Law heavy oil techology.pdf
Transcript of Law heavy oil techology.pdf
SPE Distinguished Lecturer Program
Primary funding is provided by
The SPE Foundation through member donations and a contribution from Offshore Europe
The Society is grateful to those companies that allow their professionals to serve as lecturers
Additional support provided by AIME
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Society of Petroleum Engineers Distinguished Lecturer Programwww.spe.org/dl
A New Heavy Oil Recovery Technology to Maximize Performance andto Maximize Performance and
Minimize Environmental Impact
David H.-S. LawSchlumbergerHeavy Oil Technical DirectorNorth America
Society of Petroleum Engineers Society of Petroleum Engineers Distinguished Lecturer Programwww.spe.org/dl
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OutlineOutline• Global perspective of heavy oilp p y• Overview of recovery processes
– Steam-based thermal processesS ea based e a p ocesses• Environmental impacts from current
heavy oil recoveryy y• Technology development to meet
environmental challengesg– Hybrid steam-solvent process: from
research concept to field pilots
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• Conclusions
Heavy OilHeavy OilHeavy Oil: Crude Oil with API < 22.3°(sp. gr. = 0.92)
API Gravity Viscosity (cp)Heavy Oil 10º – 22.3º 100 – 10,000 Oil Resources
Extra Heavy Oil < 10º 100 – 10,000Bitumen < 10º > 10,000 Conventional
Heavy Oil
15%Conventional
Heavy Oil
15%
Source: 12th World Petroleum Congress (WPC), 1987
Total World Crude Oil Resources:
oil 30% Extra Heavy
Oil 25%
oil 30% Extra Heavy
Oil 25%Total World Crude Oil Resources:
9 – 13 trillion bbls Bitumen & Oil Sands
30%
25%Bitumen & Oil Sands
30%
25%
More than 2/3 of total oil resources
4Source: International Energy Agency (IEA)
More than 2/3 of total oil resources are heavy oil and bitumen
Global Heavy Oil ResourcesGlobal Heavy Oil Resources
5
Heavy oil can be found in all continents both on-shore & off-shore except Antarctica 5
Global Heavy Oil ReservesGlobal Heavy Oil Reserves
Billion bbls in Place(by Country)
6
Heavy oil can be found in all continents both on-shore & off-shore except Antarctica
Source: http://www.HeavyOilinfo.com
(by Country)350+ 10+50+ <10
Global Heavy Oil ProductionGlobal Heavy Oil ProductionCanada
Oil Sands1000
HO ProductionUK
CanadaOil Sands
1000
CanadaOil Sands
1000Oil Sands
1000HO ProductionHO ProductionUKUK1000
InsituBitumen400
USA
KBOPD
Egypt
55
200
API 11-20India
30
API 15-17
1000
InsituBitumen400
1000
InsituBitumen400
1000
InsituBitumen400
USAUSA
KBOPDKBOPD
Egypt
55
Egypt
55
200
API 11-20
200
API 11-20India
30
API 15-17
India30
API 15-17
China180
API 8-18
Mexico
USA
320
API 9-19 Trinidad
55
Iraq65
API 16
API 12-20
China180
China180
API 8-18API 8-18
MexicoMexico
USA
320
API 9-19
USA
320
API 9-19 Trinidad
55
Trinidad
55
Iraq65
API 16
Iraq65
API 16
API 12-20API 12-20
API 12-20
IndonesiaDuriOmanYemen
Venezuela629Colombia
MexicoCantarrel
2080
55
API 15-20API 16
API 12-20API 12-20
IndonesiaDuri
IndonesiaDuriDuriOmanOmanYemenYemen
Venezuela629
Venezuela629ColombiaColombia
MexicoCantarrel
2080
MexicoCantarrel
2080
55
API 15-20
55
API 15-20API 16API 16
HO35
Duri210
API 15-20
Oman35
API 15-20
15API 19-20
629
API 7-20Ecuador25
80
API 12-20HO340
API 11-20
HO35
Duri210
API 15-20
HO35
Duri210HO
35
Duri210
API 15-20
Oman35
API 15-20
Oman35
API 15-20
15API 19-20
15API 19-20
629
API 7-20
629
API 7-20Ecuador25
Ecuador25
80
API 12-20
80
API 12-20HO340
API 11-20
HO340
API 11-20
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Brazil
250
API 11-20
API 14-20API 11-20
Source : Oil and Gas Journal Dec 2005; Upstream Mar 2006
Brazil
250
API 11-20
Brazil
250
API 11-20
API 14-20API 14-20API 11-20API 11-20
Source : Oil and Gas Journal Dec 2005; Upstream Mar 2006 7
Global in-situ heavy oil production ≈ 5 million bbl/day
Variety of Viscous OilsVariety of Viscous Oils10,000,000
oir T CanadaBitumen
Viscosity Reduction(Add Heat or Solvent)
100,000
1,000,000
at re
serv
o
USVenezuela/ColombiaChinaIndia/Indonesia
Bitumen (Add Heat or Solvent)
100
1,000
10,000
ity (c
p) a India/Indonesia
USCanada
Primary Production;
1
10
100
Visc
osi
ExtraHeavy Oil
Heavy Oil
Water Flooding; EOR
0 5 10 15 20 25 30 35 40 45 500.1
1
Source: OGJ EOR Survey (April 2004)API Gravity
There are many ways to recover heavy oil8
Heavy Oil Recovery ProcessesHeavy Oil Recovery ProcessesRecovery Processes Surface Mining
Primary Non-ThermalThermal
Cold ProductionCHOPS
Water FloodingChemical FloodingVAPEX
CombustionFire FloodingTHAI
Steam-BasedCSSFloodingSAGDSAGD
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CHOPS: Cold Heavy Oil Production with SandsCSS: Cyclic Steam StimulationSAGD: Steam Assisted Gravity DrainageTHAI: Toe-to-Heel Air InjectionVAPEX: Vapour Extraction
Steam-based thermal recovery processes are most extensively used
Cyclic Steam Stimulation (CSS)(CSS)
CSS
• Single well operation• Injection/production• Injection/production
cycle:– Steam injectionj– shut-in (soak)– Oil production
R f (RF)• Recovery factor (RF) ≈15% OOIP (original oil-in-place)
10Source: http://www.HeavyOilinfo.com
SteamfloodingSteamfloodingSteamflooding
• Multi-well operation in regular pattern
g
regular pattern• Inject steam into one or
more wells• Drive oil to separate
producers• Recovery factor (RF) ≈
50% OOIP
11Source: http://www.HeavyOilinfo.com
Steam-Assisted Gravity Drainage (SAGD)(SAGD)
SAGD• Horizontal well pair near
bottom of pay
SAGD
bottom of pay– Upper steam injector – Lower oil producer
S h b i d• Steam chamber rises upward, then, spreads sideway
• Oil drains downward toOil drains downward to producer
• Recovery factor (RF) > 50% OOIP
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OOIPSource: http://www.HeavyOilinfo.com
Steam-Based Thermal R PRecovery Processes
• Very energy intensive and inefficienty gy
Steam Transmission Well to Flow in Thermal Efficiency for Each Stage:
Generator(75 – 85%)
to Well(75 – 95%)
Reservoir(80 – 95%)
Reservoir(25 – 75%)
• Significant environmental impacts
Source: Butler, “GravDrain’s Blackbook”, (1998)
Final Efficiency: 11% - 58%Significant environmental impacts– Land: Surface footprint– Air: Greenhouse gas (GHG) emission
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g ( )– Water: Water usage and disposal
Surface FootprintSurface Footprint• Small well spacing for heavy oil
– less than 10 acres pattern for CSS and Steam flooding
1 000 ll>15,000 wells in ~60 km2
(~23 mile2)(~23 mile2)
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Chevron Steamflooding OperationKern River, California, USA
Surface FootprintSurface Footprint• Reduce surface footprint with horizontal or
multi-lateral wells (e.g., SAGD)CNRL CSS Operation with
Horizontal WellsHorizontal WellsPrimrose, Alberta, Canada
(62,000 bbl/d)
ESSO CSS Operation with
Reduce Surface Footprint
ESSO CSS Operation with Vertical Wells
Cold Lake, Alberta, Canada
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(140,000 bbl/d)
Sources: Google Satellite MapSources: Energy Resources Conservation Board (ERCB) of Alberta
Surface FootprintSurface Footprint• Reduce surface footprint (further) with SAGD p ( )
well pairs
Suncor Firebag SAGD Operation with Horizontal Well-Pairs, Su co ebag S G Ope at o t o o ta e a s,Athabasca, Alberta, Canada (35,000 bbl/day/Stage)
Central Plant Central Plant Stage 2 PadsCentral Plant Stage 2 Pads
Stage 1 PadsPads
Stage 1 Pads
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Greenhouse Gas EmissionGreenhouse Gas Emission• GHG emission from steam generation at 250°C
– Burning natural gas (CO2 emission = 0.532 tonne/Mscf)Environmental Canada Data158.1160 CSS & Steamflooding
105.4
131.8
100
120
140
CO2
SAGD
Reduced GHG
Emission52.7
79.1
60
80
100Emission (kg) / Oil Recovery
(bbl)
Improved
Emission26.4
20
40(bbl)
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Improved SOR0
1 2 3 4 5 6
Steam-Oil Ratio (SOR)
Water Usage and Disposal• Water usage for steam generation
Water Usage and Disposal
5
6
5
6 CSS & Steamflooding
SAGD
3
44Water Usage (bbl)
SAGD
Reduced
2
3
2
3/ Oil Recovery
(bbl)
Water Usage
1
0
1
1 2 3 4 5 6
Improved SOR
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1 2 3 4 5 6
Steam-Oil Ratio (SOR)SOR
Concept for New TechnologyConcept for New Technology• Steam-only
M th d t
Fasty
– Heat transfer controlled– High oil rate– High energy and water
Methods to Reduce
Viscosity: – High energy and water requirements
– Commercial applicationsSolvent only
Slow
• Solvent-only– Diffusion/dispersion
controlled– Low oil rate– Low energy and water
requirements
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– Field pilot stage
Courtesy of Alberta Research Council (ARC)
Hybrid Steam-Solvent ProcessesHybrid Steam Solvent Processes• Synergize advantages Heaty g g
of steam and solvent processes
• Enhance oil rates and lower SOR
• Reduce environmental• Reduce environmental impact
Hybrid Steam-Solvent
SteamSolvent Steam + SolventSolvent + Steam
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Co-inject small amount small amount of solvent with steam
Technology DevelopmentH b id St S l t PHybrid Steam-Solvent Processes
Laboratory Studies• Proof of concept• Property measurements• Scale up• Scale-up
Workflow
N i l M d lli
Workflow
Numerical Modelling• Model validation• Mechanistic Analysis• Field-scale prediction
Field Application• Pilot tests• Commercial Operation
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Field scale prediction
Hybrid Steam-Solvent ProcessesHybrid Steam Solvent Processes
• Nomenclature SAGD mode: ES-SAGD and SAPNomenclature– Expanding Solvent-SAGD
(ES-SAGD)– Solvent Aided-Process– Solvent Aided-Process
(SAP)– Liquid Addition to Steam for
Enhancing RecoveryEnhancing Recovery (LASER)
– Many more ….• Different strategies:
CSS mode: LASER• Different strategies:
– Solvent selection– Steam - solvent ratio
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– Continuous or cyclic
Laboratory StudiesS l t S l tiSolvent Selection
• Hexane and diluents (a solvent mixture)– Evaporation temperatures closest to steam temperature– Steam-solvent ratio = 64 (by vol.)
“1-D” ES-SAGD Experiments
23ES-SAGD: Nasr, et al., JCPT (2003)
Courtesy of Alberta Research Council (ARC), Canada
Laboratory StudiesP f f C tProof of Concept
• ES-SAGD versus steam-only• Continuous diluents co-injected with steam
– Steam-solvent ratio = 6.9 (by vol.)12
“2-D” Scale-Model Experiments
8
10
12
e (g
/min
) ES-SAGDSAGD
4
6od
uctio
n Ra
te
0
2Oil
Pro
24Nasr and Ayodele, SPE 101717 (2006)Deng, et al., WHOC (2006)
Courtesy of Alberta Research Council (ARC), Canada0 90 180 270 360 450
Time (min)
ES-SAGD:
Numerical ModelingM d l V lid tiModel Validation
• History match of 2 D scale model experiments• History match of 2-D scale-model experiments
9
12
g/m
in) Test
Simulation
Oil
Temperature Profile @ 240 minutes °C
3
6
Oil
Prod
uctio
n Ra
te (Oil
Production Rate
@ 240 minutes C
00 90 180 270 360 450
Time (min)
O
6
min
) Test
Lab Test
2
4
Pro
duct
ion
Rat
e (g
/m Simulation
Solvent Production
Rate
25ES-SAGD: Deng, et al., WHOC (2006)
00 90 180 270 360 450
Time (min)
Sol
vent
PRate(85% Recovery)
Si l ti R lt Simulation
Numerical ModelingM h i ti A l iMechanistic Analysis
• Understand ES-SAGD process mechanisms– Solvent appears along slope of steam chamber– Observation not available from experiments
Profile @ 240 minutes
Oil SaturationGas Saturation
26ES-SAGD: Deng, et al., WHOC (2006)Diluents mole fraction in Oil PhaseDiluents mole fraction in Gas Phase
Numerical ModelingM h i ti A l iMechanistic Analysis
Temperature Profile @ 240 minutes
• Understand ES-SAGD process mechanisms– Solvent further
reduces oil viscosity along the slope ofOil along the slope of steam chamber
Oil With Solvent
27ES-SAGD: Deng, et al., WHOC (2006)
Numerical ModelingFi ld S l P di tiField-Scale Prediction
• A bitumen asset in Western Canada– Preheat: 100 days; SAGD: 150 days– ES-SAGD: after 250 days– Solvent composition: 98% C4 & 2% C1
0So
z x
y
0
1Height of reservoir
is exaggerated
170 ft
28ES-SAGD: Akinboyewa, et al., SPE 129963 (2010)
SAGD Well Pair LocationSaturation Distribution1 gg
Numerical ModelingFi ld S l P di tiField-Scale Prediction
Oil Production and Steam InjectionIncrease Solvent
Concentration SAGD Base Case
Increase Solvent ConcentrationSAGD Base Case
• Improve oil production with solvent% Solvent in Steam (by vol.)
Improve oil production with solvent• Reduce steam injection with solvent
29ES-SAGD: Akinboyewa, et al., SPE 129963 (2010)
Numerical ModelingFi ld S l P di tiField-Scale Prediction
Increase SolventIncrease Solvent Concentration
In-Situ Upgrading
SAGD Base Case
• The presence of solvent in produced oil improves its APIThe presence of solvent in produced oil improves its API– API is calculated based on composition of produced oil
30ES-SAGD: Akinboyewa, et al., SPE 129963 (2010)
Numerical ModelingFi ld S l P di tiField-Scale Prediction
Gas Saturation Distribution
Steam Chamber with SAGD Base Case
Gas Saturation Distribution
Steam Chamber with 5% Solvent Injection
S l t l ti l th f t h b
Low High
• Solvent slows vertical growth of steam chamber (reduces heat loss) and allows it to grow more laterally
31ES-SAGD: Akinboyewa, et al., SPE 129963 (2010)
Challenges from Lab to Field O ti l S l t I j ti St tOptimal Solvent Injection Strategy
Continuous solvent injectionContinuous solvent injection
Cyclic solvent injectionConstant Rate Ramp-Up Ramp-Down
Cyclic solvent injection
Unrealistic to test all strategies in the fieldConstant Rate Ramp-Up Ramp-Down
• Unrealistic to test all strategies in the field• Lab experiments and numerical studies can be useful
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Challenges from Lab to FieldO ti l A t f S l tOptimal Amount of Solvent
Not eno gh sol ent SAGD Steam• Not enough solvent– Less solvent dissolution in
oleic phase
SAGD Steam Chamber Interface
Steam+ Gas
oiloleic phase
– Less oil viscosity reduction• Too much solvent
Not Enough Solvent
St ilEquilibrium
– Excessive solvent in gaseous phase that forms
i l ti bl k t
Steam + Gas
oil
Optimal Amount of Solventan insulation blanket near steam chamber interface
– Hinder propagation of
p
Steam + Gas
oilInsulation Blanket
Hinder propagation of steam front
33SAP: Gupta, et al., SPE 137543 (2010)
Too Much Solvent Solvent
Challenges from Lab to FieldO ti l A t f S l tOptimal Amount of Solvent
. fr.)
N i l P di tiM i
SAGD Steam Chamber
nc. (
olei
c m
ol.
Oil RateSolvent Rate
Solvent Conc. at Interface
Numerical PredictionMaximum
m);
Solv
ent C
on Solvent Rate at Interface
Solvent at steam chamber interface
ent R
ate
(t/d/
mO
il / S
olve
Time (days)
• Optimal amount of solvent varies throughout lifetime of process
34SAP: Gupta, et al., SPE 137543 (2010)
Field Pilot Tests in CanadaField Pilot Tests in CanadaHybrid Process Field Pilots:Suncor / CNRL Burnt Lake – ES-SAGDAthabasca
ALBERTASuncor / CNRL Burnt Lake – ES-SAGDSuncor Firebag – ES-SAGDNexen Long Lake – ES-SAGDEnCana Senlac – SAP
PeaceRiver
Athabasca
Fort McMurray EnCana Senlac SAPEnCana Christina Lake – SAPImperial Oil Cold Lake – LASER
y
EdmontonCold Lake
Calgary
LloydminsterHeavy Oil / Bitumen D it
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CanadaU.S.A.
100 mile
125 km
Deposits
Saskatchewan
Field Pilot TestE C S l (J 2002)EnCana Senlac (January 2002)
• One well pair already in SAGD operation– Achieved peak rate
• Butane (C4) was used as solventOil Production Rate (bbl/d) SOR and Energy Intensity (EI)
Solvent Solvent
Expected SAGD Performance
Expected SAGD Performance
36SAP: Gupta, et al., CIPC (2002) & Gupta, et al., JCPT (2005)
Field Pilot TestEnCana Christina Lake (April 2004)
• One well pair already in SAGD operation– Achieved peak rate (after two years)– Worst performance in 4 side-by-side well pairs
• Butane (C4) was used as solventButane (C4) was used as solventOil Production Rate (tonne/d) SOR
Solvent SolventPlant Shutdown
Instrument Malfunction
37SAP: Gupta and Gittins, CIPC (2005) & Gupta and Gittins, JCPT (2006)
04-Mar 01-Aug 20-Dec04-Mar 01-Aug 20-Dec
Field Pilot Test PerformanceE C S l & Ch i ti L kEnCana Senlac & Christina Lake Ver enco raging pilot res lts• Very encouraging pilot results– Improved initial oil rate over 50% in Senlac and 150%
in Christina Lakein Christina Lake– Reduced SOR– Improved API°gravity of produced oil over a range
of 0.7° - 1°• Economic improvement – Senlac
• Cenovus (previously EnCana) is planning SAP
Gupta, et al., CIPC (2002) & Gupta, et al., JCPT (2005)
Gupta and Gittins, CIPC (2005) & Gupta and Gittins, JCPT (2006)SAP:
38
( y ) gcommercialization near Christina Lake
Field Pilot TestI i l Oil C ld L k (M h 2002)Imperial Oil Cold Lake (March 2002)
• One CSS pad chosen from two adjacent id ti ll f d d id didentically performed pads considered– Cycle 6 – CSS; Cycle 7 - LASER
• Diluent (C5+ condensate) was used as solventDiluent (C5+ condensate) was used as solventOil Production Rate (m3/d) & Cumulative
OSR Base CSS wells
LASER Injection wells
CCS wells influenced by other operations
LASER CSS
CSS wells produced substantial diluent
39LASER: Leaute and Carey, CIPC (2005)
Field Pilot Test PerformanceI i l Oil C ld L kImperial Oil Cold Lake
• Very encouraging first LASER cycle• Very encouraging first LASER cycle (cycle 7) results– Recovered 80% of injected diluent– OSR declined for CSS pad but p
increased for LASER pad– Achieved an incremental “oil-to-solventAchieved an incremental oil to solvent
storage ratio*” of 10* m3 oil produced / m3 solvent retained in reservoir
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* m3 oil produced / m3 solvent retained in reservoir
LASER: Leaute and Carey, CIPC (2005)
LASER CommercializationI i l Oil C ld L kImperial Oil Cold Lake
• 10 pads• Diluent
injection (Q3 2007 – April2007 April 2009) in 10 pads
• Production is• Production is expected to reach peak rate in laterate in late 2010 to early 2011
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LASER: Energy Resources Conservation Board (ERCB) of Alberta (2010)
Hybrid Steam-Solvent ProcessesR d ti f E i t l I tReduction of Environmental Impacts• Reduce surface footprintReduce surface footprint
– Use horizontal wells (e.g., SAGD)• Reduce GHG and water usageReduce GHG and water usage
– Reduce SOR by 1 in a 100,000 bbl/day project
350–MW Coal-FiredPower Plant
(3 million tonnes CO2/year)• Reduce ∼1 million tonnes/year of
CO2 emission• Reduce 100,000 bbl/day of water
(3 million tonnes CO2/year)
usage for steam generation
• Reduce water disposalR l i ifi t t f
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– Recycle significant amount of produced water
ConclusionsConclusions• Hybrid steam-solvent process is a feasible
h il t h lheavy oil recovery technology– Concept proven - lab and numerical results– Technically successful field pilot tests
• Hybrid steam-solvent processes can:y– Improved oil rate and SOR– Reduce environmental impactsp– Improve quality of produced oilThere is continuous improvement on heavy
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There is continuous improvement on heavy oil recovery technologies to meet the challenges of environmental issues