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Collaborating Authors
Energy
Deployment of Large Scale Surfactant Manufacture for EOR Projects
Barnes, J. R. (Shell Global Solutions International B.V.) | Regalado, D. Perez (Shell Global Solutions International B.V.) | Crom, L. A. (Shell Global Solutions U.S. Inc.) | Doll, M. J. (Shell Global Solutions U.S. Inc.) | King, T. E. (Shell Global Solutions U.S. Inc.) | Covin, D. Y. (Shell Chemical Company L.P.) | Crawford, J. N. (Shell Chemical Company L.P.) | Kunkeler, P. J. (Shell Chemicals Europe B.V.)
Abstract Surfactant quantities increase dramatically moving from small field tests (e.g. single well tests) to multiwell pilots to full scale EOR projects. This paper is a companion paper to SPE-190453, presented at the SPE conference in Oman in March 2018, and shows how best practices from existing large-scale surfactant manufacture (for household and industrial applications) can be applied and adapted for manufacture and delivery of EOR surfactants as field projects are upscaled. Surfactant concentrates can be viscous, making them difficult to pump and mix. This paper presents improved methods to manufacture and handle them. In addition, dilution of the concentrate in the field to the working (injected) formulation needs to be carried done in a manner which avoids the formation of viscous phases that are common with surfactants. The main learnings from this paper are: For small field projects, it is usually advantageous to ship less concentrated products (e.g. ≤ 30% active matter, AM) as, for the small volumes involved, the advantages of ease of mixing and dilution in the field tend to outweigh the cost savings in transporting a highly concentrated product. An additive (viscosity modifier), applied during manufacture, reduces viscosity and improves handleability of highly concentrated products (e.g. ≥ 65% AM). This viscosity modifier is benign for sub-surface performance of the surfactant. For large projects, two strategies can be used to reduce logistics costs: Supply a concentrated product with viscosity modifier (to reduce the percentage of water shipped), and/or Manufacture the product (or part of the product) in country/region and near the field. A realistic supply chain was used to estimate the logistics costs to transport low and high %AM products from a USA point of manufacture to an EOR project destination in South America. This calculation assumed an equal manufacturing cost for the low and high %AM products and transportation by 20 ton ISO-tanks, a standard bulk industry container. The transportation cost for the high %AM product is around 57% of the low %AM product. Additional logistics savings are achievable through manufacturing the product (or part of the product) in country/region, and the logistics cost for high %AM product manufactured near the field can be reduced to 33% of of that for the low %AM product manufactured in the USA. More general learning for EOR projects are: Experience from the wider, bulk chemicals industry can be usefully applied for EOR projects. It is important to align surfactant manufacture/supply logistics with reservoir management and the field life plan as significant lead time is required for supply of large surfactant volumes.
- North America > United States (0.88)
- Asia > Middle East > Oman (0.24)
- Materials > Chemicals > Specialty Chemicals (1.00)
- Energy > Oil & Gas > Upstream (1.00)
Essentials of Upscaling Surfactants for EOR Field Projects
Barnes, J. R (Shell Global Solutions International B.V.) | Regalado, D. Perez (Shell Global Solutions International B.V.) | Doll, M. J. (Shell Global Solutions (US) Inc.) | King, T. E. (Shell Global Solutions (US) Inc.) | Pretzer, L. E. (Shell Global Solutions (US) Inc.) | Semple, T. C. (Shell Global Solutions (US) Inc.)
Abstract Surfactant flooding is an enhanced oil recovery (EOR) technique that involves the injection of an aqueous solution of surfactant (and, optionally, alkaline and polymer) into an oil reservoir to mobilise and produce the remaining oil. The quantities of surfactants needed for pilots and future commercial scale projects are large (100s to 10,000s of tons) and necessitate large scale manufacture using existing processes and plants for the different manufacturing steps. Upscaling of surfactants requires a rigorous QA/QC process to control and ensure the quality of batches of surfactants produced. Case studies are described from the perspective of a surfactant manufacturer where 800 and 6000 ton of surfactant were manufactured (as 60% and 20% active concentrates respectively) for two multi spot pilots. These case studies illustrate: The need to define the laboratory tests for surfactant composition and performance. Plus associated repeatability data and specifications (minimum and maximum values) for clear, unambiguous decisions. How the QC is checked at each stage in manufacture from the initial feedstock, through various stages, to the final delivered surfactant concentrate/blend. This also applies to the scale-up procedure from the laboratory made scale (kg) to pilot scale (100s of kg) to the pilot/commercial scale (100s to 1000s of tons). Novel correlations between composition and performance (e.g. optimal salinity, via oil/water phase behaviour tests), developed during the surfactant pilot scale manufacture stage, to a) put more emphasis on verifying batch consistency with faster, easier to use composition tests, and b) give more assurance that large scale production gives the expected sub-surface performance. This requires R&D over an extended time, ahead of large scale manufacture. Overall, the paper shows that industrial scale production of surfactants for chemical EOR is feasible and goes through the essential steps to achieve this. Control of large scale batch quality and performance is critical. This paper also shows results for improved, highly active (60%+) surfactants concentrates with improved rheology behaviour which will be easier to pump, mix and dilute at the facilities than earlier products. This helps to reduce logistical costs thereby improving project economics.
- North America > United States > Illinois (0.28)
- North America > United States > Texas (0.28)
- Materials > Chemicals > Specialty Chemicals (1.00)
- Energy > Oil & Gas > Upstream (1.00)
- North America > United States > Illinois > Benton Field > Tar Springs Formation (0.99)
- Asia > India > Rajasthan > Rajasthan Basin > Barmer Basin > Rajasthan Block > Mangala Field > Fatehgarh Formation (0.99)
- Asia > India > Rajasthan > Rajasthan Basin > Barmer Basin > Rajasthan Block > Mangala Field > Barmer Hill Formation (0.99)
- (2 more...)