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Refining in the
reservoir
Bringing high-value petroleum products straight to the surface
rather than raw crude and gas is the next big challenge for the
oil and gas industry, says Geoff Maitland
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subsurface hydrocarbon
processing the reservoir
refinery
Looking beyond the advances and benefits
of fluid pumping, compression and
separation on the seabed (see box: Subsea
processing) some technology providers
have a vision of a subsea factory. In this
vision, many of the surface processes are
taken to the seabed, closer to the point of
production, and the products delivered to
the surface are processed hydrocarbons.
The ultimate vision for the future would
be to move some or all of the downstream
operations into the well system or into the
reservoir itself.
As such, the concept of in situ
hydrocarbon processing involves
delivering to the surface high-value
petroleum products rather than the raw
crude oil and gas; representing a merger
subsea processing
Oil producers are increasingly taking oilfield processing down onto the ocean
floor, close to the wellheads, relocating much of the processing activity that has
previously been carried out on offshore platforms or even onshore. This is proving
to be effective in overcoming many of the challenges of producing from deep offshore
basins, enabling both accelerated production and improved overall recoveries.
Pumping liquids and compressing gas are key parts of the emerging subsea
technologies that help us overcome the challenges of falling reservoir pressures
in mature fields. This maintains the reservoir pressure and adds energy to the well
stream (artificial lift) to maximise production as reservoirs decline. For heavy, viscous
oils and low permeability reservoirs, artificial lift is often required from the start, and
reducing pumping distances improves efficiency and simplifies logistics.
As production is moved to deeper water and more remote locations, the long
gathering distances involved are a challenge, with multiphase fluids being pumped
through long tiebacks to transport the hydrocarbons to existing infrastructure.
Subsea pumping and compression has brought significant improvements but a
major problem is high water production from reservoirs, particularly as reservoirs
decline. Here, subsea fluids separation is making a big contribution. Liquid-liquid
separation of produced water from the hydrocarbons means that this is no longer
delivered to the platform or FPSO (floating production storage and offloading unit),
enabling debottlenecking of the topsides water separation facilities. This water can
be treated to remove particulates and harmful scale-forming ions such as sulphate
(by nanofiltration membranes for example) and then reinjected into the reservoir
to improve both production rates and ultimate hydrocarbon recoveries. Gas-liquid
separation enables more efficient liquid pumping and gas removal, and combined
with water removal, greatly reduces the risk of forming flowline-blocking gas hydrates
at the temperatures and pressures encountered in water depths which can now
exceed 1.5km. The risk of hydrate formation in cold subsea long-distance gathering
lines remains, but this could be minimised via electrical heating in the linings of
insulated double-pipe or coated multiphase lines which carry the produced fluids to
the surface.
The presence of remote processing equipment on the seabed has, of course, major
power demands so another key challenge is seabed transmission. The requirement
for tens of MW on the ocean floor is leading service providers to explore DC as a way
to reduce transmission losses. Of course, the best solution if a subsea-to-shore
concept is to become the norm is using locally-generated power through wave or
tidal power for instance, or fuel cells powered by locally-generated methane or even
hydrogen.
Although subsea processing is now becoming well established in some areas,
it is still in its infancy regarding its scope and the sophistication of the technology.
There is talk of unmanned robotic operations which are remotely controlled from the
surface, or from control stations halfway across the world. This would facilitate direct
and non-standard intervention (eg repair) with subsea systems operating under the
extreme conditions of low temperatures, high pressures and corrosive conditions
encountered on the ocean floor. Furthermore, working from a platform or drillship is
increasingly difficult, expensive and dangerous as water depths increase as was
tragically illustrated in 2010 by the Deepwater Horizon accident and oil spill in the
Gulf of Mexico. Eliminating the need for floating platforms would reduce the risks
associated with a manned facility as well as reducing the major capital costs involved.
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tce
application
UCG technology is well developed, with over 60 large-scale demonstration projects carried out over the world, including (left to right): Linc
Energys Chinchilla Facility (Australia) and commercial plant in Uzbekistan.
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