SAGD Thermal 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 quartz sand (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 Gravity Drainage (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 Water Characteristics

Crude 6 - 12 API Sulfur 3 - 6% (Aquathermolysis occurs > 200C) 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 Elbow in 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

Gas Processing

Skim

De-oiled

Produced
IGF

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

Brackish Source Water

BD Disposal

Steam Produced Water Boiler

Reservoir

Pads to CPF Inlet Separation

Gas Processing

Group Separator

Oil / Water Separation

REB/EB

Diluent

Skim

IGF

ORF

De-oiled

Reservoir

Inlet Treating
Free Water Knock-out:
Inlet diffuser reduces forward velocity allowing gravity to separate the water from the bitumen Chemical treatment aids in the separation 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 are added at inlet to assist in the formation of oil droplets Operates at roughly 90% 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 emulsion polymer is added to promote oil droplet formation

Induced Gas Floatation

Process Schematic De-Oiling

Water from Skimmed Oil Tank
IEP/REB

Free Water Knock Out ORF

Skim Tank
IEP/REB

Water Treatment

De-oiled Water Storage Tank

E-5

IGF
E-1

Treaters or FWKO

Slop Oil Tank

Oil
Skimmings Tank

Produced Water De-Oiling

Oil Removal Filters (ORFs):
Uses walnut shells to further remove solids and oil Operates at roughly 90% efficiency

Courtesy of Cameron Process Systems

WATER TREATMENT
Brackish water
EP

De-oil Tank Out Chemistry

Sludge recycle

Boiler Blowdown

Hot Lime Softeners

Sludge

Caustic

Sludge Pond Supernatant to De-oil tank

Afterfilters Steamgens WACs Disposal well

O2 Scavenger Chelant

Boiler Feedwater Tank

Chemistry: - Lime - Acid - Caustic soda - Magnesium oxide - Flocculant - Soda Ash

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 105C 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 and magnesium) Weak acid cation resin is the exchange media Media is regenerated through an 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

RESIN OPERATION SCHEMATIC

Na
Step 1: Operation

Water with 1 Na + Ca2+ and 1 Na Mg2+

Mg +

Water with 4 Na+

Ca + Acid Mg (HCl)
Step 2: Acid regeneration

H H H H

Acid and hardness, + Ca2+ and Mg2+

Step 3: Caustic regeneration

H H H H

Caustic (NaOH)

Na Na + Caustic and water Na Na

Steam Generation
OTSGs and HRSGs:
OTSGs produce 75 - 80% steam blowdown carries remaining minerals

HRSGs 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 energy from the turbine is used to create electricity The thermal energy of the hot exhaust gas is recovered to produce steam

Once Through Steam Generator

Upper Convection
Lower Convection Radiant

Steam Generation
OTSG

Steam Generation
OTSG burner

Steam Generation
OTSG Radiant Section View from Target Wall

Silica Scale

Tube Overheat (Creep Failure)

Steam Generation
Steam Separation

Steam Generation
Steam Separation
77-78 % steam quality
HP WET STEAM FROM GENERATORS HP STEAM (99% QUALITY)

Filming Amine

HP STEAM SEPARATOR A

HP STEAM SEPARATOR B

HP STEAM SEPARATOR C

BLOW DOWN TO MP STEAM SEPARATOR C

BLOWDOWN TO MP STEAM SEPARATOR A/B

Steam Generation
Blowdown Stream (disposal):
TDS 160,000 mg/l pH 12 Temp 60C Chloride (CI-) 93621.3 Carbonate (C03-) 666.6 Sulphate (S04=) 5808.2 Sodium (Na+) 63505.2 Potassium (K+) 562.0

Silica Solubility (Disposal)

1000 900 800

Soluble Silica (mg/L)

700 600 500 400 300 200 100 0 6 7 8 pH 9 10 5C 20C 50C 80C 110C 140C

90% Water Recycle

Disposal
Brackish Source Water BD Disposal

Produced Water

Steam Boiler

Reservoir

Water Cycle-Zero Discharge

Evaporator
Brackish Water

Blowdown

Evaporator

Crystallizer

Boiler Produced Water

Steam

Reservoir

Evaporators

Evaporators

90% Water Recycle - Steam

Brackish Source Water

BD Disposal

Produced Water

Boiler

Steam

Reservoir

Steam Distribution
Licensed with ERCB Registered with ABSA Designed to CSA Z662 Clause 14 Design pressure - 10,000 kPa Design Temp - 320C

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