make-up Water 10 °C
Diluent Feed 48 °C
6.0 GREENHOUSE GAS EMISSIONS CALCULATIONS
The GHG emissions from stationary combustion (natural gas) and mobile equipment (diesel) were calculated in
accordance with the Alberta SGER’s Technical Guidance for Completing Specified Gas Compliance Reports
(Version 7.0, January 2014) and Alberta Environment and Parks (AEP)’s Carbon Offset Emission Factor Handbook
(Version 1.0, March 2015). Cogeneration GHG emissions were calculated as per COSIA recommendations
(described in Section 4.1 of this report).
Fugitive emissions from mine face and tailings ponds were provided by COSIA, and are presented in Tables 8
through 10.
Table 8: Fugitive Emissions from Mine Face
CH4 (kg/m2/d) CO2 (kg/m2/d)
Low High Low High
High Grade 0 0.000294 0.0001333 0.007648
Low Grade 0 0.000904 0.000007085 0.0129
Table 9: Fugitive Emissions from Tailings Ponds by Paraffinic Froth Treatment Process
CH4 (kg/m2/d) CO2 (kg/m2/d)
Low High Low High
Paraffinic
Biogenic1 0 0 0 0
Non-biogenic 0.00000024 0.000424 0.000743 0.009501
1 All existing PFT ponds are not yet biogenic.
DEVELOPMENT OF A STATIC OIL SANDS MINE AND EXTRACTION REFERENCE FACILITY
FILE: 704-ENV.CENV03071 | JANUARY 12, 2017 | ISSUED FOR USE_REVISION 1
7
Development of a Static Oil Sands Mine and Extraction Reference Facility_Rev1.docx
Table 10: Fugitive Emissions from Tailings Ponds by Naphthenic Froth Treatment Process
CH4 (kg/m2/d) CO2 (kg/m2/d)
Low High Low High
NaphthenicBiogenic 0.0002933 0.028757 0.003504 0.029262
Non-biogenic 0.000000105 0.000832 0.001081 0.03645
7.0 FLOW DIAGRAMS
The material and energy flow diagrams are provided in Appendix A. The diagrams are developed using Excel
spreadsheets. The detailed material compositions in the material flows are provided in the spreadsheets, including
maltene, asphaltene, water, sand, fines, and diluent/solvent. The total energy demand with energy consumption
distribution for both NFT and PFT is included in the material and energy diagrams. The key assumptions and
variables are highlighted in yellow in the spreadsheet.
DEVELOPMENT OF A STATIC OIL SANDS MINE AND EXTRACTION REFERENCE FACILITY
FILE: 704-ENV.CENV03071 | JANUARY 12, 2017 | ISSUED FOR USE_REVISION 1
8
Development of a Static Oil Sands Mine and Extraction Reference Facility_Rev1.docx
8.0 CLOSURE
We thank COSIA for the opportunity to assist in advancing the understanding of this subject and look forward to
further development of this valuable process. We trust this report meets your present requirements. If you have any
questions or comments, please contact the undersigned.
Respectfully submitted,
Tetra Tech Canada Inc.
Prepared by:
Min Si, M.N.R.M., CEM
Energy and GHG Analyst
Direct Line: 403.723.1565
Min.Si@tetratech.com
Prepared by:
Bruno Dion, P.Eng.
Process Engineer
Direct Line: 418.871.3414
Bruno.Dion@tetratech.com
Reviewed by:
Ross Huddleston, M.E.Des., EP(CEA).
Senior Consultant
Direct Line: 403.723.6875
Ross.Huddleston@tetratech.com
DEVELOPMENT OF A STATIC OIL SANDS MINE AND EXTRACTION REFERENCE FACILITY
FILE: 704-ENV.CENV03071 | JANUARY 12, 2017 | ISSUED FOR USE_REVISION 1
Development of a Static Oil Sands Mine and Extraction Reference Facility_Rev1.docx
REFERENCES
Quantifying land use of oil sands production: a life cycle perspective (Sarah M Jordaan, David W Keith, and BradStelfox, Environmental Research Letters 2009 (4), 024004
Heavy Crude Oils: From Geology to Upgrading: an Overview. Alain-Yves Huc, 6.2.3.3 Upgrading
Pembina Institute Forecasting the impacts of oilsands expansion June 2013, Jennifer Grant, Eli Angen and SimonDyer
DEVELOPMENT OF A STATIC OIL SANDS MINE AND EXTRACTION REFERENCE FACILITY
FILE: 704-ENV.CENV03071 | JANUARY 12, 2017 | ISSUED FOR USE_REVISION 1
Development of a Static Oil Sands Mine and Extraction Reference Facility_Rev1.docx
APPENDIX A
MATERIAL AND ENERGY FLOW DIAGRAMS
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.
COSIA Mining & Extraction: High Grade - Naphthenic Froth Treatment - Energy FlowOre Grade wt%Fine Contents wt%Waste to Ore wt%
Processing Plant80 °C
45 °CMine Face 1 °C Ore Preparation 45 °C Primary ExtractionTruck and Shovel 50 °C 50 °C Stripping Steam Legend
78 GJ/h BitumenDiesel Hydrotransport Pump Water
478 GJ/h SteamFuel gas
Deaerated Froth Pump DiluentTailing
AbbreviationsPSC Tailing Pump BFW Boiler Feed Water
CW Cooling WaterCWR Cooling Water Return
225 °C GTG Gas Turbine GeneratiorHHV High Heating ValueHRSG Heat Recovery Steam GeneratorLPS Low Pressure Steam
Diluent Diluent Storage 48 °C MPS Medium Pressure Steam48 °C NRU Naphtha Recovery Unit
Diluent Feed / MPS PSC Primary Separation CellExchanger Duty PW Process Water
199 GJ/hEnergy Output SummaryCogen GTG Electricity
HRSG BFW PreheatingSteam
84 °C Cogen LossesSubtotal - Cogen
99 °C Boilers Steam200,000 bbl of Bitumen/d Boiler Losses
Subtotal - BoilersTotal
Stripping Steam112 GJ/h Flue Gas
Tailing Pond Natural Gas HHVExcess air @ 13% O2 in CogenExcess O2
NRU Tailing Pump Cogen Flue GasCW (Cold) CWR (Warm) CO2 in Flue Gas from Cogen
30 °C 60 °C H2O in Flue Gas from CogenReclaimed Water 10 °C Boiler Flue Gas
CO2 in Flue Gas from BoilersH2O in Flue Gas from Boilers
Condensate 186 °C Flue Gas Temperature - Acid Dew Point LimitFlue Gas - Max. without Economizer
Make Up Water Raw Water Pond Recycled Water 10 °C 53 °C 59 °C 80 °C Hot Water Tank10 °C 10 °C Pond 10 °C 80 °C Exchanger
PW/CW Exchanger Duty PW/Condensate PW/LPS Process Water / Cooling WaterGJ/h Exchanger Duty 255 GJ/h Exchanger Duty Process Water / Condensate
GJ/h Process Water / LPS62 °C Diluent Feed / MPS
10 °C Warm Water Tank45 °C Energy Consumption Summary
99 °C GTG10 °C HRSG
Cogen Losses Building Heating and Flare68 °C 333 GJ/h Boilers
Diesel51 °C Boiler Losses Energy Intensity (GJ / bbl bitumen produced)
MPS Output 25 GJ/h Electricity Generated85% Efficiency 389 GJ/h Electricity Consumed
Cogen Energy Output Auxilary Boiler 266 GJ/h MPSElectricity GJ/h Electricity GHG Emissions Summary
127 MW GJ/h BFW Preheating Stationary Combustion & FlaringGJ/h Steam Mobile Equipment
GTG Duct burner HRSG GJ/h LPS Output Fugitive Mine 0.0001 - 0.0150921 GJ/h Fugitive Pond 0.0119 - 0.8054
GTG Duct Burner HRSG Flue Gas LPS Total Cogen Emissons (Gt)Natural Gas Required GJ/h GJ/h e3m3/h Boilers Boilers Flue Gas Deemed emissions from Heat by Cogen (DH)
GJ/h HHV m3/h m3/h CO2 vol.% GJ/h 147 e3m3/h Deemed emissions from Electricity by Cogen (DE)m3/h Unit Unit H2O vol.% m3/h 9% CO2 vol.% MPS LPSe3m3/sd 121 - 274 °C Efficiency 17% H2O vol.% 100 % Quality 90 % Quality Project: Static Reference Oil Sands Mine and Extraction Reference Facility
unit 121 - 274 °C °C °C Case: Naphthenic - High Grade Revision: V 1.6Natural Gas kPag kPag Owner: COSIA
10 °C 366 GJ/h T/h Stripping Steam T/h Date:Space Heating T/h Processing Heating Energy / Heat FlowPurge Gas to Flare High Temperature Extraction, High Grade, Average Condition
71,9091,726
80 °C
921
38,678 16,8122
2917,27391.5%
2,8766721,547
1,044
457
1,044386
448
5002,069
10404-Oct-1568
MWH/d
°C
1,879255921199
Duty (GJ/h)
Natural Gas
kg CO2e/m2/dkg CO2e/m2/d
t CO2e/d
3,329827
2,569
274
t CO2e/d
GJ/bbl
1211.74.3
2
4
1,879
225 2102,100 1,050
Cogen Facility
2,6604%7%
MWH/d
t CO2e/d
1,547 928GJ/h e3m3/d
6723662914780.40
3,0443,600
4032201750.3
t CO2e/dt CO2e/d
1,547Input (GJ/h) Output (GJ/h)
2,220
291
457
40
e3m3/h
672
291
3861,044333
2,22026625
291
1479%
MJ/m3
vol.%vol.%
°C
%e3m3/h
2,511 2,511
4% vol.%7% vol.%
%179%13%
2,660
17%121
Centrifuge 84 °C
NRU
Diluted Bitumen
Inclined Plate Separator 84 °C
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.
COSIA Mining & Extraction: Low Grade - Naphthenic Froth Treatment - Energy FlowOre Grade wt%Fine Contents wt%Waste to Ore wt%
Processing Plant80 °C
45 °CMine Face 1 °C Ore Preparation 45 °C Primary ExtractionTruck and Shovel 50 °C 50 °C Stripping Steam Legend
90 GJ/h BitumenDiesel Hydrotransport Pump Water
684 GJ/h SteamFuel gas
Deaerated Froth Pump SolventTailing
AbbreviationsPSC Tailing Pump BFW Boiler Feed Water
CW Cooling WaterCWR Cooling Water Return
225 °C GTG Gas Turbine GeneratiorHHV High Heating ValueHRSG Heat Recovery Steam GeneratorLPS Low Pressure Steam
Diluent Diluent 48 °C MPS Medium Pressure Steam48 °C Storage NRU Naphtha Recovery Unit
Diluent Feed / MPS PSC Primary Separation CellExchanger Duty PW Process Water
335 GJ/hEnergy Output Summary Input (GJ/h) Output (GJ/h)Cogen GTG Electricity
HRSG BFW Preheating84 °C Steam
Cogen LossesSubtotal - Cogen
99 °C Boilers Steam200,000 bbl of Bitumen /d Boiler Losses
Subtotal - BoilersTotal
Stripping Steam112 GJ/h Flue Gas
Tailing Pond Natural Gas HHVExcess air @ 13% O2Excess O2
NRU Tailing Pump Cogen Flue GasCW (Cold) CWR (Warm) CO2 in Flue Gas from Cogen
30 °C 60 °C H2O in Flue Gas from CogenReclaimed Water 10 °C Boiler Flue Gas
CO2 in Flue Gas from BoilersH2O in Flue Gas from Boilers
Condensate 186 °C Flue Gas Temperature - Acid Dew Point LimitFlue Gas - Max. without Economizer
Make Up Water Raw Water Pond Recycled Water 10 °C 55 °C 61 °C 80 °C Hot Water Tank10 °C 10 °C Pond 10 °C 80 °C Exchanger
PW/CW Exchanger Duty PW/Condensate PW/LPS Process Water / Cooling WaterGJ/h Exchanger Duty 368 GJ/h Exchanger Duty Process Water / Condensate
GJ/h Process Water / LPS61 °C Diluent Feed / MPS
10 °C Warm Water Tank45 °C Energy Consumption Summary
99 °C GTG10 °C HRSG
Cogen Losses Building Heating and Flare68 °C 475 GJ/h Boilers
Diesel51 °C Boiler Losses Energy Intensity (GJ / bbl bitumen produced)
MPS Output 37 GJ/h Electricity GeneratedCogen Facility 85% Efficiency 537 GJ/h Electricity Consumed
Cogen Energy Output Auxilary Boiler GJ/h MPSElectricity GJ/h Electricity GHG Emissions Summary
175 MW GJ/h BFW Preheating Stationary Combustion & FlaringGJ/h Steam Mobile Equipment
GTG Duct burner HRSG GJ/h LPS Output Fugitive Mine 0.0001 - 0.0150GJ/h Fugitive Pond 0.0119 - 0.8054
GTG Duct Burner HRSG Flue Gas LPS Total Cogen Emissons (Gt)Natural Gas Required GJ/h GJ/h e3m3/h Boilers Boilers Flue Gas Deemed emissions from Heat by Cogen (DH)
GJ/h HHV m3/h m3/h CO2 vol.% GJ/h 218 e3m3/h Deemed emissions from electricity by Cogen (DE)m3/h Unit Unit H2O vol.% m3/h 9% CO2 vol.% MPS LPSe3m3/sd 121 - 274 °C Efficiency 17% H2O vol.% 100 % Quality 90 % Quality Project: A Static Oil Sands Mine and Extraction Reference Facility
unit 121 - 274 °C °C °C Case: Naphthenic - Low Grade Revision: V 1.6Natural Gas kPag kPag Owner: COSIA
10 °C 414 GJ/h T/h Stripping Steam T/h Date:Space Heating T/h Processing Heating Energy / Heat FlowPurge Gas to Flare High Temperature Extraction, Low Grade, Average Condition
40 MJ/m3
4%7%2189%
121
%%
e3m3/hvol.%vol.%
e3m3/hvol.%vol.%
°C
1,074
3,164431
4313,595
630597
1,463475
3,16439437
4313,595
2,4062 2
91.5%
682
t CO2e/dt CO2e/d
100,231 10,778
kg CO2e/m2/dkg CO2e/m2/d
t CO2e/dt CO2e/d
26,838 4314,009 t CO2e/d1,0742,090
1,320
7%
4
04-Oct-15
225 2102,100 1,050
72 642175
3,0581,320
920
1.5
80 °C
4,6401,184
GJ/h
6840.56
4,1983,600
Natural Gas
2,0901,074414431
3,796
180%13%
17%
1,463
2,090
630597
1,463
394
52,257
MWH/dMWH/d
3,6612,9793,796
4%
e3m3/d1,254644249259
GJ/bbl
274 °C
0.4
Duty (GJ/h)3,058368
1,320335
NRU
Diluted Bitumen
Inclined Plate Separator 84 °C
Centrifuge 84 °C
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.
COSIA Mining & Extraction: High Grade - Naphthenic Froth Treatment - Material FlowOre Grade wt%Fine Contents wt%Waste to Ore wt%
Ore Preparation: Conditioning, Crushing and Conveying
Mine Face T/h Crusher Conveyor Feed Rotary BreakerTruck and Shovel 1 °C System 50°C RejectsBitumen 12 wt% Bitumen 4 wt%Water 3 wt% Water 6 wt%Solids 85.6 wt% Solids 90.8 wt%
T/h Hot Process Water 80 °C T/hGland Cooling Water T/h T/h Breaker RejectsWarm Dilution Water 45 °C T/h T/h
Primary Extraction 50 °C Vent to atmosphereT/h
Caustic Stripping Steam 28 T/h Deaerator 40-50 °CNaOH Flotation Froth
Deaerated Froth 77 °C MiddlingsT/h
Bitumen 58 wt%Water 32 wt% Middlings Displacement
Cooling Water T/h Solids 10 wt%
PSC TailingT/h
Bitumen 0.1 wt%Secondary Extraction- Froth Treatment Water 58 wt%
Solids 42 wt%Diluent 955 T/h T/h
IPS CentrifugeWarm Water 19 T/h T/h T/h
59 wt% Bitumen 58 wt% Bitumen1.5 wt% Water 3 wt% Water
Diluent 0 wt% Solids 1 wt% Solids48 °C 0.7 wt/wt Diluent : Bitumen 0.7 wt/wt Diluent : Bitumen
Diluent:Bitumen 0.7 wt / wtDiluent Loss:Bitumen 0.4 vol. / vol.
T/h28 wt% Bitumen Legend38 wt% Water Bitumen12 wt% Solids Water
Steam70 T/h NRU Tailing T/h Fuel Gas
T/h 2 wt% Bitumen DiluentStripping Steam 40 T/h 2 wt% Bitumen 69.8 wt% Water Tailing
76 wt% Water 21 wt% Solids22 wt% Solids 7 wt% Diluent Abbreviations
0.4 wt% Diluent BFW Boiler Feed WaterT/h Bitumen GTG Gas Turbine Generatiorbbl Bitumen HHV High Heating Value
T/h Tailing T/h Diluent HRSG Heat Recovery Steam GeneratorRecycled Water Reclaimed Water T/h Tailing Pond wt / wt Diluent :Bitumen LPS Low Pressure Steam
10 °C 85 % Process Water Recycled vol / vol Diluent : Bitumen MPS Medium Pressure Steamwt% Asphaltene in Bitumen NRU Naphtha Recovery Unitwt% Solids + Water PSC Primary Separation Cell
T/h LossesT/h Bitumen Recovery Summary
Utilities Ore PreparationRaw Water Pond 202 T/h 470 T/h Recovered MPS Primary ExtractionWater treatment Condensate GTG 100 % Quality Froth Treatment (without rejected asphaltenes)
GJ/h kPag Total Bitumen Recoverym3/h °C Asphaltenes Rejection
T/h MW T/h Stripping Steam Total Bitumen Recovery (with rejected asphaltenes)BFW Unit T/h Process Heating
T/h Duct Burner MPS LPS Utility Steam Water Summary (T/H)Make-up Water mg/L TDS GJ/h HRSG 2 Unit 90 % Quality Cooling Water
10 °C mg/L Silica m3/h Efficiency 85 % kPag Heated Watermg/L Hardness Unit °C Reclaimed Water
Make-up Water mg/L TOC GTG Duct Burner HRSG T/h Raw Watermg/L TDS BFWmg/L Silica Boiler Blowdownmg/L Hardness Make-Up Watermg/L TOC Recovered Condensate 470 T/h Boilers LPS Condensate Return
Fresh Water : Bitumen GJ/hvol./vol. Natural Gas Required Space Heating m3/h Project: Static Oil Sands Mine and Extraction Reference Facility
GJ/h Purge Gas to Flare 91.5 % Efficiency Case: Naphthenic - High Grade Revision: V 1.3m3/h GJ/h unit Owner: COSIA
Natural Gas e3m3/sd Auxilary Boiler Date:Boiler Blowdown Material Flow
T/h High Temperature Extraction, High Grade, Average Condition
6
3198.9%
1,977
1,019
928
T/h
23,623
24 5,045412
1211.7
4.3
12,187
17,072227
2,357
5,372
3,514
12,051
2,100225
2
2
68
1,050
448
67216,812
27-Sep-15366
7,273291
1,72671,909
95.2%0.0%
95.2%
8,5795,599
127
2,328
Process Water
12,0512,12720220
104
210515
1,354
1,354
470
2,876
98.0%98.2%
928
173
1,339200,000
8810.7
1,54738,678
20
1.8
1049
203.96
4
14,178
6,05934
202
2,328
2,127
6,0597
0
1
Primary Separation Cell
Flotation & Cyclone
Centrifuge 84 °C
Inclined Plate Separator 84 °C
Diluted Bitumen
NRU
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.
COSIA Mining & Extraction: Low Grade - Naphthenic Froth Treatment - Material FlowOre Grade wt%Fine Contents wt%Waste to Ore wt%
Ore Preparation: Conditioning, Crushing and Conveying
Mine Face T/h Crusher Conveyor Feed Rotary BreakerTruck and Shovel 1 °C System 50°C RejectsBitumen 9 wt% Bitumen 3 wt%Water 6 wt% Water 4 wt%Solids 85 wt% Solids 92 wt%
T/h Hot Process Water 80 °C T/hGland Cooling Water T/h T/h Breaker RejectsWarm Dilution Water 45 °C T/h T/h
Primary Extraction 50 °C Vent to atmosphereT/h
Caustic Stripping Steam 32 T/h Deaerator 40-50 °CNaOH Flotation Froth
Deaerated Froth 77 °C MiddlingsT/h
Bitumen 55 wt%Water 32 wt% Middlings Displacement
Cooling Water T/h Solids 13 wt%
PSC TailingT/h
Bitumen 0.31 wt%Secondary Extraction- Froth Treatment Water 62 wt%
Solids 37 wt%Diluent 955 T/h T/h
IPS CentrifugeWarm Water 19 T/h T/h T/h
59 wt% Bitumen 58 wt% Bitumen1.5 wt% Water 3 wt% Water
Diluent 0 wt% Solids 1 wt% Solids48 °C 0.7 wt/wt Diluent:Bitumen 0.7 wt/wt Diluent:Bitumen
Diluent:Bitumen 0.7 wt/wtDiluent Loss:Bitumen 0.4 vol./vol.
T/h27 wt% Bitumen Legend38 wt% Water Bitumen15 wt% Solids Water20 wt% Diluent Steam
70 T/h NRU Tailing T/h Fuel GasT/h 2 wt% Bitumen Diluent
Stripping Steam 40 T/h 2 wt% Bitumen 66 wt% Water Tailing71 wt% Water 25 wt% Solids26 wt% Solids 6 wt% Diluent Abbreviations0.3 wt% Diluent BFW Boiler Feed Water
T/h Bitumen GTG Gas Turbine Generatiorbbl Bitumen HHV High Heating Value
T/h Tailing T/h Diluent HRSG Heat Recovery Steam GeneratorRecycled Water Reclaimed Water T/h Tailing Pond wt / wt Diluent :Bitumen LPS Low Pressure Steam
10 °C 85 % Process Water Recycled vol / vol Diluent : Bitumen MPS Medium Pressure Steamwt% Asphaltene in Bitumen NRU Naphtha Recovery Unitwt% Solids + Water PSC Primary Separation Cell
T/h LossesT/h Bitumen Recovery Summary
Utilities Ore PreparationRaw Water Pond 267 T/h 694 T/h Recovered MPS Primary ExtractionWater treatment Condensate GTG 100 % Quality Froth Treatment (without rejected asphaltenes)
GJ/h kPag Total Bitumen Recoverym3/h T/h Stripping Steam Asphaltenes Rejection
T/h MW T/h Process Heating Total Bitumen Recovery (with rejected asphaltenes)BFW Unit
T/h Duct Burner MPS LPS Water Summary (T/H)Make-up Water mg/L TDS GJ/h HRSG 2 Unit 90 % Quality Cooling Water
10 °C mg/L Silica m3/h Efficiency 85 % kPag Heated Watermg/L Hardness Unit T/h Reclaimed Water
Make-up Water mg/L TOC GTG Duct Burner HRSG Raw Watermg/L TDS LPS Utility Steam BFWmg/L Silica Water Heating Boiler Blowdownmg/L Hardness Make-Up Watermg/L TOC Recovered Condensate 694 T/h Boilers LPS Condensate Return
Fresh Water : Bitumen GJ/hvol./vol. Natural Gas Required Space Heating m3/h Project: COSIA: A Static Oil Sands Mine and Extraction Reference Facility
GJ/h Purge Gas to Flare 91.5 % Efficiency Case: Naphthenic - Low Grade Revision: V 1.3m3/h GJ/h unit Author Tetra Tech EBA Inc.
Natural Gas e3m3/sd Auxilary Boiler Date:Boiler Blowdown Material Flow
T/h High Temperature Extraction, Low Grade, Average Condition
23928
3,626694
98.2%
6,84915,73119,1933,387
92.3%98.2%89.0%
0%89%
1,354
6
2,479
9201.2
17,451
35 9,267323 863
6,445 26,213
6,526
36,730
3
1,354
928 928T/h
2,099
1,1701,141
1,339200,000
8810.7117
72
44
2,090 2,100
3,654 175 175
22,58019,193
3,387
267
52,257
2
6,0597
203.96
431
414 4
10,778
28
Process Water
2.74,009
100,2312,406 27-Sep-15
1,0500 2 642
515
6,059 1,07434 26,838
Primary Separation Cell
Flotation & Cyclone
FSU 80 °C
Bitumen
Primary Separation Cell
Flotation & Cyclone
Centrifuge 84 °C
Inclined Plate Separator 84 °C
Diluted Bitumen
NRU
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.
COSIA Mining & Extraction: High Grade - Paraffinic Froth Treatment - Energy FlowOre Grade wt%Fine Contents wt%Waste to Ore wt%
Processing Plant78 °C Legend
50 °C BitumenMine Face 5 °C Ore Preparation 50 °C Primary Extraction WaterTruck and Shovel 50 °C 50 °C Stripping Steam Steam
70 GJ/h Fuel gasDiesel Hydrotransport Pump Solvent
515 GJ/h Tailing
Deaerated Froth Pump AbbreviationsBFW Boiler Feed WaterCW Cooling WaterCWR Cooling Water Return
CWR PSC Tailing Pump FSU Froth Settling UnitGTG Gas Turbine Generator
CW HHV High Heating Value225 °C HRSG Heat Recovery Steam Generator
LPS Low Pressure SteamMPS Medium Pressure SteamPSC Primary Separation Cell
Make Up Solvent Solvent Storage PW Process Water20 °C SRU Solvent Recovery Unit
SRU/MPS Exchanger Duty TSRU Tailing Solvent Recovery UnitStrippingg Steam 199 GJ/h
76 GJ/h Energy Output Summary Input (GJ/h)99 °C Cogen GTG Electricity
HRSG BFW PreheatingSteam
103 °C 38 °C Cogen LossesCooler Duty Subtotal - Cogen357 GJ/h Boilers Steam
CW CWR Boiler LossesSubtotal - BoilersTotal
Strippingg Steam Flue Gas - Based on Stochiometric CombustionCW CWR 89 GJ/h Natural Gas HHV
Tailing Pond Excess air @ 13% O2Excess O2Cogen Flue Gas
TSRU Tailing Pump CO2 in Flue Gas from CogenCW (Cold) CWR (Warm) H2O in Flue Gas from Cogen
30 °C 60 °C Boiler Flue GasReclaimed Water 25 °C CO2 in Flue Gas from Boilers
H2O in Flue Gas from BoilersFlue Gas Temperature - Acid Dew Point Limit
Condensate 186 °C Flue Gas - Max. without Economizer
Make Up Water Raw Water Pond Recycled Water 49 °C 56 °C 78 °C Hot Water Tank Exchanger & Cooler25 °C 25 °C Pond 25 °C 78 °C Process Water / Cooling Water
PW/CW Exchanger Duty PW/Condensate PW/LPS Process Water / CondensateGJ/h Exchanger Duty 301 GJ/h Exchanger Duty Process Water / LPS
GJ/h SRU Feed / MPS57 °C Cooler
25 °C Warm Water Tank50 °C Energy Consumption Summary
99 °C GTGHRSG
Cogen Losses Building Heating and Flare63 °C 333 GJ/h Boilers
Diesel51 °C Boiler Losses Energy Intensity (GJ per bbl of bitumen produced)
MPS Output 64 GJ/h Electricity GeneratedCogen Facility 85% Efficiency 434 GJ/h Electricity Consumed
Cogen Energy Output Auxillary Boiler GJ/h MPSElectricity GJ/h Electricity GHG Emissions Summary
127 MW GJ/h BFW Preheating Stationary Combustion & Flaring t CO2e/dGJ/h Steam Mobile Equipment t CO2e/d
GTG Duct burner HRSG GJ/h LPS Output Fugitive Mine 0.0001 - 0.0150 kg CO2e/m2/dGJ/h Fugitive Pond 0.0007 - 0.0201 kg CO2e/m2/d
GTG Duct Burner HRSG Flue Gas LPS Total Cogen Emissons (Gt) t CO2e/dNatural Gas Required GJ/h GJ/h e3m3/h Boilers Boilers Flue Gas Deemed emissions from Heat by Cogen (DH) t CO2e/d
GJ/h HHV m3/h m3/h CO2 vol.% GJ/h 380 e3m3/h Deemed emissions from Electricity by Cogen (DE) t CO2e/dm3/h Unit Unit H2O vol.% m3/h 9% CO2 vol.% MPS LPSe3m3/sd 121 - 274 °C Efficiency 17% H2O vol.% 100 % Quality 90 % Quality Project: Static Oil Sands Mine and Extraction Reference Facility
unit 121 - 274 °C °C °C Case: Paranffic - High Grade Revision: V 2.3.9Natural Gas kPag kPag Owner: COSIA
25 °C 604 GJ/h T/h Stripping Steam T/h Date:Space Heating T/h Processing Heating Energy / Heat FlowPurge Gas to Flare High Temperature Extraction, High Grade, Summer Condition
2,145
78 °C
1,051
38,678 16,8122
75118,78091.5%
3,57589,376
1211.94.3
2
6
1,108
25 °C
1,547 672
457633797
797
2,6604%7%
e3m3/d
04-Oct-15
2252,10010253
2101,050511
515
9284033634510.3
3,142
2,069500
4,137892
1,051
Natural Gas
687
Output (GJ/h)
333
380 e3m3/h9% vol.%
17% vol.%
2,660 e3m3/h4% vol.%7% vol.%
40 MJ/m3179 %
1,547 457672 633
797
121 °C
2,569
MWH/d
1,547672604751
Duty (GJ/h)1,108301
1,051199
GJ/bbl3,044 MWH/d0.49
357
GJ/h
274 °C
751 7512,971 2,971
2,220 2,220751 687
64
13 %
SRU 215 °C FSU 70 - 90 °C
TSRU 90 °C
Bitumen 200,000 bbl/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.
COSIA Mining & Extraction: Low Grade - Paraffinic Froth Treatment - Energy FlowOre Grade wt%Fine Contents wt%Waste to Ore wt%
Processing Plant Legend85 °C Bitumen
45 °C WaterMine Face -3 °C Ore Preparation 45 °C Primary Extraction SteamTruck and Shovel 50 °C 50 °C Stripping Steam Fuel gas
80 GJ/h SolventDiesel Hydrotransport Pump Tailing
735 GJ/hAbbreviations
Deaerated Froth Pump BFW Boiler Feed WaterCW Cooling WaterCWR Cooling Water ReturnFSU Froth Settling Unit
CWR PSC Tailing Pump GTG Gas Turbine GeneratorHHV High Heating Value
CW HRSG Heat Recovery Steam Generator225 °C LPS Low Pressure Steam
MPS Medium Pressure SteamPSC Primary Separation CellPW Process Water
Make Up Solvent Solvent Storage SRU Solvent Recovery Unit2 °C TSRU Tailing Solvent Recovery Unit
SRU/MPS Exchanger DutyStripping Steam 368 GJ/h Flue Gas
73 GJ/h Natural Gas HHV99 °C Excess air @ 13% O2
Excess O2Cogen Flue Gas
100 °C 38 °C CO2 in Flue Gas from CogenCooler Duty H2O in Flue Gas from Cogen341 GJ/h Boiler Flue Gas
CW CWR CO2 in Flue Gas from BoilersH2O in Flue Gas from BoilersFlue Gas Temperature - Acid Dew Point LimitFlue Gas - Max. without Economizer
Stripping SteamCW CWR 101 GJ/h Energy Output Summary
Tailing Pond Cogen GTG ElectricityHRSG BFW Preheating
SteamTSRU Tailing Pump Cogen Losses
CW (Cold) CWR (Warm) Subtotal - Cogen30 °C 60 °C Boilers Steam
Reclaimed Water 2 °C Boiler LossesSubtotal - BoilersTotal
Condensate 186 °CExchanger & Cooler
Make Up Water Raw Water Pond Recycled Water 42 °C 52 °C 85 °C Hot Water Tank Process Water / Cooling Water2 °C 2 °C Pond 2 °C 85 °C Process Water / Condensate
PW/CW Exchanger Duty PW/Condensate PW/ LPS Process Water / LPSGJ/h Exchanger Duty 544 GJ/h Exchanger Duty Treated Water / LPS
2 °C GJ/h SRU / MPS53 °C Cooler
71 °C 210 °C 2 °C Warm Water Tank45 °C Energy Consumption Summary
Treated Water/ 36 GJ/h 99 °C Natural Gas GTGLPS Exchanger Duty HRSG
25 °C Cogen Losses Building Heating and Flare60 °C 475 GJ/h Boilers
Diesel43 °C Boiler Losses Energy Intensity (GJ per bbl of bitumen produced)
MPS Output 182 GJ/h Electricity Generated85% Efficiency 623 GJ/h Electricity Consumed
Cogen Energy Output Auxilary Boiler GJ/h MPSElectricity GJ/h Electricity GHG Emissions Summary
175 MW GJ/h BFW Preheating Stationary Combustion & FlaringGJ/h Steam Mobile Equipment
GTG Duct burner HRSG GJ/h LPS Output Fugitive Mine 0.000007-0.036GJ/h Fugitive Pond 0.0007 - 0.0201
GTG Duct Burner HRSG Flue Gas LPS Total Cogen Emissions (Gt)Natural Gas Required GJ/h GJ/h e3m3/h Boilers Boilers Flue Gas Deemed emissions from Heat by Cogen (DH)
GJ/h HHV m3/h m3/h CO2 vol.% GJ/h e3m3/h Deemed emissions from Electricity by Cogen (DE)m3/h Unit Unit H2O vol.% m3/h CO2 vol.% MPS LPSe3m3/sd 121 - 274 °C Efficiency H2O vol.% 100 % Quality 90 % Quality Project: Static Oil Sands Mine and Extraction Reference Facility
unit 121 - 274 °C °C °C Case: Paraffinic - Low Grade Revision: V 2.3.9Natural Gas kPag kPag Owner: COSIA
2 °C 949 GJ/h T/h Stripping Steam T/h Date:Space Heating T/h Processing Heating Energy / Heat FlowPurge Gas to Flare High Temperature Extraction, Low Grade, Winter Condition
40 MJ/m3
2,090
3,164
2,143
630
vol.%17% vol.%121 °C
2,143
1,074
Output (GJ/h)Input (GJ/h)
5,307
MWh/dMWh/d
2,143 1,286735
36368
1,840
Duty (GJ/h)
Cogen Facility
156,398 53,5743,754
291.5%
2
6
04-Oct-15
1,876
17%
1,522538
538
1961
3,7964%7%
1,0839%
630
6,256 26,838 2,143
2,1941,840
85 °C
1,074
7,2401,274
3,661
682
t CO2e/dt CO2e/d
kg CO2e/m2/d
t CO2e/d
192
225 2102,100 1,050111 895
4,119
920
1.5
kg CO2e/m2/dt CO2e/dt CO2e/d2,090
52,2571,074
180% %13% %
3,796 e3m3/h4% vol.%7% vol.%
1,083 e3m3/h9%
5442,194
2,979
GJ/h e3m3/d
274 °C
3,164
2,143
644949 570
1,2542,090
341
0.50.84 GJ/bbl
1,961182
1,522538475
5,307
4,198
SRU 215 °C FSU 70 - 90 °C
TSRU 90 °C
Bitumen 200,000 bbl/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.
COSIA Mining & Extraction High Grade - Paraffinic Froth Treatment - Material FlowOre Grade wt%Fine Contents wt%Waste to Ore wt%
Ore Preparation: Conditioning, Crushing and Conveying
Mine Face T/h Crusher Conveyor Feed Rotary BreakerTruck and Shovel 5 °C System 50°C RejectsBitumen 12 wt% Bitumen 3 wt%Water 3 wt% Water 6 wt%Solids 85.3 wt% Solids 91 wt%
T/h Hot Process Water 80 °C T/hGland Cooling Water T/h T/h Breaker RejectsWarm Dilution Water 45 °C T/h T/h
SG 1.5-1.6Primary Extraction 50 °C Vent to atmosphere
T/hCaustic Stripping Steam 30 T/h Deaerator 40-50 °CNaOH Flotation Froth
Deaerated Froth 77 °C MiddlingsT/h
Bitumen 60 wt%Water 28 wt% Middlings Displacement
Cooling Water T/h Solids 12 wt%
PSC TailingT/h
Bitumen 0.3 wt%Secondary Extraction- Froth Treatment Water 60 wt%
Solids 40 wt%Make Up Solvent 4 T/h Solvent - Bitumen to SRU T/h
Bitumen 38 wt%Gland Cooling Water 61 T/h Solvent to Bitumen 1.65 wt/wt
Bitumen 10.4 wt%Solvent Make up Water 62 wt% Stripping Steam 33 T/h Legend
20 °C Solids 23 wt% BitumenWater
Recovered Solvent Tailing to TSRU T/h SteamT/h SRU Recovered Water 34 T/h Fuel gas
Solvent Loss : Bitumen Gland Cooling Water 143 T/h Solvent0.3 % vol./vol. TSRU Tailing Tailing
T/hStripping Steam 39 T/h Bitumen 7 % Abbreviations
Water 70 % BFW Boiler Feed WaterSolids 21 % FSU Froth Settling Unit
GTG Gas Turbine Generator51 T/h HHV Higher Heating Value
T/h HRSG Heat Recovery Steam GeneratorLPS Low Pressure Steam
bbl/sd MPS Medium Pressure SteamBitumen 99.9 % PSC Primary Separation Cell
T/h Tailing Asphaltene 12.0 % SG Specific GravityRecycled Water Reclaimed Water 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 SolidsTOC Total organic carbon TSRU Tailing Solvent Recovery Unit
T/h LossesT/h Bitumen Recovery Summary
Utilities Ore PreparationRaw Water Pond 241 T/h 479 T/h Recovered MPS Primary ExtractionWater treatment Condensate GTG 100 % Quality Froth Treatment (without rejected asphaltenes)
GJ/h °C Total Bitumen Recoverym3/h kPag Asphaltenes Rejection
T/h MW T/h Stripping Steam Total Bitumen Recovery (with rejected asphaltenes)Unit T/h Processing Heating
Duct Burner MPS LPS Water Summary (T/H)Make-up Water BFW GJ/h HRSG 2 Unit 90 % Quality Cooling Water
25 °C T/h m3/h Cogen Efficiency 85 % °C Heated Watermg/L TDS Unit kPag Reclaimed Water
Make-up Water mg/L Silica GTG Duct Burner HRSG T/h Raw Watermg/L TDS mg/L Hardness BFWmg/L Silica mg/L TOC LPS Utility Steam Boiler Blowdownmg/L Hardness Make-Up Watermg/L TOC Recovered Condensate 479 T/h Boilers LPS Condensate Return
Fresh Water : Bitumen GJ/hvol./vol. Natural Gas Required Space Heating m3/h Project: A Static Oil Sands Mine and Extraction Reference Facility
GJ/h HHV Purge Gas to Flare 91.5 % Efficiency Case: Paraffinic - High Grade Revision: V 2.7.7m3/h unit Owner: COSIA
Natural Gas e3m3/sd GJ/h Auxilary Boiler Date:25 °C Boiler Blowdown Material Flow
T/h High Temperature Extraction, High Grade, Summer Condition
2,145
2
2,255
2,480
16,531
241
2,721
2.03
203.96
6,0597
6,059
034
38,678
3,57589,376
14,0512,48024121
4792,721
04-Oct-15604
18,780
2,204
2252,100
751
2
102
210
200,000
21
Process Water
6
1211.9
4.3
18,888244
4,396
13,142
99.0%
6,217
26 5,918441
2,443
14,051
1,382
26,634
94.6%
3,546
1,217
5,769
6
33
515
127
98.4%92.2%7.6%
85.1%
10,314
53
5111,050
67216,812
1,547
PSC
Flotation & Cyclone
TSRU 90 °C
FSU 70-90 °C SRU 215 °C
Bitumen
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.
COSIA Mining & Extraction Low Grade - Paraffinic Froth Treatment - Material FlowOre Grade wt%Fine Contents wt%Waste to Ore wt%
Ore Preparation: Conditioning, Crushing and Conveying
Mine Face T/h Crusher Conveyor Feed Rotary BreakerTruck and Shovel -3 °C System 50°C RejectsBitumen 8.6 wt% Bitumen 3 wt%Water 6.4 wt% Water 4 wt%Solids 85 wt% Solids 92.5 wt%
T/h Hot Process Water 80 °C T/hGland Cooling Water T/h T/h Breaker RejectsWarm Dilution Water 45 °C T/h T/h
SG 1.5-1.6Primary Extraction 50 °C Vent to atmosphere
T/hCaustic Stripping Steam 35 T/h Deaerator 40-50 °CNaOH Flotation Froth
Deaerated Froth 77 °C MiddlingsT/h
Bitumen 53 wt%Water 35 wt% Middlings Displacement
Cooling Water T/h Solids 12 wt%
PSC TailingT/h
Bitumen 0.38 wt%Secondary Extraction- Froth Treatment Water 54 wt%
Solids 46 wt%Make Up Solvent 3.5 T/h Solvent - Bitumen to SRU T/h
Bitumen 33 wt%Gland Cooling Water 72 T/h Solvent to Bitumen 1.65 wt/wt
Bitumen 8.2 wt%Solvent Make up Water 67 wt% Stripping Steam 32 T/h Legend
2 °C Solids 22% wt% BitumenWater
Recovered Solvent Tailing to TSRU T/h SteamT/h SRU Recovered Water 33 T/h Fuel gas
Solvent Loss : Bitumen Gland Cooling Water 168 T/h Solvent0.3 % vol./vol. TSRU Tailing Tailing
T/hStripping Steam 44 T/h Bitumen 7 % Abbreviations
Water 70.1 % BFW Boiler Feed WaterSolids 20.5 % FSU Froth Settling Unit
GTG Gas Turbine Generator47 T/h HHV Higher Heating Value
T/h HRSG Heat Recovery Steam GeneratorLPS Low Pressure Steam
bbl/sd MPS Medium Pressure SteamBitumen 99.9 % PSC Primary Separation Cell
T/h Tailing Asphaltene 12 % SG Specific GravityRecycled Water Reclaimed Water T/h Tailing Pond Solids + Water 0.04 % SRU Solvent Recovery Unit
2 °C 85 % Process Water Recycled Asphaltene Rejection 7.7 % TDS Total Dissolved SolidsTOC Total organic carbon TSRU Tailing Solvent Recovery Unit
T/h LossesT/h Bitumen Recovery Summary
Utilities Ore PreparationRaw Water Pond 384 T/h 925 T/h Recovered MPS Primary ExtractionWater treatment Condensate GTG 100 % Quality Froth Treatment (without rejected asphaltenes)
GJ/h °C Total Bitumen Recoverym3/h kPag Asphaltenes Rejection
T/h MW T/h Stripping Steam Total Bitumen Recovery (with rejected asphaltenes)Unit T/h Process Heating
Duct Burner MPS LPS Water Summary (TPH)Make-up Water BFW GJ/h HRSG 2 Unit 90 % Quality Cooling Water
2 °C T/h m3/h Cogen Efficiency 85 % °C Heated Watermg/L TDS Unit kPag Reclaimed Water
Make-up Water mg/L Silica GTG Duct Burner HRSG T/h Raw Watermg/L TDS mg/L Hardness BFWmg/L Silica mg/L TOC LPS Utility Steam Boiler Blowdownmg/L Hardness Make-Up Watermg/L TOC Recovered Condensate 925 T/h Boilers LPS Condensate Return
Fresh Water : Bitumen GJ/hvol./vol. Natural Gas Required Space Heating m3/h Project: A Static Oil Sands Mine and Extraction Reference Facility
GJ/h Purge Gas to Flare 91.5 % Efficiency Case: Paraffinic - Low Grade Revision: V 2.7.7m3/h GJ/h unit Owner: COSIA
Natural Gas e3m3/sd Auxilary Boiler Date:Boiler Blowdown Material Flow
50 T/h High Temperature Extraction, Low Grade, Winter Condition
32,406
6,0597
203.9
3,754
62,143
2.25
0
53,574
515
6,05934
17,51614,889
04-Oct-15
6,256156,398 949 6
200,000
1,751
2
2,627
384
52,257 2100
60
2,090 225
3,012 1752
111
105026,838
2,251
2,251
347 9281,716 26,417
7,017
1,074
3,548
1,551
192
210
7
2,773
9201.5
18,765
38 8,195
925
98.2%
7,6059,91114,8892,627
92.3%98.4%89.1%7.7%82.3%
895
Process Water
38450
3,012
Primary Separation Cell
Flotation & Cyclone
TSRU 90 °C
FSU 70-90 °C SRU 215 °C
Bitumen
DEVELOPMENT OF A STATIC OIL SANDS MINE AND EXTRACTION REFERENCE FACILITY
FILE: 704-ENV.CENV03071 | JANUARY 12, 2017 | ISSUED FOR USE_REVISION 1
Development of a Static Oil Sands Mine and Extraction Reference Facility_Rev1.docx
APPENDIX B
TETRA TECH’S GENERAL CONDITIONS
1
GENERAL CONDITIONS
GEOENVIRONMENTAL REPORT
This report incorporates and is subject to these “General Conditions”.
1.1 USE OF REPORT AND OWNERSHIP
This report pertains to a specific site, a specific development, and a specific scope of work. It is not applicable to any other sites, nor should it be relied upon for types of development other than those to which it refers. Any variation from the site or proposed development would necessitate a supplementary investigation and assessment.
This report and the assessments and recommendations contained in it are intended for the sole use of TETRA TECH’s client. TETRA TECH does not accept any responsibility for the accuracy of any of the data, the analysis or the recommendations contained or referenced in the report when the report is used or relied upon by any party other than TETRA TECH’s Client unless otherwise authorized in writing by TETRA TECH. Any unauthorized use of the report is at the sole risk of the user.
This report is subject to copyright and shall not be reproduced either wholly or in part without the prior, written permission of TETRA TECH. Additional copies of the report, if required, may be obtained upon request.
1.2 ALTERNATE REPORT FORMAT
Where TETRA TECH submits both electronic file and hard copy versions of reports, drawings and other project-related documents and deliverables (collectively termed TETRA TECH’s instruments of professional service); only the signed and/or sealed versions shall be considered final and legally binding. The original signed and/or sealed version archived by TETRA TECH shall be deemed to be the original for the Project.
Both electronic file and hard copy versions of TETRA TECH’s instruments of professional service shall not, under any circumstances, no matter who owns or uses them, be altered by any party except TETRA TECH. The Client warrants that TETRA TECH’s instruments of professional service will be used only and exactly as submitted by TETRA TECH.
Electronic files submitted by TETRA TECH have been prepared and submitted using specific software and hardware systems. TETRA TECH makes no representation about the compatibility of these files with the Client’s current or future software and hardware systems.
1.1 NOTIFICATION OF AUTHORITIES
In certain instances, the discovery of hazardous substances or conditions and materials may require that regulatory agencies and other persons be informed and the client agrees that notification to such bodies or persons as required may be done by TETRA TECH in its reasonably exercised discretion.
1.2 INFORMATION PROVIDED TO TETRA TECH BY OTHERS
During the performance of the work and the preparation of the report, TETRA TECH may rely on information provided by persons other than the Client. While TETRA TECH endeavours to verify the accuracy of such information when instructed to do so by the Client, TETRA TECH accepts no responsibility for the accuracy or the reliability of such information which may affect the report.