MEASUREMENT AND MONITORING OF SOLVENT PROCESSES FOR ...
Transcript of MEASUREMENT AND MONITORING OF SOLVENT PROCESSES FOR ...
MEASUREMENT AND MONITORING OF SOLVENT PROCESSES FOR ALBERTA’S OILSANDS: WORKSHOP 3
SOLVENT LEADERSHIP SERIES March 7, 2018
CLEAN ENERGY:
1
ADVANCED HYDROCARBONSBRYAN HELFENBAUMEXECUTIVE DIRECTOR, ADVANCED HYDROCARBONS
MARCH 7 2018
CANDICE PATONDIRECTOR, RECOVERY TECHNOLOGIES
ALBERTA INNOVATES AT-A-GLANCE
2
Role: Support economic diversification and job creation
Canada’s largest provincial research and innovation agency: the catalyst in an environment where invention, innovation and industry thrive.
3
DIGITAL
OMICS
ADVANCEDMANUFACTURINGAND MATERIALS
PLATFORM TECHNOLOGIES
SUBSIDIARIES
NEW STRATEGIC DIRECTION – FOCUSED, USER-CENTRIC CLUSTERS
Laura Kilcrease, CEO
CLEAN ENERGY
• AI Clean Energy develops and invests in strategic programs to achieve Alberta’s goals for energy, the environment and economic prosperity.
• We provide insight to the GOA on climate leadership, energy diversification and water policies, and support Emissions Reduction Alberta in technical due diligence and project management.
• Clean Energy’s strength is creating the partnerships necessary to achieve the goals.
4
Energy andGHG Mitigation
Environment and Climate Adaptation
Emerging Technologies
25%Revenue increase in cleantech
$40 billion AB’s manufacturing output
$20 billion AB’s digital economy
INNOVATION FOR IMPACTS: 2030 TARGETS – Moving Forward
CLEAN ENERGY
ADVANCED HYDROCARBONS PORTFOLIO - PROGRAMS
Advanced Hydrocarbons
Recovery Technologies
Partial Upgrading
Methane Emissions Reduction & Value Add
Bitumen Beyond Combustion
Objective: Improve the competitiveness of Alberta’s oil and gas industry; increase the value of natural resources; transition to a low carbon economy
8
MEASURING IMPACTS
9
RECOVERY TECHNOLOGIES: OUTLOOK
• Program Strategy• Improve hydrocarbon recovery efficiency by decreasing GHG
emissions, fresh water use, and supply cost
Example: Solvent-assisted recovery for deep cuts in production cost and GHG emissions
10
R & D Piloting Demonstration Commercial
ESEIEH
eMVAPEXCyclic Solvent
Process
HBEP
SA-SAGD
AACI
ES-SAGD
Solvent Driven Process
25% - 90% reduction of GHG emissions intensity
RECOVERY TECHNOLOGIES: PROGRAM DEVELOPMENT
SOLVENT LEADERSHIP SERIES
• Workshop 1: In Situ• Workshop 2: Mining• Workshop 3: Measurement and Monitoring
11
9:15 Alex Filstein – Cenovus EnergyMeasurement and sampling plans for solvent pilots: how to generate the data we need from pilot operations.
10:15 Kyle Thacker – MEG EnergyField challenges and successes with collecting high quality samples from solvent pilots.
11:30 Haibo Huang - Director, AACI Research ProgramKey aspects of fluid sampling and analysis in solvent processes – measurement perspectives from the lab.
AACI Technical Workshop – April 19 & 20, 2017 CONFIDENTIAL
AI Clean Energy Solvent Leadership Series: Workshop 3 March 7, 2018 Calgary
Key Aspects of Fluid Sampling & Analysis in
Solvent Processes – Measurement Perspectives
from the Lab
1
Authors Haibo Huang
AACI Technical Workshop – April 19 & 20, 2017 CONFIDENTIAL
AI Clean Energy Solvent Leadership Series: Workshop 3 March 7, 2018 Calgary 2
Outline
Importance of solvent quantification in pilot test of solvent processes
Field fluid sample characteristics
Measurement of solvent content in field samples
Pre-analysis sample treatment
Sampling/monitoring locations
Sampling operation
New development in the subject area
AACI Technical Workshop – April 19 & 20, 2017 CONFIDENTIAL
AI Clean Energy Solvent Leadership Series: Workshop 3 March 7, 2018 Calgary 3
Importance of Solvent Quantification in Pilot Test of Solvent Process
Main drives to mobilize oil in solvent processes
Solvent only processes at reservoir temperature – solvent dilution of oil
Heated solvent processes (no steam) – thermally assisted solvent dilution
Steam-solvent co-injection processes – solvent dilution of heated oil (thermal dominant) or thermally assisted solvent dilution (solvent dominant)
Solvent
(Vapex/CSI)
Steam
(SAGD/CSS)
Solvent + heat/steam Steam + solvent
Reduced energy intensity
AACI Technical Workshop – April 19 & 20, 2017 CONFIDENTIAL
AI Clean Energy Solvent Leadership Series: Workshop 3 March 7, 2018 Calgary 4
Information from solvent content & composition change in produced fluid in a solvent process
Solvent injected = Solvent produced + Solvent remain in reservoir
Determine the net oil rate
Incremental oil production rate/solvent production rate - indicator of solvent impact to oil production behaviour
Determine solvent retention
Cum solvent retention/cum incremental oil production - indicator of solvent utilization efficiency
Composition change → reconditioning recovered solvent of multiple components
Accurate quantification of solvent production during the operation is important to assess the process performance
AACI Technical Workshop – April 19 & 20, 2017 CONFIDENTIAL
AI Clean Energy Solvent Leadership Series: Workshop 3 March 7, 2018 Calgary 5
Field Fluid Sample Characteristics
Process Solvent Prod. Fluids Fluid Characteristics
Cyclic Solvent Injection C3/C1, C3/CO2, C2, CO2
Vapor, liquid • Vapor – light HCs • Liquid – oil/solvent/water
with low water content
Vapex (reservoir temp.) C4, C3 Vapor, liquid • Vapor – light HCs • Liquid – oil/solvent/water
with low water content
Heated Solvent (hot Vapex) C4, C3 Vapor, liquid • Vapor – light HCs • Liquid – oil/solvent/water
with low water content
Steam-Solvent Co-injection C3, C4, C6, diluent, naphtha
Vapor, liquid • Vapor – light HCs & steam • Liquid – oil/solvent/water
with high water content
AACI Technical Workshop – April 19 & 20, 2017 CONFIDENTIAL
AI Clean Energy Solvent Leadership Series: Workshop 3 March 7, 2018 Calgary 6
Meas. of Solvent Content in Field Samples
Density measurement on the liquid samples
Applicable for samples with single component solvent rO+S+H2O (T,P) = wt%H2O x rH2O (T,P) + (100 – wt%H2O) x rO+S (T,P)
rO+S (T,P) = (rO+S+H2O (T,P) - wt%H2O x rH2O (T,P))/(100 - wt%H2O)
rO+S (T,P) = (100 – wt%S) x rO (T,P) + wt%S x rS (T,P)
* At the same T/P condition under which there is no presence of vapor phase
AACI Technical Workshop – April 19 & 20, 2017 CONFIDENTIAL
AI Clean Energy Solvent Leadership Series: Workshop 3 March 7, 2018 Calgary 7
Composition analysis of the fluid samples using gas chromatography (GC)
Applicable for vapor phase and oil phase samples with multi-component solvent
single component solvent
Solvent content in the vapor & liquid phases from a test separator – an example of GC analysis
Vapor Phase Composition
C1
CO2
C2
C3
I-C4
N-C
4I-C
5
N-C
5C6s
C7s
C8s
C9s
C10
s
C12
s
Co
nt.
(m
ole
%)
Low C # Components in Testing Fluids_GC Analysis
Retention
Inte
nsit
y
Standards
Original oil
Oil + solvent
n-C5
n-C6
n-C8n-C7
AACI Technical Workshop – April 19 & 20, 2017 CONFIDENTIAL
AI Clean Energy Solvent Leadership Series: Workshop 3 March 7, 2018 Calgary 8
C # distribution determined by C30+
0
10
20
30
40
50
60
C1
C3
n-C
4 n
-C5
Mcy
clo-
C5
Cyc
lo-C
6 M
cycl
o-C
6 C
8
m&
p-Xyl
ene
C9
C11
C
13
C15
C
17
C19
C
21
C23
C
25
C27
C
29
mo
le%
OSN
MR bitumen
Multi component solvent Bitumen
Solvent characteristics in the bitumen/solvent mixture Solvent content in fluid – 10 wt%
Reasonably well resolved from bitumen (insignificant overlap in composition) by GC analysis
0
2
4
6
8
10
12
14
Cyc
lo-C
6
C7
Mcy
clo-
C6
Tol
uen
e C
8 C
2-Ben
zene
m
&p-
Xyl
ene
o-X
ylen
e
C9
C10
C
11
C12
C
13
C14
mo
le%
OSN
MR bitumenBitumen
Solvent
AACI Technical Workshop – April 19 & 20, 2017 CONFIDENTIAL
AI Clean Energy Solvent Leadership Series: Workshop 3 March 7, 2018 Calgary 9
Determine solvent content/composition change in produced fluid by GC
Established for composition analysis of crude oil
Currently used in solvent injection & steam/solvent co-injection pilots
Experienced problems
QC in sampling, pre-analysis sample treatment, analysis is critical
AACI Technical Workshop – April 19 & 20, 2017 CONFIDENTIAL
AI Clean Energy Solvent Leadership Series: Workshop 3 March 7, 2018 Calgary 10
Pre-analysis Sample Treatment
Field gas sample (vapor streams, casing gas)
(gases: C1-4, CO, CO2, N2, NOx, H2S, SOx)
Field gas sample
(ambient T/pressurized)
Gas sample
(ambient T/P)
Meas. gas volume
Flash at 60 oC
Dry gas sample
(ambient T/P)
De-moisture
Gas sample Composition
GC
Applicable samples:
Test separator vapor phase, wellhead vapor phase
AACI Technical Workshop – April 19 & 20, 2017 CONFIDENTIAL
AI Clean Energy Solvent Leadership Series: Workshop 3 March 7, 2018 Calgary
Two-phase liquid sample – water/oil emulsion (Single solvent-, diluent/naphtha-diluted bitumen, water)
Field emulsion sample
(ambient T/pressurized)
De-gassed emulsion sample
(ambient T/P), meas. weight
Flash at 60 oC
Separated oil
W/O separation
Dry oil sample
GC
Applicable samples:
Test separator liquid phase
Separated water
Hydrocarbon comp.
Gas sample Gas sample Composition
GC
CS2 extraction
CS2 extract GC
De-moisture Solvent Composition
AACI Technical Workshop – April 19 & 20, 2017 CONFIDENTIAL
AI Clean Energy Solvent Leadership Series: Workshop 3 March 7, 2018 Calgary 12
Single phase liquid sample – water (Water, organic compounds)
Field water sample
(ambient T/pressurized)
Water sample
(ambient T/P), meas. weight
Flash at 60 oC
CS2 extract
CS2 extraction
Organics Composition
GC
Applicable samples:
Secondary separator liquid phase
Residual water
Gas sample Gas sample Composition
GC
AACI Technical Workshop – April 19 & 20, 2017 CONFIDENTIAL
AI Clean Energy Solvent Leadership Series: Workshop 3 March 7, 2018 Calgary 13
Liquid sample flash system schematic
AACI Technical Workshop – April 19 & 20, 2017 CONFIDENTIAL
AI Clean Energy Solvent Leadership Series: Workshop 3 March 7, 2018 Calgary 14
Sampling/Monitoring Locations
Primary test separator
Vapor phase
Condenser
Condensed liquid (water + HCs)
Gases (low C# HCs +)
Liq. phase O/W
emulsion
Wellhead Vapor/water/oil multiphase fluid
Wellhead fluids High P/T
Slugged flow
Concurrent V/L/L multiple phases sample
Fluids from the separator Reduced P/T
L/L two phases sample (stable emulsion)
Multiple-stream sample (gas, condensed liquid, emulsion)
AACI Technical Workshop – April 19 & 20, 2017 CONFIDENTIAL
AI Clean Energy Solvent Leadership Series: Workshop 3 March 7, 2018 Calgary 15
Wellhead fluids
Wellhead T/P
Flu
ids
sam
ple
Vapor phase
Homo. liquid phase
Water cut
Pre-analysis treated
Separator
Composition analysis
Ambient T/P
Composition analysis
AACI Technical Workshop – April 19 & 20, 2017 CONFIDENTIAL
AI Clean Energy Solvent Leadership Series: Workshop 3 March 7, 2018 Calgary 16
Separator fluids
Separator Condensed liquid sample
Pre-analysis treated
Separator Vapor
Sep
arat
or
liqu
id s
amp
le
Ab
ove
am
bie
nt
T/P
Vapor phase
Homo. liquid phase
Pre-analysis treated
Water cut
Ambient T/P
Composition analysis
Composition analysis
Gases
Composition analysis
AACI Technical Workshop – April 19 & 20, 2017 CONFIDENTIAL
AI Clean Energy Solvent Leadership Series: Workshop 3 March 7, 2018 Calgary 17
Wellhead Fluids Separator Fluids
Sampling Difficult Less difficult
Concurrent V&L phases Yes No
V-L phase separation before
composition analysis
Yes Yes
Homo. liquid phase before
composition analysis
Yes Yes
Analysis turnaround Slow Slow
AACI Technical Workshop – April 19 & 20, 2017 CONFIDENTIAL
AI Clean Energy Solvent Leadership Series: Workshop 3 March 7, 2018 Calgary 18
Sampling Operation One-stage sample collection Appropriate sampler
Adequate volume
Operates under pressure and leak-tight
Easy to discharge the content & clean
Simple & safe to operate
Easy to transport
Adequate sample collection Sampling frequency – weekly, bi-weekly, or more
frequent in early stage and tapers off in late stage
Duplicate sample per sampling for backup need
Periodical sampling from the neighboring well(s)
Transport & storage Sampler in protection case
Stored in place with proper temperature
Accumulator sampler - suitable
Bomb or bottle sampler – not suitable
AACI Technical Workshop – April 19 & 20, 2017 CONFIDENTIAL
AI Clean Energy Solvent Leadership Series: Workshop 3 March 7, 2018 Calgary 19
New Development in the Subject Area Two-stage sample collection Primary sampler
Connected to the sampling point on the production line
Automate multiple sampling at desired incremental volume & frequency from the production line during a sampling period
Homogenize the compound fluid sample for sub-sampling to the secondary sampler
Empty the sampler after sub-sampling (to the production line) for next sampling period
Secondary sampler Operate similarly to the one-stage sampling procedure
Secondary sampler
Wellhead T/P
Pri
mar
y sa
mp
ler
Test separator
Secondary sampler
AACI Technical Workshop – April 19 & 20, 2017 CONFIDENTIAL
AI Clean Energy Solvent Leadership Series: Workshop 3 March 7, 2018 Calgary 20
New solvent detection methods – ITA internal study
Head-space GC for composition analysis of HC samples with water in presence A pre-GC device to separate water and other low boiling point HC compounds
from the original liquid fluid sample
Elution of the HC components through the GC column
Homogeneity of the fluid sample is important
Could eliminate the step of water-oil separation in pre-analysis treatment
NIR detection for composition analysis of HC samples NIR measurement of solvent/bitumen mixture spectra
Derive solvent component concentration profile from NIR spectra data
Quantification of multi components solvent in solvent/bitumen binary fluid system - proven
Quantification of multi components solvent in solvent/bitumen/water ternary fluid system – in progress
Detection probe operates at elevated temperature under pressure
AACI Technical Workshop – April 19 & 20, 2017 CONFIDENTIAL
AI Clean Energy Solvent Leadership Series: Workshop 3 March 7, 2018 Calgary 21
Examples of NIR spectra: C-H stretching bands of nC4, nC5 and nC6 (left), combination bands of nC4, nC5 and nC6 (right)
Blue – nC4 Red – nC5 Yellow – nC6
NC7 concentration in bitumen/C7 mixture from NIR measurement
AACI Technical Workshop – April 19 & 20, 2017 CONFIDENTIAL
AI Clean Energy Solvent Leadership Series: Workshop 3 March 7, 2018 Calgary 22
Inline solvent monitoring technique Sensitive to the change in oil composition
Directly probe the liquid phase without O/W separation
Robust to the process operation condition
Easy to operate & low maintenance
Cost effective
NIR implementation potential Measure solvent content in solvent/bitumen/water mixture (emulsion)
in lab needs high efficiency homogenizer to pre-treat the collected fluid sample
As the inline measurement probe enabling continuous measurement needs further development
AACI Technical Workshop – April 19 & 20, 2017 CONFIDENTIAL
AI Clean Energy Solvent Leadership Series: Workshop 3 March 7, 2018 Calgary 23
Acknowledgments
InnoTech Alberta (ITA) – support to the R&D work
Colleagues at ITA – technical support
Colleagues from O&G companies – share knowledge & experiences on the relevant subjects
AI Clean Energy – opportunity to share the ideas/learning with Workshop participants
March 2018
Field Challenges and Successes collecting samples from solvent pilotsKyle ThackerReservoir Engineer
Overview
• eMVAPEX Conceptual Model
• eMVAPEX Benefits
• Recovery Process Evaluation – Importance of Sampling
• Solvent Recovery from Sampling
– Gas Phase
– Liquid Phase
• Sample Analysis
• Summary
2
MEG Energy Corp.Who we are
3
A Canadian oil sands company focused on sustainable in situ development and production in the southern Athabasca oil sands region of Alberta
eMVAPEX Modelenhanced Modified VAPour EXtraction (eMVAPEX)
4
Inject condensable gas (CG) to:• Maintain reservoir pressure, reducing
steam injection to near zero• Dilute the warm bitumen to further
improve viscosity• Partly de-asphalt the bitumen improving
API gravity and value of product
1 2 3Warmed bitumen mixed with light hydrocarbon is pushed toward infill well by pressure difference and gravity.
Freed-up steam is re-diverted to new SAGD well pairs to increase production.
Potential eMVAPEX BenefitsFurther reduction of SOR over SAGD/eMSAGP
Lower capital requirements to grow
Lower operating costs
Lower carbon emission intensity
Lower steam requirement per barrel reduces steam and water handling capacity necessary at the central plant facility to support future growth
Reduced energy costsper barrel
Growth results in fixed cost amortization across larger number of barrels, contributing to increased cash margin per barrel
Significantly lower steam requirement per barrel directly translate into lower GHG intensity per barrel
5
Recovery Process Evaluation
• Key Data for SAGD– Bitumen Production– Bitumen Recovery– Steam Injection
• Additional Data required for Steam/Solvent processes– Solvent Injection– Solvent Recovery
• Gas and Liquid– Bitumen/Solvent Solubility– Bitumen Quality
Requires Additional Sampling/Monitoring
6
Solvent Recovery – Gas PhaseTest Separator Overhead Gas Sample
Sample Cylinder (vacuum)
Rough Procedure1. Sample cylinder is attached2. Sample cylinder is filled
Test Separator
Challenge:Air Contamination
up to ~1%
Emulsion
Produced Gas
Oil/Water Production Header
7
Solvent Recovery – Gas Phase
• One problem with well level sampling is it does not monitor solvent recovery from the wells that are not sampled
• Gas phase solvent recovery from all producing wells can be estimated at the CPF using the:– Produced Gas Rate– Produced Gas solvent composition
Utilizing Central Processing Facility (CPF) Produced Gas Samples
Potential Sample Contamination
Solvent Recovery – Liquid PhaseTest Separator Bottoms Liquid Sample – Original Set-up for eMVAPEX Pilot
Sample Cylinder (vacuum)
Test Separator
• Contamination by different well
Emulsion
Produced Gas
Oil/Water
Production Header
Potential Air Contamination
Potential Challenges:
• Air Contamination• Live oil flashes as the valve is
opened to the vacuum cylinder –Potentially extra gas flashing into the cylinder (Inflated GOR)
Rough Procedure1. Sample cylinder is attached2. Sample cylinder is filled
9
Solvent Recovery – Liquid PhaseTest Separator Bottoms Liquid Sample – Updated Set-up for eMVAPEX Pilot
Sample Cylinder (vacuum)
Test Separator
• Contamination by different well
Emulsion
Produced Gas
Oil/WaterProduction Header
The Purge eliminates previous Challenges:
• Air Contamination• Live oil flashes as the valve is
opened to the vacuum cylinder –Potentially extra gas flashing into the cylinder (Inflated GOR)
Rough Procedure1. Sample cylinder is attached2. Sample cylinder is filled & Purged
10
Bitumen/Solvent Sampling
• Sample Draw Point?– Top/Bottom/Side of pipe– Sample Quill in middle of pipe – plugging issues?
• How are the samples analyzed in the lab?
• How does the presence of a solvent affect BS&W determination?
• Others?
Other Sampling Challenges
11
Bitumen/Solvent Sample Analysis
• A key component of the lab analysis is to determine solvent (C3) dissolution in the oil phase
• Lab results are compared to a vapor liquid equilibrium (VLE) estimate
Solvent Dissolution in Bitumen
12
Bitumen/Solvent Sampling
• In Steam based processes emulsion is produced to surface, but must understood in terms of Water and Oil. This is typically done with inline analyzers or sample analysis.
• How does the presence of solvent in the produced emulsion affect BS&W measurement?
• Inline analyzers may not be able to accurately measure Water vs Oil with a solvent present.
• Non-pressurized samples likely won’t capture all of the light ends
• Pressurized samples can be taken, but how will they be analyzed to capture all the light ends?
13
Emulsion Sampling and BS&W Determination
Summary
• Gas & Liquid Sampling and Lab Analysis are very important for evaluating Steam/Solvent processes
• Sampling Challenges and Successes
– Success – Using CPF Produced Gas to Estimate Total Solvent Recovery in the Gas Phase
– Success – Inline liquid sampling systems are believed to be optimal with a favorable pressure profile and the ability to purge
– Challenge – What is the ideal liquid sample draw point?
– Challenge – How are the liquid samples analyzed?
– Challenge – How do solvents affect BS&W determination?
14
SDP/Hot Solvent Projectmeasurement
Alex Filstein, P.EngCenovus Energy IncReservoir Engineer | Technology DevelopmentDirect: (403) 766-3266 | Cell: (403) 604-1296
Natasha Pounder, P.EngCenovus Energy IncProcess Engineer | Technology DevelopmentDirect: (403) 766-3112 | Cell: (204) 583-6915