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SAGDThermal In situ Recovery
PRESENTED BY:
Daryl Foley
Presentation Overview
What is SAGD and In situ?
Recovery Processes
Gathering Facilities
Processing Facilities
The Future
Background• 1,700 billion bbls of original bitumen in place• 173 billion bbls (10%) economically recoverable• 35 billion bbls surface mineable• 98 billion bbls recoverable by in situ methods
Bitumen
Oil Sands• 75-80% inorganic material
» 90% of which is quartzsand (silica)
• 3-5% water• 10-18% bitumen• Unconsolidated
Origins of SAGD• In 1978, Dr. Roger Butler, introduced the concept
of Steam Assisted Gravity Drainage (SAGD).• UTF operation first phase in 1987
In-situ• SAGD is a type of in situ technology• Sand left in place (“in situ” - Latin for “in place”).• This compares to Mining where sand is extracted
with oil
Steam Assisted GravityDrainage (SAGD) Process
• Involves drilling pairs of horizontal wells• Steam continuously injected• Steam to Oil Ratio (SOR) varies
(typically 2.5 - 3.5)• Bitumen / Water (emulsion) is continuously
produced• > 50% bitumen recovery
- 300 - 450 m TVD- 1,000 - 1,500 m measured depth
Bitumen Production
Steam Assisted Gravity Drainage (SAGD)
Bitumen Production• API < 10• Viscosity > 10,000 cp
Courtesy of Suncor Energy
Crude and WaterCharacteristics• Crude 6 - 12 API• Sulfur 3 - 6% (Aquathermolysis occurs > 200ºC)• H2S – typically 1,000 - 5,000 ppm• CO2 – 2 - 20% from reservoir• Sand / Silt• Chlorides 1,600 - 5,000 ppm
Projects
Proposed / Under Construction:• $38 billion of SAGD Projects• 32 SAGD Projects• 25 Companies
Types of In situ Processes• Cold Flow – Programming Cavity Pumps• Huff and Puff / Cyclic Steam Stimulation• Toe To Heel Air Injection (THAI)• VAPEX – Vapor Extraction Process
Advantages of SAGD• Significantly greater per well production rates• Greater reservoir recoveries• Reduced water treating costs• Dramatic reductions in SOR
Typical SAGD Facility
SAGD Processes
Field Facilities• Wells (producers / injectors)• Well pads (group and text separators)• Flow lines
» Emulsion (above ground)» Vapor (above ground)» Steam distribution (above ground)
• Lift gas or sweep gas (below ground)• Source water system• Disposal water system
Typical Well Pad• Well pairs• Group / Test• Condensate management
Typical Production Well
Producer Configuration
Injector Configuration
Production Strategy• Steam is always injected below the fracture
pressure of the rock mass
• Production well controlled to maintain temp below saturated steam to prevent steam from entering producer
Sand Erosion of Wellhead
Sand Jetting
Erosion of First Elbowin Producer
Well Pad Facilities• Group
Separator• Test Separator• Piping• Condensate
Systems• Pop Tank
Recovered Production• Produced vapor
(95% steam vapor)• Produced emulsion
(oil / water)• Saturated steam• Fuel gas
Other Field Facilities• Water disposal
» As high as 160,000 TDS pH 12
• Source Water» Brackish (> 4,000 TDS)» Fresh
Central Processing Facility (CPF)
SAGD Process Areas - CPF• Inlet separation• De-oiling• Water treatment• Steam generation• Produced Gas Handling
Produced Gas Handling
Processes:• Condensate removal• Dehydration (Glycol)• Sweetening (Amine)
Gas used for:• Lift gas• Fuel gas
Inlet Producer Vapor Exchangers
Vapor Recovery System• Acid Gases - CO2, H2S• Condensing steam vapor
Skim De-oiled Produced
IGF
Gas Processing
Water Management• Basically a large water Plant• Recycle produced water for boiler feed• Most SAGD are 90% water recycle• Brackish water makes up 10%• Some are “Zero discharge”• Tight restrictions on fresh water
90% Water Recycle
Reservoir
Produced Water
Brackish Source Water
Steam
Boiler
BD Disposal
Pads to CPF Inlet Separation
Reservoir
GroupSeparator
Oil / Water Separation
Gas Processing
Skim IGF ORF De-oiled DiluentREB/EB
Inlet Treating
Free Water Knock-out:• Inlet diffuser reduces forward velocity
allowing gravity to separate the waterfrom the bitumen
• Chemical treatment aids in theseparation process
Inlet Treating
Free Water Knock-out
Inlet Treating
Electro-static Grid Treater:• Designed under the same premise as the FWKO• However, induces an electrical current
Produced Water De-Oiling
Skim Tank:• Vortex flow to increase
residence time• Coagulant and invert
emulsion polymer areadded at inlet to assist in the formation of oil droplets
• Operates at roughly90% efficiency
Produced Water De-Oiling
Baffled Skim Tank (Kinosis)
Produced Water De-Oiling
Induced Gas Flotation Vessel:• Purge gas enters vessel as micro-bubbles
which attach to the oil droplets to increase droplet buoyancy
• Invert emulsionpolymer is addedto promoteoil droplet formation
Induced Gas Floatation
Process Schematic De-Oiling
Skim Tank
Free Water Knock Out
De-oiled Water
Storage Tank
Skimmings Tank
Treaters or FWKO
Slop Oil Tank
IEP/REB
Water Treatment
Oil
Water from Skimmed Oil Tank
E-1
IGF
IEP/REB
E-5
ORF
Produced Water De-Oiling
Oil Removal Filters (ORF’s):• Uses walnut shells to further remove solids and oil• Operates at roughly 90% efficiency
Courtesy of Cameron Process Systems
Chemistry:-Lime- Acid- Caustic soda- Magnesiumoxide-Flocculant- Soda Ash
Supernatant to De-oil tank
Sludge
Chemistry
Boiler Blowdown
Disposal well
De-oil Tank Out
Sludge recycle
Hot Lime Softeners
Sludge Pond
Afterfilters
WACs
Boiler Feedwater
Tank
Steamgens
Brackish water
Caustic
EP
O2 Scavenger Chelant
WATER TREATMENT
Produced Water Softening
Hot Lime Softener:• Removes silica• Also removes some
hardness, iron and oil• Make-up water is
introduced at this point• Chemical addition
includes: Lime, Magox,Caustic, and Flocculant
Water Treatment(Technologies)
• Hot Lime (most popular)• Warm Lime (most popular)• Demineralization (RO / Membrane)• Evaporators / Crystallizers
Water Softening (HLS)• Silica (Si02)
Reduction• Requires heat 105ºC• pH > 9.5• Mechanical Deaeration
< 5 ppb 02
PRODUCED WATER SOFTENING
Produced Water Softening
After Filters:• Removes suspended
solids• Anthracite is the filtering
media• Media is regenerated
through backwash
Produced Water Softening
Weak Acid Cation Exchangers:(Primary and Polishing)
• Removes hardness(calcium andmagnesium)
• Weak acid cation resinis the exchange media
• Media is regenerated throughan acid and caustic soak
Weak Acid Cation Exchangers(WACs)Function:• Reduce hardness concentration to below
BFW specification• Primary and polisher in series to accomplish the target
Operation:• Run• Acid regeneration in separate vessel• Caustic treatment in separate vessel
Step 1: OperationStep 1: Operation
Na
NaNa
Water with 1 Ca2+ and 1 Mg2+
Mg
Water with 4 Na+
Step 2: Acid regenerationStep 2: Acid regeneration
Step 3: Caustic regeneration
Step 3: Caustic regeneration
+
Ca
MgAcid (HCl)
HHHH
Acid and hardness, Ca2+ and Mg2+
+ +
+
Caustic (NaOH)
NaNa
NaNa
++Caustic and water
HHHH
RESIN OPERATION SCHEMATIC
Steam Generation
OTSG’s and HRSG’s:• OTSG’s produce 75 - 80% steam –
blowdown carries remaining minerals• HRSG’s produce
75 - 80% steam from hot gas exhausted by gas turbine
Steam Generation
Cogeneration:• Simultaneous generation
of heat and power• Mixed gas is burnt to
provide the energy required to turn the gas turbines
• The mechanical energyfrom the turbine is usedto create electricity
• The thermal energy of the hot exhaust gas is recovered to produce steam
Upper Convection
Lower ConvectionRadiant
Once Through Steam Generator
Steam Generation
OTSG
Steam Generation
OTSG’ burner
OTSG Radiant Section -View from Target Wall
Steam Generation
Silica Scale
Tube Overheat (Creep Failure)
Steam Generation
Steam Separation
Steam Generation
HP STEAMSEPARATOR A
HP STEAMSEPARATOR B
HP STEAMSEPARATOR C
HP WET STEAM FROM GENERATORS
HP STEAM (99% QUALITY)
BLOW DOWN TO MP STEAM SEPARATOR C
BLOWDOWN TO MPSTEAM SEPARATOR A/B
Filming Amine
77-78 % steam quality
Steam Separation
Steam Generation
Blowdown Stream (disposal):• TDS 160,000 mg/l• pH 12• Temp 60ºC• Chloride (CI-) 93621.3• Carbonate (C03-) 666.6• Sulphate (S04=) 5808.2• Sodium (Na+) 63505.2• Potassium (K+) 562.0
Silica Solubility (Disposal)
0
100
200
300
400
500
600
700
800
900
1000
6 7 8 9 10
pH
Solu
ble
Silic
a (m
g/L)
5C
20C
50C
80C
110C
140C
90% Water Recycle
Disposal
Reservoir
Produced Water
Brackish Source Water
Steam
Boiler
BD Disposal
Water Cycle-Zero Discharge
Evaporator
Reservoir
Produced Water
Brackish Water
SteamBoiler
BlowdownEvaporator Crystallizer
Evaporators
Evaporators
90% Water Recycle - Steam
Reservoir
Produced Water
Brackish Source Water
SteamBoiler
BD Disposal
Steam Distribution• Licensed with ERCB• Registered with ABSA• Designed to CSA Z662 Clause 14• Design pressure - 10,000 kPa• Design Temp - 320ºC
Steam Distribution Pipeline
Water Hammer
New Advancements• Enhanced Solvent Extraction Incorporating
Electromagnetic Heating (ESEIEH and pronounced “easy”)
• VAPEX• C02 Injection
Thank You
PRESENTED BY:
Daryl Foley