Petroleum EngineeringWaterflooding EOR and Hydraulic FracturingWaterflooding, EOR, and Hydraulic Fracturing

이경행과장 –삼성중공업프로세스설계팀

석유공학관련세미나 KISTI / 한국산업단지공단 – 11/1/2012

Petroleum Engineering

Where??– Geology– GeostatisticsGeostatistics

Oil is not in an underground pool; but in pore spaces ofporous (concrete-like) rock

Gas Cap

Oil Column

AquiferAquifer

Petroleum EngineeringH h?? Well TestingHow much?? Well Testing

Well Logging

Petroleum EngineeringH t d ??How to produce??– Reservoir Engineering– Petrophysics– Production Engineering– Enhanced Oil Recovery (Polymer & Surfactant)– Transport PhenomenaTransport Phenomena– Artificial Lift– Natural Gas Engineering

Near Wellbore Problems– Near Wellbore Problems– Geomechanics– Drilling and Well Completion

VLP (Vertical Lift Performance) & IPR (Inflow Performance Relationship)

– Drilling Engineering

Oil Industry Technical Areas Drilling• Drilling

-- Drill bits; Drill stems; Casing-- Cementing; Drilling fluids

• Reservoir Engineering-- Logging; Tracer tests-- Downhole monitoring

-- Multi-laterals; Coiled tubing

• Surface Facilities

g

• Enhanced Oil RecoveryG fl dSurface Facilities

-- Pipelines; Pumps & compressors-- Fluids separators; Treating

-- Gas flood -- Emulsion flood-- Polymer flood

• Production Operation-- Tubing; Perforating

-- Alkaline/surfactant floods

• Heavy Oil Recovery-- Completions; Sand control

• Production/Injection

ea y O eco e y-- Steam-based processes-- In-situ combustion

Electromagnetic heating• Production/Injection Assurance

-- Matrix acidizing; Fracturing

-- Electromagnetic heating-- Bitumen mining

-- Conformance control

-- Artificial lift

• Unconventional Resources• Environmental Remediation

Production Operation

• High-strength, light-weight tubingT h l f l d i b d l d

Tubing/ Completion Systems

-- Technology for low-cost mass production yet to be developed

• Integrity of tubing jointsT h l l i d t b il bl i t d d-- Technology claimed to be available; improvement needed

• Improved elasticity & long-term integrity of packers/joints/o-ringsd h h ditiunder harsh conditions

-- Technology for nano-polymer composites available; improvement needed

Formation damage control/Sand control• Perforation/sand screen that can control flow of different fluid phases

-- Intelligent linings that respond to reservoir conditions or external field

Formation damage control/Sand control

• Multi-functional downhole sensors that can endure harsh conditionsDownhole Monitoring

-- p, T, gas measurement techniques available; technology for assembly needed

Life of an Oil Field

• Primary Recovery: 10–20% Original-Oil-In-Place

• Secondary Recovery (Waterflooding, Gas cycling): 20–30% OOIP

E h d R P l fl di 5 15% OOIP• Enhanced Recovery: Polymer flooding 5–15% OOIPGas flooding 5–15% OOIPSurfactant flooding 15–30% OOIPg

• Heavy Oil Primary Recovery: 0–10% OOIP

• Heavy Oil Thermal EOR: > 50% OOIP

Like people, maintaining good productivity into old age (goal of EOR) requires maintaining a disciplined “life style” with good advance planningy g p g

Petroleum EngineeringArtificial LiftArtificial Lift

Heavy Oil Production

Petroleum EngineeringHydraulic FracturingHydraulic Fracturing

Petroleum EngineeringShale GasShale Gas

중앙일보 6.13중앙일보 6.13

Primary and Secondary Recovery MethodsPrimary and Secondary Recovery Methods

• Aquifer Drive • Solution Gas Drive

• Water Flood • Pressure Maintenance

• Gas Cap Drive • (Artificial Lift)

Technical Basis for Water and Polymer Flooding

• Polymer flooding recovers the mobile oil that has been bypassed by earlier waterflooding or aquifer intrusion due to reservoirby earlier waterflooding or aquifer intrusion, due to reservoirheterogeneity. It does not recover the residual oil that is trapped atrock pores even after extensive waterflooding.

Polymer Flooding• Polymer flooding is a field proven mature technology• Polymer flooding is a field-proven, mature technology

-- Large-scale flood at Petro-China’s Daqing field, China -- Elf Aquitaine’s Chateaurenard field, France (40-cp oil at 30 C) q , ( p )-- Shell’s Marmul field, Oman (80-cp oil at 46 C)

• Key properties for EOR polymers y p p p y

-- High viscosification efficiency-- Effective transport through porous media (Shear-thinning rheology)-- Low retention in rock-- Thermal and chemical stability -- Low cost-- Resistance to mechanical degradation

• Common EOR polymers are polyacrylamide and xanthan gump y p y y g

• Key operational considerations for polymer flooding

f f-- Dissolution of polymer in brine to generate a solution of ~1000 ppm-- Filtration to generate a homogeneous solution

Increase of Water Viscosity by Dilute Polymer

Xanthan Viscosity vs. Shear Rate and

Apparent Viscosity in Rockvs. Flow Velocity and

Concentrationy

Concentration

cp cp

Overall Assessment of Polymer Flooding

• For most reservoirs, especially for those with oil viscositybetween 10 and 500 cp, a significant amount of mobile oil is still left due to reservoir heterogeneitystill left due to reservoir heterogeneity

• For the heavy-oil reservoirs, application of polymer flooding at early stage e g at the beginning of waterflooding resultsat early stage, e.g., at the beginning of waterflooding, results in better oil recovery

• Polymer flooding at high salinity and high temperature conditions are still difficult

Polyacrylamide loses viscosity for salinities > ~3 wt%-- Polyacrylamide loses viscosity for salinities > ~3 wt%-- Xanthan biopolymer is better for both salinity and temperature-- New polymers (e.g., with sulfonate graft) are being tested to extend

th li it d t tthe salinity and temperature range

• Development of polymer flooding technology, combined withlow-cost manufacturing of polymer, holds promise as a wayfor Korea to acquire oil reserves

Technical Basis for Surfactant/Polymer Flooding

• The main target of surfactant/polymer flood is the residual oil gangliatrapped at pore throats even after extensive waterfloods

• Mobilization of the residual oil is governed by the capillary numbercorrelation

Surfactant/Polymer Flood Process Design

ExxonMobil’s Loudon Field Design

• Microemulsion bank should be able to generate interfacial tension of• Microemulsion bank should be able to generate interfacial tension of0.01 dyne/cm or lower

• For the purpose of mobility control, polymer is added into the microemulsionp p y , p ybank; and the polymer drive bank has a higher viscosity and larger size

Surfactant/Polymer Flooding

A ll d i d f t t/ l fl d i t ll ll• A well-designed surfactant/polymer flood can recover virtually all the oil in the reservoir. Technology has been proven in the field.

• A successful surfactant/polymer flooding requires a well-trainedtechnical team

-- “Microemulsion”, a thermodynamically stable dispersion of surfactant, oil and brine, is usually injected

-- Surfactant structure, and the injection composition, need to be tailored for each reservoir, to generate the ultra-low interfacial tension condition

• With improved process economics, the potential for reserve addition is high

-- 64% of U.S. discovered (~510 B bbl) unrecoverable by primary and secondarymeans

• Surfactant flooding has been effectively employed for remediation of subsurface contaminants, e.g., DNAPL.

Overall Assessment of Surfactant/Polymer Flooding

• For virtually all mature reservoirs, a significant amount of oil is still left as the residual oil, a large portion of which could be produced by a well-designed surfactant/polymer floodingproduced by a well designed surfactant/polymer flooding

• Surfactant/polymer flooding is still quite expensive. With improved process economics however the potential forWith improved process economics, however, the potential for reserve addition is high

A f l f t t/ l fl di i ll t i d• A successful surfactant/polymer flooding requires a well-trainedtechnical team

• Development of surfactant/polymer flooding technology, combined with efficient manufacturing of surfactant and polymer, holds promise as a way for Korea to acquire oil reservesholds promise as a way for Korea to acquire oil reserves

• Surfactant/polymer flooding technology can be utilized as a reliable method of subsurface contaminants remediationmethod of subsurface contaminants remediation

EOR by CO2 flooding

Technical Basis for Gas Injection Processes

• Primary oil recovery mechanism for gas injection processes isthe generation of miscibility between oil and gas

• Swelling of oil by gas is also an important recovery mechanism

www.netl.doe.gov

Gas Injection Processes

• Wherever a secure and low-cost supply of gas is available gas• Wherever a secure and low-cost supply of gas is available, gasflooding is generally economical

-- At Permian Basin of West Texas, an extensive pipeline network brings CO2from CO2 reservoirs in New Mexico and Colorado

-- With CO2 price of ~$1.50 for incremental bbl of oil, CO2 flooding is widelyimplemented

• Because of the low viscosity and low density of gas, the recoveryefficiency for gas floods is generally poor

-- Channeling through high-permeability layers and gravity segregation -- For improved sweep efficiency, water-alternating-gas (WAG) is employed

N2 d H d b fl d• N2 and Hydrocarbon gas floods

-- Mexico’s offshore Cantarell field: N2 injection for pressure maintenance -- Prudhoe Bay Miscible Gas Project: gas plant capacity of 8 bcfd

solvent composition: 20% CO2, 34% C1, 30% C2, 23% C3

• CO2 flood is an attractive option to sequestrate CO2 from power plantflue gas emission

Overall Assessment of Gas Injection Processes

• Wherever a secure and low-cost supply of gas is available, gasflooding is generally economical

• Extraction of CO2 from power plant flue gas, or from othercombustion sources, and injection into mature reservoirs for CO2flooding is an economic way of reducing CO2 emission into air

• Co-development of low-cost CO2 extraction technology and CO2p gyinjection EOR technology could be a way for Korea to contributeto the CO2 sequestration effort

-- Transport of CO2 from the flue-gas source to the mature oil reservoiris the key economic consideration

• Development of ways to directly thicken the supercritical CO2 willgreatly improve the oil recovery efficiency of CO2 flooding

-- Fluoride-based polymers so far developed are much too expensive

Technical Challenges for Light-Oil EOR Processes• Surfactant Flooding• Surfactant Flooding

-- Surfactant adsorption (consumption) in the reservoir -- Efficient process design for a given reservoir

• Polymer Flooding

Polymer adsorption; Mechanical and thermal degradation-- Polymer adsorption; Mechanical and thermal degradation-- Long-term viscosification under high-salinity, high-temperature environment

CO2 and Hydrocarbon Gas Floods• CO2 and Hydrocarbon Gas Floods

-- Use of direct thickener for CO2 phase (Fluoride-based chemicals too costly) -- Design of effective WAG condition, possibly with surfactantg , p y

• Cost-efficient ways to improve light-oil recovery

I t t d fl d t (Effi i t l i d l d t li bl-- Integrated flood management (Efficient geologic model update; reliablesimulation of large-scale project; permanent wellbore monitoring)

E i t l• Environmental concerns

-- Potential to use flue gas for gas flood (Synergy with CO2 sequestration)

Potential Heavy Oil Recovery Methods

In Situ Combustion

Approximate Range of Applicability

Steamflood California

Polymer Flood Oman

Cold Flow w/o sand

Cold Flow w/sand

Orinoco Belt,Venezuela

cess Lloydminster

Cyclic Solvent Process

Proc Cyclic Steam Stimulation Cold

Lake

Steam-Assisted Gravity Drainage (SAGD)

Vapor Extraction (VAPEX)Cold Lake, Athabasca

Athabasca, Cold Lake

1 10 100 1,000 10,000 100,000 1,000,000 10,000,000

Surface MiningAthabasca

Viscosity, cp

Steam-Assisted Gravity Drainage

• Production dominated by

y g

Steam

ygravity drainage

• Heat conduction is a primary process driver

Oil Drainage

• Convection effects are also important in and around the steam chamber

Conduction • Phase behavior is similar to other steam injection processes

• Opened new phase in thermal development and spawned new classes of processes and activity in Canadian Heavy OilMan “commercial” and pilot projects nder a in Canada• Many “commercial” and pilot projects underway in Canada

Heavy-Oil EOR Conclusions

• Trillions of barrels of bitumen in Canada and Venezuela isexpected to be an important future source of energy

• Use of steam needs to be phased out, because of the high natural-gas cost and the CO2 emission. Development of cost-effective non-thermal methods is the key technical challenge

• Development of physico-chemical ways to drastically reducebitumen viscosity, and a better understanding of effects ofgeomechanics of unconsolidated sands on the transport ofinjected fluids and bitumen production are major technical tasksinjected fluids and bitumen production, are major technical tasksto be solved

D t it i l f l h il j t• Due to its immense scale, a successful heavy oil recovery project requires a large capital investment, and a well-designed project management by a well-trained technical team. Korea’s strength ing y gthese areas potentially offers an opportunity.

장비업체현황

•한진디엔비 (HANJIN D&B)-시추기제조업체 (Drilling Equipment)지하수/지열드릴 광산조사드릴 발파드릴 방향제어드릴-지하수/지열드릴, 광산조사드릴, 발파드릴, 방향제어드릴

-- Shale Gas Production 과관련-에어컴프레셔, 워터햄머, 물펌프, 머드펌프등, , ,

-- Hydraulic Fracturing (수압파쇄와관련)

현대하이스코 (HYUNDAI HYSCO)•현대하이스코 (HYUNDAI HYSCO)-일반배관용, 대형송유관등 – Shale Gas Transportation 과관련

•에너지홀딩스그룹 (Energy Holdings Group)-프로젝트제안, 중계, 파이낸싱, 예측및전망, 전략수립등

•골든오일 (Golden Oil Corp.)-탐사사업, 개발사업, 생산사업, ,

Thank youThank you

Q ti ?Questions?

석유공학관련세미나 KISTI / 한국산업단지공단 – 11/1/2012