The 21st Formation Evaluation Symposium of Japan, October 13 - 14, 2015

NUMERICAL MODELING OF EMULSION TO INVESTIGATE

THE SAGD OIL PRODUCTION BASED ON VISCOSITY MEASUREMENTS

Junpei Kumasaka1, Kyuro Sasaki2, Yuichi Sugai2 and Masanori Nakano3

1.
Graduate School of Engineering, KYUSHU UNIVERSITY
F
2.
Faculty of Engineering, KYUSHU UNIVERSITY
3.
Research Center, JAPEX

This paper was selected for presentation by a JFES program committee following
review of an abstract submitted by the author(s).
ABSTRACT
In this study, the effects of emulsion generation in a steam
chamber formed in oil sands reservoir have been studied
for bitumen production using Steam Assisted Gravity
Drainage (SAGD). Some viscosity measurements of
heavy oil emulsion were performed to investigate the
characteristics of emulsion at different values of W/O,
shear rates, pressures and temperatures. Based on these
results, a numerical model of viscosity change was
presented for the emulsion generation. The numerical
simulations of the SAGD bitumen production were also
carried out based on the model of viscosity change to
estimate distribution of emulsion, water, and bitumen at
steam chamber boundary and effects of emulsion on
bitumen production behavior. With a model named
SAGD-Emulsion Model, we highlighted that recovery
factor of bitumen was higher than that of conventional
SAGD simulation because higher water content would
invariably allow bitumen to flow at higher relative
permeability. The increase in viscosity was expected to
induce delay of bitumen production.
INTRODUCTION
Steam Assisted Gravity Drainage (SAGD) method is
widely used to produce bitumen from oil sands reservoir.
The API gravity of bitumen is less than 10° (i.e. specific
gravity=0.9994) and its mobility at reservoir condition is
nearly equal to zero. In general, two types of techniques,
including open pit mining and in-situ recovery that has
been a commercial method, are applied to produce
bitumen from oil sands. SAGD method is one of the in-
situ recovery method. In SAGD method, two horizontal
wells are used as injector and producer. Steam is injected
into the reservoir from the upper horizontal injector to
head bitumen in order to decrease its viscosity from order
of 106 cp to less than 10 cp. Heated oil and steam
condensate are produced simultaneously from lower
horizontal producer by gravity. Some experimental studies
on SAGD process have been conducted by independent
researchers. Numerical modeling of effective phenomena
have been observed in these experiments and their
applications to commercial field receive attentions from
some researches. Al-Bahlani and Babadagli (2009) have
reviewed current status and future issues of SAGD in
terms of experimental and numerical simulation studies.
They referred emulsification in the reservoir as one of
these topics. Figure 1 shows the mechanism of a typical
SAGD process and in-situ emulsification occurring in the
steam chamber (Sasaki et al. 2002).
Figure 1: Mechanism of SAGD process and in-
situ emulsification presented by Sasaki et al.
(2002).
Throughout a thermal process using steam, oil is typically
produced as water-in-oil (W/O) emulsion, which is almost
stable, in the field. Previous experimental studies also
suggested that W/O emulsions were produced during
experimental SAGD process (Chung and Butler 1987;
Sasaki et al. 2001 & 2002; Noik et al. 2005;
Mohammadzadeh and Chatzis 2009). Especially, Sasaki
et al. (2001) conducted experimental studies on SAGD
process by using two-dimensional scaled reservoir model
to investigate fluids flow characteristics in the steam
chamber. They also carried out visualization of micro-
phenomena at inclined interface on the side of steam
chamber by means of a high-resolution optical-fiber scope.
They observed very fine droplets at the interface between
steam and heavy crude oil phase and assumed that these
droplets generated on cold oil surface entered into oil
phase just after generation and released their heat into the

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The 21st Formation Evaluation Symposium of Japan, October 13 - 14, 2015

oil phase, while other water droplets became condensed
water. It is expected that the gravitational flow of
emulsion exists between condensed water and heated oil
flows.
However, these emulsions are much viscous than original
oil (Chung and Butler, 1987) and viscosity properties of
the emulsion may affect gravitational flow of produced
fluids and oil production behavior.
In this study, viscosity of the emulsions, that were formed
by injecting steam into oil, were measured versus water-
oil ratio (W/O) at different shear rates, pressures and
temperatures. Based on these results, a numerical model
of viscosity change were constructed for emulsion
generation. The distribution of emulsion, water and
bitumen at the steam chamber boundary and effects of
emulsion formation on bitumen production behavior were
simulated numerically by thermal simulator, CMG
STARSTM.
EXPERIMENTAL SAMPLES AND APPARATUS
Experiments were performed to investigate effects of the
degree of emulsification on viscosity change at different
conditions. In this experiment, water-in-oil emulsions
were formed from a heavy crude oil and their viscosity
properties were measured. The API gravity of the heavy
crude oil was 11.6° (i.e. density=0.998) and kinetic
components, water droplet size and shear rate. Figure 3
shows results of viscosity measurements of the emulsions
by using the rotational viscometer. It was observed that
apparent viscosity became higher with W/O because
droplet-droplet interaction was stronger with the increase
in number of water droplets. In the case of W/O > 0.6, the
viscosity change caused by changing shear rate was
obviously observed, however, it was much smaller than
that caused by W/O. It is assumed that apparent viscosity
change of the emulsion is mainly determined by W/O. As
shown in Figure 4, viscosities of emulsions, that have
different W/O, were measured at high pressure and
temperature to investigate effects of temperature and
pressure on viscosity change. Viscosity-increasing ratio γ,
which was defined by (1), was also plotted as shown in
Figure 5.
Apparent viscosity of emulsion
γ= (1)
Apparent viscosity of original oil
Apparent viscosity increased under high pressure and
decreased with rise in temperature. Furthermore, γ
increased linearly with W/O. Based on these results, it was
found that viscosity change strongly depends on W/O and
was determined mainly by W/O.
4000
38.4 s-1
19.2 s-1
Apparent viscosity (cP)

viscosity was 874 cSt at 30°C. Emulsions with different 3000

W/O were generated by injecting steam into heavy crude

oil. Steam generator (Yamazen, YSC-130) was used to 2000
generate steam. Plumbing type viscosity sensor 76.8 s-1
(Cambridge Viscosity, Model SPL372) was set in high
1000
temperature oven as shown in Figure 2 and measured the
viscosity of emulsions at high pressure and temperature.
Moreover, a rotational viscometer (BROOKFIELD, 0
0 0.2 0.4 0.6 0.8 1
MODEL DV-Ⅲ) was also used at atmospheric pressure to W/O (-)
investigate the effects of shear rate on viscosity of
Figure 3: Relationship of apparent viscosity vs.
emulsion. W/O for different shear rate (heavy oil; API
gravity=11.6°).
4000
30℃ 0.1MPa
50℃ 0.1MPa
Apparent viscosity (cP)

3000
30℃ 5.1MPa
50℃ 5.1MPa
2000

1000

Figure 2: Viscosity measurement apparatus.

0
0 0.2 0.4 0.6 0.8 1
EXPERIMENTAL RESULTS AND DISCUSSION W/O (-)
Figure 4: Relationship of apparent viscosity vs.
The viscosity behavior of the emulsion depends on many W/O for different pressure and temperature
factors such as chemical composition of crude oil, (heavy oil; API gravity=11.6°).
temperature, each viscosity of oil and water, surfactant

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 The 21st Formation Evaluation Symposium of Japan, October 13 - 14, 2015

4 The Avisc of emulsion was given by multiplying Avisc of

Viscosity-Increasing ratio, γ (-)

the original bitumen by γ. The numerical model using

3 equations (2) to (4) is hereinafter called SAGD-Emulsion
γ = 2.6411・W/O + 1 Model. On the other hand, the model not considering in-
2
situ emulsification is called Base Model.
In numerical simulations, two dimensional numerical
simulations were performed to investigate the effects of
1
viscosity change on bitumen production from field scale
oil sands reservoir. The reservoir model was 100.8m in
0
0 0.2 0.4 0.6 0.8 1
width and 15m in height. In this model, 215.5 °C steam F
W/O (-) was injected from upper horizontal well, which was
located 4.875 m above the production well as shown in
Figure 5: Relationship of viscosity-increasing Figure 6. Table 2 shows properties of oil sands reservoir
ratio γ vs. W/O (heavy oil; API gravity=11.6°). and operation condition that were used for present
simulations. These conditions are reservoir properties of
CONSTRUCTION OF NUMERICAL MODEL Athabasca oil sands used by Souraki et al. (2012).

In this research, emulsification at the steam chamber

surface has been expressed with pseudo reaction in the
reservoir simulator, CMG STARSTM (2012). For instance,
when W/O in the emulsions is assumed as 0.2, pseudo
reaction formula is presented by (2):

1 (Bitumen) + 5.83 (H2 O) → 1 (Emulsion) (2)

This formula was registered with STARS to generate

emulsions numerically. In this model, the constant W/O
(0.2, 0.4 and 0.6) in the generated emulsions were
assumed for the simulations. Table 1 shows pseudo
reaction formula modeled for each emulsification. Figure 6: Illustration of numerical model.

Table 1: Pseudo reaction formula for each Table 2: Properties of Athabasca reservoir and
emulsion generation. condition of steam injection (Souraki et al. 2012).
W/O (-) Reaction formula Porosity, % 38
0.2 Bitumen + 5.83 H2O → Emulsion Horizontal permeability, md 7000
0.4 Bitumen + 11.7 H2O → Emulsion Vertical permeability, md 2100
0.6 Bitumen + 17.5 H2O → Emulsion Initial pressure, kPa 2068
Initial temperature, °C 10
The experimental result of γ vs. W/O is represented by Initial water saturation, % 20
sublinear formula at any difference pressures, Initial bitumen saturation, % 80
temperatures and shear rates as shown in Figure 5. Steam temperature injected, °C 215.5
Therefore, the relationship between γ and W/O for the Steam quality, % 90
heavy oil was represented by following linear formula Steam injection rate, m3/day 0.5
expressed by (3): Bottom hole pressure of producer, kPa 1700
γ = 1 + 2.64 ∙ W/O (3)
NUMERICAL SIMULATION RESULTS AND
Viscosity of each fluid modeled in STARS is given by DISCUSSION
following Andrade equation that depends on temperature.
The numerical simulation results of SAGD-Emulsion
Bvisc
μ = Avisc exp ( ) (4) Model (W/O=0.2, 0.4 and 0.6) were compared with the
T ones of Base Model (W/O=0). Figure 7 shows
where, comparisons of fluids saturation in steam chambers. In
μ : Apparent viscosity, cP; this figure, grids occupied by steam (saturation > 0.1),
T : Temperature, K; water (saturation > 0.4) and emulsion (saturation > 0.4)
Avisc : Constant, cP; were respectively represented as steam phase, water phase
Bvisc : Constant, K. (condensed water phase) and emulsion phase. Others were

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The 21st Formation Evaluation Symposium of Japan, October 13 - 14, 2015

represented as bitumen phase. It has been shown that process. A numerical model about viscosity change was
emulsion was generated at the steam chamber boundary, constructed based on the measurement results. Moreover,
especially between gravitational flows of condensed water effects of in-situ emulsification in a field scale oil sands
and heated bitumen. In SAGD-Emulsion Model, bitumen reservoir were evaluated by numerical simulations. This
was produced as a state of both emulsion and bitumen research is summarized as:
because produced emulsion also contains original bitumen. 1) Experimental results showed viscosity-increasing
Thereby, net cumulative bitumen production was ratio γ, which define the ratio of emulsion viscosity
calculated as shown in Figure 8. Production of SAGD- over crude oil viscosity, was represented by
Emulsion Model showed a delay of one month later than sublinear formula for any different shear rates,
that of Base Model, while final cumulative oil production pressures and temperatures.
was about 5-10% higher than that of Base Model. These 2) The numerical models of viscosity change and in-
results are attributed to two main reasons: viscosity situ emulsification were constructed.
change and swelling by including water droplets. In 3) Numerical simulation results of SAGD oil
SAGD-Emulsion Model, viscosity change causes delay of production by considering in-situ emulsification
bitumen production. Furthermore, bitumen in emulsion expected that emulsion and condensed water were
flows at high relative permeability because emulsion formed at the steam chamber boundary.
containing water flows as oil phase (like swelling). In 4) Numerical simulation results also showed that net
other word, emulsion flow depends on relative bitumen recovery factor at the end of production
permeability curves. This assumption agrees with Ezeuko increased with water-oil ratio (W/O) of the
et al. (2013). They also stated that final cumulative emulsions and the increase in viscosity was expected
production decreased with an increase in W/O because of to induce delay of production.
viscosity increase. However, cumulative recovery at end
of production became larger as W/O became also larger. It REFERENCES
is concluded that higher water content in emulsion allows
bitumen to flow at higher relative permeability and its Al-Bahlani, A. and Babadagli, T., 2009, SAGD laboratory
viscosity increase induces delay of production. experiment and numerical simulation studies: A review of
current status and future issues: Journal of Petroleum
Science and Engineering, vol. 68, p.135-150.

Chung, K.H. and Butler, R.M., 1987, Geometrical effect

of steam injection on the formation of emulsions in the
Steam-Assisted Gravity Drainage process: SPE Annual
Technical Meeting, PETSOC-87-38-22.

Ezeuko, C.C., Wang, J. and Gates, I.D., 2013,

Figure 7: Comparison of steam chamber by Base Investigation of emulsion flow in Steam-Assisted Gravity
Model (left) and SAGD-Emulsion (W/O=0.2) Drainage: Society of Petroleum Engineers Journal, vol. 18,
Model (right). p.440-447.
2500
CUMULATIVE OIL PRODUCTION

Mohammadzadeh, O. and Chatzis, L., 2009, Pore-level

2000
(bbl/1m horizontal well)

investigation of heavy oil recovery using Steam Assisted

1500
Gravity Drainage (SAGD): International Petroleum
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500 SAGD-Emulsion Model (W/O=0.4) 2005, characterization and emulsion behavior of
SAGD-Emulsion Model (W/O=0.6)
0
Athabasca extra heavy oil produced by SAGD: SPE
0 500 1000 1500 2000 2500 3000 3500 International Thermal Operations and Heavy Oil
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Figure 8: Net cumulative bitumen production.
Sasaki, K., Akibayashi, S., Yazawa, N., Doan, Q. and
CONCLUSIONS Farouq Ali, S.M., 2001, Experimental modeling of the
SAGD process-enhancing SAGD performance with
In this research, viscosity measurements of water-in-oil periodic stimulation of the horizontal producer: Society of
(W/O) emulsion were carried out to investigate production Petroleum Engineers Journal, vol. 6, p.89-97.
behavior by Steam Assisted Gravity Drainage (SAGD)

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 The 21st Formation Evaluation Symposium of Japan, October 13 - 14, 2015

Sasaki, K., Akibayashi, S., Yazawa, N., Doan, Q. and

Farouq Ali, S.M., 2001, Numerical and experimental
modeling of the Steam Assisted Gravity Drainage
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Sasaki, K., Akibayashi, S., Yazawa, N. and Kaneko, F.,

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ABOUT THE AUTHORS

Junpei Kumasaka is a master second year student of

Resource Production and Safety Engineering, Department
of Earth Resources Engineering at the Faculty of
Engineering, Kyushu University, Japan.

Kyuro Sasaki is a professor of Resource Production and

Safety Engineering, Department of Earth Resources
Engineering at the Faculty of Engineering, Kyushu
University, Japan.

Yuichi Sugai is an associate professor of Resource

Production and Safety Engineering, Department of Earth
Resources Engineering at the Faculty of Engineering,
Kyushu University, Japan.

Masanori Nakano is a senior reservoir engineer working

at the research center of JAPEX.

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