sagd thermal in situ

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