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Chemical EOR Progress in China Advances and Challenges. Harry L. Chang Harrylchang@chemortech.com www.chemortech.com. Outline of Presentation. Overview Recent advancements Chemical EOR in China Polymer flooding ASP flooding Facilities Some controversial issues and challenges Summary.
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Chemical EOR Progress in China Advances and Challenges Harry L. Chang Harrylchang@chemortech.com www.chemortech.com
Outline of Presentation • Overview • Recent advancements • Chemical EOR in China • Polymer flooding • ASP flooding • Facilities • Some controversial issues and challenges • Summary
Chemical EOR Global Status • China has most field experiences • US has focused on improvements in chemicals, lab studies, and simulators • Increased chemical EOR mechanistic understandings and field activities in US and world-wide in recent years Harry L. Chang
General Understanding • Polymer flooding (PF): A mature EOR process • Polymer gels: Used successfully in water shut-off and profile modification in selected reservoirs • Surfactant-polymer (SP): Effective but expensive • ASP: Effective, less expensive, but requires extensive treatment of injection/produced fluids Harry L. Chang
Recent Advancements • Chemicals • Laboratory Studies • Simulation and Simulators • Project Design and Implementation • Facilities, Monitoring, and Evaluation • More Field Experiences Harry L. Chang
EOR Chemicals • Polymers and related chemicals • Surfactants • Co-surfactants • Co-solvents Harry L. Chang
50 40 1500 ppmHPAM polymer, 23 °C, 11 s-1 30 NaCl Viscosity[cp] 20 9:1 NaCl/CaCl2 10 ElectrolyteConcentration [TDS, ppm] 0 0 50,000 100,000 150,000 200,000 Improvements on Polymers(UT David Levitt Dissertation) Harry L. Chang
Improved Laboratory Techniques • Phase behavior/solubalization ratio • High temperature and live oil • Core flood techniques Harry L. Chang
Phase Behavior Experiments • Phase behavior experiments • Inexpensive technique for surfactant formulation • Measure solubalization parameters/IFT’s • Measure coalescence/equilibration time • Determinemicroemulsion viscosities • Specific surfactant(s) can be tailored for specific oils Harry L. Chang
Salinity, %: 0.0 0.5 0.75 1.0 1.25 1.5 1.75 2.0 2.25 2.5 2.75 3.0 3.5 4.0 An Excellent ME Phase Behavior
Core Flooding • High oil recovery >90% Sorw, or Sorc<0.04 • Adequate mobility control • Good surfactant/polymer transport • Low surfactant retention Harry L. Chang
Simulation and Simulators • Mechanistic model for core flood and pattern simulation • Calibration and field scale simulation • Advanced simulators Harry L. Chang
Daqing Oilfield • Largest polymer and ASP floods in the world • PF oil production in Daqing has been stabilized at ~200,000 bbl/d over 10 years • Polymer requirement has doubled in last 10 years from ~80,000 t/yr to ~160,000 t/yr • Large-scale ASP floods have been implemented since 2006 Harry L. Chang
Shengli Oilfield • Second largest PF in China • Also has polymer manufacturing facilities • Several ASP pilot tests have been conducted in the past but decided to use SP instead Harry L. Chang
PF in China Showed • Incremental recovery depends on • reservoir quality • polymer selection • polymer amount, > 500 ppm.pv now • Production of polymer and emulsions may be expected • Large scale injection/production facilities are necessary for successful operations Harry L. Chang
Polymer Flooding also Showed • Simplified field operations have been practiced in field-wide operations • On-site polymer production would improve the economics • KYPAM polymers appears to be more effective in high perm and high salinity reservoirs • Visco-elastic behavior can reduce Sor (SPE127453) • CDG will enhance PF performance Harry L. Chang
KYPAM Polymers • Comb like with short branched chain to maintain effectiveness in high salinity brines • Wide MW range for reservoirs with different permeabilities • Successfully applied in some reservoirs in China Harry L. Chang
Viscosity Data of KYPAM Polymer viscosity Concentration
ASP Floods in China • Pilot testing: Daqing, Shengli, Karamay • Large scale field projects in Daqing • Large scale injection/production facilities have been developed in Daqing • Emulsion and scale productions were observed Harry L. Chang
Field Examples • Daqing • Karamay • ASP pilot simulation Harry L. Chang
ASP Pilot Tests Conducted in Daqing Oilfield Harry L. Chang
ASP Results in Daqing • High incremental recovery • Severe emulsion production • Severe scale production • SP with A instead of ASP? • One of the most difficult oil for SP flooding Harry L. Chang
Karamay ASP Pilot Test Design and Field Performance (SPE 64726) • Process design/management: Harry Chang • Project implementation: Karamay Oilfield • A single surfactant system using petroleum sulfonates produced in a local refinery • Applied the salinity gradient with STPP for sequestration
ASP Pilot Test Well Pattern, 2Z-B9-3 Well GroupKaramay Oil Field (SPE 64726)
Modelling of Pilot Area Performance (SPE 39610 and 64726)
Some Comments on ASP • ASP requires special crude oils to improve performances • ASP slug cost less but other costs would be substantial (treating injection brine and produced fluids) • Low surfactant concentration (<0.5% active) SP formulations are available now • Some ASP projects may be just SP with A or just P Harry L. Chang
Chemical Injection Facilities • SPSW vs. SPMW injection facilities • Large-scale polymer dispersion/mixing • Large-scale ASP injection facilities • Emulsion treatment facilities • Fully automatic modular units for pilot testing Harry L. Chang
SPMW Polymer injection system Spec.: 16 Mpa, 60 m3/hr, polymer conc.,1000 mg/l,27 injection wells SPMW Polymer injection pumps Spec.: 16 Mpa, 4 m3/hr, And 5000 mg/l polymer
Polymer Dispersion Polymer Mixing
Produced Fluid Treatment Facilities ASP Produced Fluid Treatment, 24,000 m3/d
A Fully Automatic Modular Pre-Factory Tested ASP Pilot Injection Facility • Designed Rate: 640 m3/day • Designed Pressure: 12 Mpa • Chemical Processing Includes: • Dry polymer handling, processing, & maturation • Dry soda ash handling, processing, & dissolution • Surfactant handling & metering • Water conditioning chemicals (oxygen scavenger and biocide) • Nitrogen blanket • Automation: Allen-Bradley PLC based with full PID Loop control for accurate chemical recipe control and data collection • Special Systems Included: • R-O water softening • Fe removal system • Heat exchanger system for high temp fluid injection
A Polymer Handling System Designed by Chemor Tech and Fabricated by Dafeng/COT in China