Demonstration of oxy-fuel combustion in once-through steam generators

Demonstration of oxy-fuel combustion in once-through steam generators for CO 2 capture Carbon Capture & Storage Workshop 28 March, 2013 The High Commission of Canada, Canada House, London Prepared by: Mark Bohm (Suncor) Capture Team Member Mark Crombie (BP): CCP 3 Program Manager Presented by: Mark Crombie (BP): CCP 3 Program Manager

CCP Project Overview The CO 2 Capture Project (CCP) is an award-winning partnership of several major energy companies working to advance the technologies that will underpin the deployment of industrial-scale CO 2 capture and storage (CCS). The CCP is currently in its third phase of activity: • • • Phase 1 (CCP 1, 2001 -2004) technology screening/proof of concept – completed Phase 2 (CCP 2, 2004 -2009) intensive development – completed Phase 3 (CCP 3, 2009 -2013) demonstration – on going The CCP is funded primarily by: • Member contributions • Government grants • In-kind contributions

CCP Mission Statement “To develop technologies that will reduce the risks of and further advance CO 2 capture and geological storage; making CCS a practical reality for atmospheric carbon mitigation” How does CCP work? Collaboration of leading oil & gas companies, government, NGOs, academic institutions, • Current members are BP, Chevron, ENI, Petrobras, Shell and Suncor • Over 200 joint projects to date, broad scope ranging from policy to technology development, R&D and knowledge sharing • Incorporates oil & gas industry expertise + power industry experience • CCP is now a leading authority on CCS, sharing research findings 3

OTSG - Importance of Capture Solution • 80 -85% of oil sands are currently accessible only through in-situ production methods; these are less invasive than mining and with a smaller environmental footprint • SAGD is the leading technology, but is more energy and GHG intensive because of the large steam requirements • Current carbon emissions from SAGD facilities exceed 25 Mt/yr, and are expected to be the oil sand sector’s largest source of future emission growth • A cost-effective solution for CO 2 capture from once-through steam generators (OTSG) is needed for both greenfield and retrofit applications CCP and its Partners recognize the importance of an economic, retrofitable CCS solution for OTSGs 4

Unparalleled Project Team Expertise Project Lead: Suncor Funding Partners: Cenovus Energy (host site), CO 2 Capture Project, Devon, Praxair, Statoil, MEG Energy Technology Providers: Praxair – industrial gas & combustion technology 5

Potential CCS Solutions for OTSGs Amines Oxy-fuel • Requires solvents; potential source of secondary emissions • 90% Capture rate • Large steam requirements • Commercially available • No solvents needed; near zero emissions • 99% Capture rate • Requires power • Need to demonstrate oxy-fuel burners and CO 2 purification 6

Oxy-fuel Technology for OTSGs Air Separation Unit (ASU) Oxygen Nitrogen Flue Gas Recirculation Vent of Non-Condensable Gases ( N 2, Ar, excess O 2) Flue gas Fuel OTSG-Boiler (CO 2 - rich) CO 2 Processing Unit (CPU) CO 2 Water • Key Technologies • ASU – Air Separation Technology • CPU – CO 2 Separation and Compression Technology • Large Plant Engineering (Design, Construct, Operate, Maintain) • Oxy-Fuel Combustion Technology • Safety, System Integration and Optimization Key to Success: Integration and Optimization of Existing Technologies 7

Overview of Project Three Phase Project: • Phase I (completed): Develop design basis and cost estimates for test and commercial scale OTSG • Phase II (2013): Pilot oxy-fuel combustion on 50 mmbtu/hr test boiler • Phase III (2014+): Pilot oxy-fuel combustion, compression and purification on test boiler Overall Objective: To demonstrate that oxy-fuel combustion is a safe, reliable and cost-effective technology for CO 2 capture from once-through steam generators 8

Phase II - Oxy-fuel Boiler Test • Existing commercial OTSG Boiler at Cenovus Energy - Christina Lake • Retrofit with flue gas recirculation • Installation of oxygen supply and control integration OTSG-Boiler Liquid Oxygen Natural Gas Oxygen (gas) Steam Flue gas ~95% CO 2 + H 2 O Evaporator FGR Damper Eco Feedwater Flue Gas Recirculation FD-Fan Air Damper Air Project will demonstrate technical viability and safety of oxy-fuel combustion at operating in-situ site 9

Oxy-Fuel Technology Challenges • • Heat transfer changes in boiler versus air combustion Burner design for desirable flame shape and stability Material temperature limits, scale-up, emissions Startup, operation, boiler performance and controls Net Heat Flux on Boiler Tubes (W/m 2) Gas Temperature (o. F) Air Baseline 140, 000 0 2, 000 1, 000 Oxy-fuel Mixture of FGR and Oxygen 10

Oxy-Fuel Burner Designs Oxygen Mixer • uses existing Coen burner → • potential limitations on flame stability and heat transfer profile A-Burner • high degree of flame and heat transfer adjustment • water cooled JL-Burner • very simple design • need to prove operation at commercial scale Natural Gas Oxygen Sparger to mix oxygen into FGR Natural Gas Oxygen Existing Air Burner Flue Gas Recirculation Existing Opening A-Burner with new burner block Flue Gas Recirculation Oxygen Natural Gas Existing Opening JL-Burner with new burner block Flue Gas Recirculation 11

Technical Demonstration Goals • Establish operating parameters for oxy-fuel combustion applied to SAGD boilers (heat transfer, steam flow and quality) • Confirm CFD model predictions with test results • Identify and understand scale-up issues and retrofit risks • Startup and control boiler to suit process needs • Verify boiler NOx emissions with test measurements Goal: Reliable Oxy-fuel Operation with known capture costs 12

Project Summary Project addresses significant and growing source of GHG emissions in Alberta • CO 2 capture is an option as large facilities exist (for retrofits or greenfield) Strong Group of Committed Participants • Consortium of energy companies working towards a common solution • World leading technology providers Compelling Technology Solution • Oxy-fuel combustion with flue gas purification is expected to have a cost advantage over amine systems • Applicable to other combustion sources including upgrading and refining 13

Thank You Mark Bohm, P. Eng Suncor Energy Tel: 403 513 -4613 Email: mbohm@suncor. com Mark Crombie, MBA BP Alternative Energy Tel: 0779 886 924 Email: mark. crombie@uk. bp. com 14