CA2884849C - In-situ upgrading and recovery of hydrocarbons - Google Patents
In-situ upgrading and recovery of hydrocarbons Download PDFInfo
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- CA2884849C CA2884849C CA2884849A CA2884849A CA2884849C CA 2884849 C CA2884849 C CA 2884849C CA 2884849 A CA2884849 A CA 2884849A CA 2884849 A CA2884849 A CA 2884849A CA 2884849 C CA2884849 C CA 2884849C
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- 150000002430 hydrocarbons Chemical class 0.000 title claims abstract description 123
- 229930195733 hydrocarbon Natural products 0.000 title claims abstract description 122
- 238000011084 recovery Methods 0.000 title claims abstract description 33
- 238000011065 in-situ storage Methods 0.000 title claims abstract description 24
- 239000003054 catalyst Substances 0.000 claims abstract description 115
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 46
- 229910001868 water Inorganic materials 0.000 claims abstract description 46
- 239000010426 asphalt Substances 0.000 claims abstract description 42
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- 238000006243 chemical reaction Methods 0.000 claims abstract description 18
- 238000000034 method Methods 0.000 claims description 109
- 238000002347 injection Methods 0.000 claims description 28
- 239000007924 injection Substances 0.000 claims description 28
- 239000011943 nanocatalyst Substances 0.000 claims description 19
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- 229910052739 hydrogen Inorganic materials 0.000 claims description 16
- 239000001257 hydrogen Substances 0.000 claims description 16
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 claims description 15
- 238000000197 pyrolysis Methods 0.000 claims description 14
- 238000010796 Steam-assisted gravity drainage Methods 0.000 claims description 13
- 230000004913 activation Effects 0.000 claims description 13
- 238000004517 catalytic hydrocracking Methods 0.000 claims description 13
- 239000002904 solvent Substances 0.000 claims description 13
- CXWXQJXEFPUFDZ-UHFFFAOYSA-N tetralin Chemical compound C1=CC=C2CCCCC2=C1 CXWXQJXEFPUFDZ-UHFFFAOYSA-N 0.000 claims description 13
- 238000006555 catalytic reaction Methods 0.000 claims description 12
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- LCGLNKUTAGEVQW-UHFFFAOYSA-N methyl monoether Natural products COC LCGLNKUTAGEVQW-UHFFFAOYSA-N 0.000 claims description 10
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 claims description 9
- 238000010794 Cyclic Steam Stimulation Methods 0.000 claims description 8
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- 238000010793 Steam injection (oil industry) Methods 0.000 claims description 7
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- MCMNRKCIXSYSNV-UHFFFAOYSA-N ZrO2 Inorganic materials O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims description 5
- 229910052878 cordierite Inorganic materials 0.000 claims description 5
- JSKIRARMQDRGJZ-UHFFFAOYSA-N dimagnesium dioxido-bis[(1-oxido-3-oxo-2,4,6,8,9-pentaoxa-1,3-disila-5,7-dialuminabicyclo[3.3.1]nonan-7-yl)oxy]silane Chemical compound [Mg++].[Mg++].[O-][Si]([O-])(O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2)O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2 JSKIRARMQDRGJZ-UHFFFAOYSA-N 0.000 claims description 5
- 239000011148 porous material Substances 0.000 claims description 5
- 229910052782 aluminium Inorganic materials 0.000 claims description 4
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 4
- 238000009826 distribution Methods 0.000 claims description 4
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 claims description 4
- 229910052697 platinum Inorganic materials 0.000 claims description 4
- QGZKDVFQNNGYKY-UHFFFAOYSA-O Ammonium Chemical compound [NH4+] QGZKDVFQNNGYKY-UHFFFAOYSA-O 0.000 claims description 3
- 229910021536 Zeolite Inorganic materials 0.000 claims description 3
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 claims description 3
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical compound [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 claims description 3
- PXXNTAGJWPJAGM-UHFFFAOYSA-N vertaline Natural products C1C2C=3C=C(OC)C(OC)=CC=3OC(C=C3)=CC=C3CCC(=O)OC1CC1N2CCCC1 PXXNTAGJWPJAGM-UHFFFAOYSA-N 0.000 claims description 3
- 239000010457 zeolite Substances 0.000 claims description 3
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 claims description 2
- SRXOCFMDUSFFAK-UHFFFAOYSA-N dimethyl peroxide Chemical group COOC SRXOCFMDUSFFAK-UHFFFAOYSA-N 0.000 claims description 2
- 229910052708 sodium Inorganic materials 0.000 claims description 2
- 239000011734 sodium Substances 0.000 claims description 2
- 229910052720 vanadium Inorganic materials 0.000 claims description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims 1
- 229910052593 corundum Inorganic materials 0.000 claims 1
- 229910001845 yogo sapphire Inorganic materials 0.000 claims 1
- 238000004519 manufacturing process Methods 0.000 description 22
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- YXFVVABEGXRONW-UHFFFAOYSA-N Toluene Chemical compound CC1=CC=CC=C1 YXFVVABEGXRONW-UHFFFAOYSA-N 0.000 description 3
- VLKZOEOYAKHREP-UHFFFAOYSA-N n-Hexane Chemical compound CCCCCC VLKZOEOYAKHREP-UHFFFAOYSA-N 0.000 description 3
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- 206010073306 Exposure to radiation Diseases 0.000 description 2
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- 230000003213 activating effect Effects 0.000 description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 2
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- 229910052757 nitrogen Inorganic materials 0.000 description 2
- 229910052760 oxygen Inorganic materials 0.000 description 2
- 239000001301 oxygen Substances 0.000 description 2
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- 241001566735 Archon Species 0.000 description 1
- RWSOTUBLDIXVET-UHFFFAOYSA-N Dihydrogen sulfide Chemical compound S RWSOTUBLDIXVET-UHFFFAOYSA-N 0.000 description 1
- CTQNGGLPUBDAKN-UHFFFAOYSA-N O-Xylene Chemical compound CC1=CC=CC=C1C CTQNGGLPUBDAKN-UHFFFAOYSA-N 0.000 description 1
- KEAYESYHFKHZAL-UHFFFAOYSA-N Sodium Chemical compound [Na] KEAYESYHFKHZAL-UHFFFAOYSA-N 0.000 description 1
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 1
- 238000007259 addition reaction Methods 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 150000001336 alkenes Chemical class 0.000 description 1
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- 125000003118 aryl group Chemical group 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000001273 butane Substances 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 125000004432 carbon atom Chemical group C* 0.000 description 1
- 229910002091 carbon monoxide Inorganic materials 0.000 description 1
- 229910002090 carbon oxide Inorganic materials 0.000 description 1
- 238000004523 catalytic cracking Methods 0.000 description 1
- 239000003153 chemical reaction reagent Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
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- 229910052736 halogen Inorganic materials 0.000 description 1
- 150000002367 halogens Chemical class 0.000 description 1
- 125000005842 heteroatom Chemical group 0.000 description 1
- 150000002431 hydrogen Chemical class 0.000 description 1
- 125000004435 hydrogen atom Chemical group [H]* 0.000 description 1
- 230000003993 interaction Effects 0.000 description 1
- 150000002605 large molecules Chemical class 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 229920002521 macromolecule Polymers 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- IJDNQMDRQITEOD-UHFFFAOYSA-N n-butane Chemical compound CCCC IJDNQMDRQITEOD-UHFFFAOYSA-N 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 229910000480 nickel oxide Inorganic materials 0.000 description 1
- 229910052755 nonmetal Inorganic materials 0.000 description 1
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 1
- GNRSAWUEBMWBQH-UHFFFAOYSA-N oxonickel Chemical compound [Ni]=O GNRSAWUEBMWBQH-UHFFFAOYSA-N 0.000 description 1
- 230000035699 permeability Effects 0.000 description 1
- 239000012466 permeate Substances 0.000 description 1
- 150000002978 peroxides Chemical class 0.000 description 1
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- 229910052717 sulfur Inorganic materials 0.000 description 1
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- 230000002459 sustained effect Effects 0.000 description 1
- 230000002195 synergetic effect Effects 0.000 description 1
- 238000007725 thermal activation Methods 0.000 description 1
- 239000008096 xylene Substances 0.000 description 1
- 229910001928 zirconium oxide Inorganic materials 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/16—Enhanced recovery methods for obtaining hydrocarbons
- E21B43/24—Enhanced recovery methods for obtaining hydrocarbons using heat, e.g. steam injection
- E21B43/2406—Steam assisted gravity drainage [SAGD]
- E21B43/2408—SAGD in combination with other methods
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K8/00—Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
- C09K8/58—Compositions for enhanced recovery methods for obtaining hydrocarbons, i.e. for improving the mobility of the oil, e.g. displacing fluids
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K8/00—Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
- C09K8/58—Compositions for enhanced recovery methods for obtaining hydrocarbons, i.e. for improving the mobility of the oil, e.g. displacing fluids
- C09K8/592—Compositions used in combination with generated heat, e.g. by steam injection
Abstract
A hydrocarbon reservoir is treated with a catalyst for in-situ upgrading and recovery of upgraded hydrocarbons. The catalyst is dispersed into a mobile water phase present in the reservoir and activated by electromagnetic radiation. The activated catalyst induces in-situ chemical reactions with bitumen, heavy oil, or other hydrocarbons during recovery, thereby reducing viscosity and upgrading the hydrocarbons.
Description
IN-SITU UPGRADING AND RECOVERY OF HYDROCARBONS
TECHNICAL FIELD
[001] The technical field relates to treatment of a hydrocarbon reservoir with a catalyst for in-situ upgrading and recovery of upgraded oil or bitumen.
BACKGROUND
TECHNICAL FIELD
[001] The technical field relates to treatment of a hydrocarbon reservoir with a catalyst for in-situ upgrading and recovery of upgraded oil or bitumen.
BACKGROUND
[002] Bitumen or heavy oil is abundant in different parts of the world, including Canada, the United States, Venezuela, and Brazil. However, the oil is highly viscous at reservoir temperatures and does not flow readily. Therefore, bitumen cannot be produced by conventional methods. In a number of cases, the heavy oil is thermally treated to reduce the viscosity and this makes it flow more easily.
[003] Currently, the most common thermal-recovery processes are steam-based technologies, such as steam-assisted gravity drainage (SAGD) and cyclic-steam stimulation (CSS). In these processes, bitumen reservoirs are heated by steam injection; the bitumen is brought to the surface and later diluted with condensates for pipeline transportation.
[004] Solvent injection can be used to enhance the performance of SAGD and CSS
by introducing hydrocarbon solvent additives to the injected steam. The operating conditions for the solvent co-injection process are similar to SAGD.
by introducing hydrocarbon solvent additives to the injected steam. The operating conditions for the solvent co-injection process are similar to SAGD.
[005] Non-thermal recovery can also be effective for some bitumens or heavy oils. It is potentially less energy- and capital-intensive. Non-thermal recovery includes cold heavy oil production with sand (CHOPS), which involves sand influx into the production well.
[006] Even after successful production of bitumen ¨ based on either thermal or non-thermal recovery ¨ its viscosity is usually too high for pipeline transportation.
Diluents are used to reduce viscosity to enable flow. In Alberta, for example, diluent cost is a major factor for transporting bitumen to refineries. Therefore, there is an ongoing need for at least partially upgrading bitumen after oil recovery, or, more ideally, in situ during oil recovery, to minimize or avoid use of diluent.
Diluents are used to reduce viscosity to enable flow. In Alberta, for example, diluent cost is a major factor for transporting bitumen to refineries. Therefore, there is an ongoing need for at least partially upgrading bitumen after oil recovery, or, more ideally, in situ during oil recovery, to minimize or avoid use of diluent.
[007] In-situ upgrading of bitumen and heavy oil, especially catalytic upgrading, is currently considered to be a desirable next-generation technology. However, no commercially-viable process is currently being used.
SUMMARY
SUMMARY
[008] In general, the present specification describes methods to treat a reservoir to recover hydrocarbons, particularly viscous hydrocarbons. The methods include delivering a catalyst into a mobile water phase within the reservoir and directing electromagnetic radiation to the catalyst to activate the catalyst and thereby initiate bitumen-upgrading reactions.
1009] In one implementation, there is provided a method for treating a reservoir to recover hydrocarbons. The method includes delivering a catalyst into the reservoir using a mobile water phase present in the reservoir and directing electromagnetic radiation to the catalyst to activate the catalyst; the activated catalyst then initiates at least one catalytic reaction.
[010] In some aspects of the methods, the reservoir is an oil sands reservoir.
In some aspects of the methods, the hydrocarbons include bitumen. In some aspects of the methods, the hydrocarbons include heavy oil. In some aspects of the methods, the hydrocarbons include bitumen and heavy oil.
10111 In some aspects of the methods, the catalyst is a nanocatalyst. In further aspects of the methods, the catalyst is a metal-based catalyst. Exemplary catalysts include, without limitation, vanadium, sodium, aluminum, or platinum, or a combination of more than one of any of the foregoing. In some aspects of the methods, the catalyst is A1/y-A1203, ammonium Y zeolite, zirconium dioxide (Zr02), or cordierite, or a combination of more than one of any of the foregoing. In further aspects of the methods, the cordierite is Mg2A14Si5018.
[012] In some aspects of the methods, the catalyst is selected such that the catalytic reaction operates to at least partially upgrade the hydrocarbons contained in the reservoir. In some aspects of the methods, partially upgrading the hydrocarbons includes reducing the viscosity of the hydrocarbons. In some aspects of the methods, partially upgrading the hydrocarbons include pyrolysis, aquathermolysis (hydrous pyrolysis), gasification, hydrocracking, hydrogenation, desulphurization, denitrogenation, demetallation, or deasphalting, or a combination of more than one of any of the foregoing.
[013] In some aspects of the methods, an interconnected pore network of the reservoir contains the mobile water phase. In some aspects of the methods, the catalyst is delivered to the reservoir by injection through a wellbore. In some aspects of the methods, sufficient time passes between injection of the catalyst into the reservoir and activation of the catalyst by the electromagnetic radiation to permit sufficient distribution of the particles of the catalyst within the reservoir via the mobile water phase. In further aspects of the methods, up to one year passes between the injection and the activation.
10141 In some aspects of the methods, the electromagnetic radiation has a frequency in the range of about 60 Hz to about 1,000 GHz. In some aspects of the methods, the electromagnetic radiation is directed to the catalyst using an antenna. In some aspects of the methods, the antenna is a vertical or horizontal antenna or a phased array of mixed geometry.
[015] In some aspects, the methods include delivering a hydrogen source to the reservoir. In some aspects of the methods, the hydrogen source is peroxide, dimethyl ether (DME), light hydrocarbons, tetralin (1,2,3,4-tetrahydronaphthalene), decalin (decahydronaphthalene), or naphthalene, or a combination of more than one of any of the foregoing. In some aspects, the methods include delivering a solvent to the reservoir.
10161 In another implementation, there is provided a method for recovering hydrocarbons from a hydrocarbon-containing reservoir. The method includes delivering a nanocatalyst to the reservoir by injection through a wellbore in the reservoir; allowing a pre-determined period of time to pass such that particles of the nanocatalyst are dispersed into the reservoir via a mobile water phase present in the reservoir; directing electromagnetic radiation to the nanocatalyst to activate the nanocatalyst; and, when the activated nanocatalyst has induced at least one chemical reaction which at least partially upgrades the hydrocarbons, recovering the at least partially upgraded hydrocarbons from the reservoir.
[017] In some aspects of the methods, the reservoir is an oil sands reservoir.
In some aspects of the methods, the hydrocarbons include bitumen. In some aspects of the methods, the hydrocarbons include heavy oil. In some aspects of the methods, the hydrocarbons include bitumen and heavy oil. In some aspects of the methods, the at least partially upgraded hydrocarbons are recovered from the reservoir using steam injection (SAGD or CSS) recovery.
[018] In some aspects of the methods, partially upgrading the hydrocarbons includes reducing the viscosity of the hydrocarbons. In some aspects of the methods, partially upgrading the hydrocarbons comprises pyrolysis, aquathermolysis (hydrous pyrolysis), gasification, hydrocracking, hydrogenation, desulphurization, denitrogenation, demetallation, or deasphalting, or a combination of more than one of any of the foregoing.
10191 In some aspects, the methods include refreshing the nanocatalyst in the reservoir by at least one of re-injection into the wellbore, injection through a secondary injector, and injection along an antenna. In some aspects, the methods include renewing the nanocatalyst in situ through application of steam or solvent wash.
[020] In another implementation, there is provided a reservoir treated with a catalyst for recovery of at least partially upgraded hydrocarbons. The catalyst is distributed through a mobile water phase present in the reservoir and is activatable by electromagnetic radiation. In some aspects, the reservoir is an oil sands reservoir. In some aspects, the hydrocarbons include bitumen. In some aspects, the hydrocarbons include heavy oil. In some aspects, the hydrocarbons include bitumen and heavy oil.
[021] The methods described in this specification are advantageous over other in-situ upgrading methods, such as those using thermally-activated catalysts. For example, the present methods distinguish the energy source for activating the catalyst and catalyzing the reactions from the energy source for heating the bitumen, thereby increasing efficiency of catalytic upgrading of bitumen and reducing steam consumption. Activation of a catalyst and initiation of a catalytic reaction are endothermic and require energy. Where thermal activation is employed, the catalyst uses heat for activation from steam that is also injected to mobilize bitumen during a steam-assisted recovery operation. In that case, although the catalyst is added to enhance bitumen recovery, this addition of catalyst can initially slow down heating of bitumen or increase consumption of steam, due to the extra heat load of catalyst activation or catalysis initiation.
[022] The present methods can also reduce certain negative effects of mobile water in the reservoir during thermal recovery. While it is known that hydrocarbons do not couple well with electromagnetic radiation due to lack of a dipole moment, water can be an excellent candidate for dielectric heating or electromagnetic heating. During radio-frequency radiation of a bitumen reservoir, for example, water in the reservoir is locally heated and can induce thermal cracking of bitumen. In such cases, the mobile water phase in the reservoir can function as another energy source for upgrading bitumen and heavy oils in accordance with the present methods. A
synergistic effect can also arise from the combination of: (a) dispersing the catalyst in the water phase; and (b) activating the catalyst with radiation. As noted above, water can absorb radiation and provide heat to the surroundings. Thus, water can facilitate activation of the catalyst in addition to electromagnetic radiation.
1023] The details of one or more implementations are set forth in the description below. Other features and advantages will be apparent from the specification and the claims.
BRIEF DESCRIPTION OF THE DRAWING
1024] Features and advantages of embodiments of the present application will become apparent from the following detailed description and the appended drawing, in which:
[025] FIG. 1 is a flowchart exemplifying implementation of the methods described herein for treating a hydrocarbon reservoir with a catalyst to recover upgraded oil or upgraded bitumen.
DETAILED DESCRIPTION
[026] The present description relates to treatment of an underground reservoir for upgrading hydrocarbons, particularly bitumen and heavy oil, in situ. The treatment includes distributing or dispersing a catalyst that is activatable (i.e., capable of or susceptible to activation) by electromagnetic radiation into a mobile water phase present in the reservoir.
The mobile water phase within the reservoir can include mobile water films that wet the sand grains within the reservoir rock. The water films are sufficiently connected throughout the reservoir volume due to grain-to-grain contacts; the hydrocarbon phase is present in the pore space between the water films.
10271 Mobile water in a hydrocarbon reservoir is generally considered to be disadvantageous to thermal recovery processes. However, as the methods described herein illustrate, a mobile water phase can be utilized for in-situ upgrading and recovery of hydrocarbons, including bitumen and/or heavy oil. A mobile water phase flows through the tiny interconnected pore spaces in the reservoir matrix. This continuous water network provides means for transporting the catalyst, especially in nanocatalyst form, throughout the reservoir at cold reservoir conditions.
1028] The following requirements for existing in-situ upgrading processes have been identified: (i) provision of a catalyst; (ii) achievement of appropriate reaction temperature; and (iii) mobilization of hydrocarbons over the catalyst. Most in-situ technologies currently attempt to carry out catalytic reactions in the production well in order to gain better control over the requirements. CAPRITM (catalytic upgrading process in-situ) (Archon Technologies Ltd.) is an example.
10291 The present methods take a different approach with respect to the following factors:
scale of upgrading, timing of distribution and activation of the catalyst, and delivery of activation energy. First, a catalyst is broadly distributed throughout the reservoir, instead of being contained or localized within the production well. Second, the catalyst is provided to the reservoir prior to mobilization of the hydrocarbons, and activated concurrently with or prior to mobilization of the hydrocarbons. Third, activation energy is delivered to the catalyst by electromagnetic radiation, rather than thermal heating. Therefore, when mobilization of hydrocarbons commences in the reservoir using one of the recovery processes (e. g. , SAGD, CHOPS, solvent injection), catalytic reactions can be carried out simultaneously in the reservoir. As a result, permanent partial upgrading in situ and improved recovery of hydrocarbons can be achieved at lower energy consumption.
[030] Throughout this specification, numerous terms and expressions are used in accordance with their ordinary meanings. Provided below are definitions of some additional terms and expressions that are used in the description that follows.
[031] "Hydrocarbon" and "hydrocarbons", as used herein, refer to hydrocarbon molecules that contain carbon atoms and, in many cases, attached hydrogen atoms. Examples include bitumen and heavy oil.
[032] "Bitumen" and "heavy oil" are normally distinguished from other petroleums based on their relative densities and/or viscosities, which often depend on context.
Commonly-accepted definitions classify "heavy oil" as petroleum (the density of which is between 920 and 1,000 kg/m3) and "bitumen" as oil produced from bituminous sand formations (the density of which is greater than 1,000 kg/m3). For purposes of this specification, the terms "bitumen" and "heavy oil" are used interchangeably such that each one includes the other. For example, where the term "bitumen" is used alone, it includes within its scope "heavy oil".
[033] As used herein, "reservoir" refers to a subsurface formation that is primarily composed of a matrix of unconsolidated sand, with hydrocarbons occurring in the porous matrix.
[034] The "mobile water phase" is a continuous water network that can be formed by interstitial water present in the porous matrix of a hydrocarbon reservoir and can allow reservoir water to flow throughout the reservoir.
[035] As used herein, "electromagnetic radiation" refers to radiation encompassing microwave and radio-frequency radiation, particularly with frequencies anywhere in the range of about 60 Hz to about 1,000 GHz.
[036] The "metal-based catalyst" described herein is a catalyst that includes at least one metal element and optionally one or more components of non-metal elements (e.g., C, N, 0, Si, P. S, etc.). For example, the metal-based catalyst can be a pure metal catalyst or a metal-oxide catalyst (e.g., nickel or nickel oxide). The "metal-based catalyst" described herein includes a catalyst with a support (e.g., Pt/y-A1203, Al/y-A1203, etc.).
[037] The "natural reservoir temperature" or "reservoir temperature" is an ambient temperature of a cold or unheated reservoir.
[038] The terms "upgrading" and "at least partially upgrading", which are used interchangeably herein, refer to any treatment of oil or bitumen that increases its value. The minimum objective is to reduce the viscosity of oil, and the maximum objective is to obtain a crude oil substitute of higher quality. Upgrading includes a number of processes, such as pyrolysis, aquathermolysis (hydrous pyrolysis), gasification, hydrocracking, hydrogenation, desulphurization, denitrogenation, demetallation, and deasphalting, or a combination of more than one of the foregoing.
[039] "Cracking" means the breaking down of larger hydrocarbon chains into smaller-chained compounds. In other words, a long-chain hydrocarbon will break up into smaller-chain hydrocarbons.
[040] The term "hydrogenation" is used herein to refer to an addition or substitution reaction in which hydrogen is consumed; a non-limiting example of hydrogenation is hydrocracking.
[041] "Hydrocracking" means a hydrogenation reaction which utilizes hydrogen as a reagent and chemically converts hydrocarbons to relatively lighter hydrocarbons.
Additional reactions, including olefin and aromatic saturation and heteroatom (e.g., oxygen, nitrogen, sulfur, halogen) removal, can also occur during hydrocracking.
[042] The term "in situ" refers to the environment of a subsurface hydrocarbon reservoir.
10431 "Nanoscale" or "nano" means smaller than microscopic in scale. The term "nanocatalyst" is used herein to refer to a particulate catalyst, the particle size of which is less than 1,000 nm.
[044] FIG. 1 illustrates an implementation of the present methods for treating a hydrocarbon reservoir in which heavy oil or bitumen is recovered by SAGD techniques (100).
In this implementation, a catalyst is injected into at least one of an injection well and a production well drilled in a hydrocarbon reservoir (110). The catalyst reaches the reservoir through the well(s), and is dispersed into a mobile water phase within the reservoir (130).
Optionally, a hydrogen source and/or a solvent can be injected along with the catalyst through the injection well (120).
After a period of time, the catalyst is sufficiently distributed within the reservoir. To activate the catalyst, electromagnetic (EM) radiation is directed to the catalyst in the reservoir (140).
After sufficient exposure to radiation, one or more catalytic reactions initiate in-situ upgrading of the bitumen (150). In the SAGD recovery process, steam is injected into the reservoir through the injection well to mobilize the hydrocarbons (160). The timing of the steam injection can be varied and flexible. Steam injection can commence shortly before step 140, anytime between step 140 and step 150, or shortly after step 150; any appropriate timing or duration of steam injection can be determined by a skilled person. Upgraded oil or upgraded bitumen is recovered from the reservoir through a production well (170). The process (100) can be repeated from step 110 if a second recovery operation is desired.
1045] Specific examples of the present methods are described below. Details are provided for the purpose of illustration, and the methods can be practiced without some or all of the features discussed herein. For clarity, technical materials that are known in the fields relevant to the present methods are not discussed in detail.
A. Delivery of Catalyst to Hydrocarbon Reservoir [046] The present methods utilize a catalyst that can be activated by electromagnetic radiation.
The catalyst can be a metal-based catalyst, such as a vanadium-, sodium-, or platinum-based catalyst. The catalyst can also be a supported catalyst, such as alumina-supported platinum or alumina-supported aluminum. Examples of the catalyst include, without limitation, ammonium Y zeolite, aluminum-based crystallite (e.g., Al/y-A1203), zirconium oxide (Zr02), and cordierite (Mg2A14Si5018).
[047] The catalyst can be delivered to the reservoir through a variety of methods commonly known in the art. Typical methods used in the art include injecting a liquid containing catalytic particles (e.g., aqueous dispersion) through a wellbore drilled in the reservoir. The wellbore can be for an injection or production well for a hydrocarbon recovery process.
[048] In general, the catalyst is first dispersed in an aqueous (water) phase on the surface prior to introduction into the reservoir. The catalyst is then injected into the reservoir in the water phase. The catalyst flows through mobile water films that wet the sand grains in the reservoir.
Since the water is mobile, the catalyst that is dispersed within the aqueous phase moves freely through the water films in the reservoir under pressure or gravity. In this manner, the catalyst moves and spreads throughout the reservoir, thereby improving its ability to contact the
1009] In one implementation, there is provided a method for treating a reservoir to recover hydrocarbons. The method includes delivering a catalyst into the reservoir using a mobile water phase present in the reservoir and directing electromagnetic radiation to the catalyst to activate the catalyst; the activated catalyst then initiates at least one catalytic reaction.
[010] In some aspects of the methods, the reservoir is an oil sands reservoir.
In some aspects of the methods, the hydrocarbons include bitumen. In some aspects of the methods, the hydrocarbons include heavy oil. In some aspects of the methods, the hydrocarbons include bitumen and heavy oil.
10111 In some aspects of the methods, the catalyst is a nanocatalyst. In further aspects of the methods, the catalyst is a metal-based catalyst. Exemplary catalysts include, without limitation, vanadium, sodium, aluminum, or platinum, or a combination of more than one of any of the foregoing. In some aspects of the methods, the catalyst is A1/y-A1203, ammonium Y zeolite, zirconium dioxide (Zr02), or cordierite, or a combination of more than one of any of the foregoing. In further aspects of the methods, the cordierite is Mg2A14Si5018.
[012] In some aspects of the methods, the catalyst is selected such that the catalytic reaction operates to at least partially upgrade the hydrocarbons contained in the reservoir. In some aspects of the methods, partially upgrading the hydrocarbons includes reducing the viscosity of the hydrocarbons. In some aspects of the methods, partially upgrading the hydrocarbons include pyrolysis, aquathermolysis (hydrous pyrolysis), gasification, hydrocracking, hydrogenation, desulphurization, denitrogenation, demetallation, or deasphalting, or a combination of more than one of any of the foregoing.
[013] In some aspects of the methods, an interconnected pore network of the reservoir contains the mobile water phase. In some aspects of the methods, the catalyst is delivered to the reservoir by injection through a wellbore. In some aspects of the methods, sufficient time passes between injection of the catalyst into the reservoir and activation of the catalyst by the electromagnetic radiation to permit sufficient distribution of the particles of the catalyst within the reservoir via the mobile water phase. In further aspects of the methods, up to one year passes between the injection and the activation.
10141 In some aspects of the methods, the electromagnetic radiation has a frequency in the range of about 60 Hz to about 1,000 GHz. In some aspects of the methods, the electromagnetic radiation is directed to the catalyst using an antenna. In some aspects of the methods, the antenna is a vertical or horizontal antenna or a phased array of mixed geometry.
[015] In some aspects, the methods include delivering a hydrogen source to the reservoir. In some aspects of the methods, the hydrogen source is peroxide, dimethyl ether (DME), light hydrocarbons, tetralin (1,2,3,4-tetrahydronaphthalene), decalin (decahydronaphthalene), or naphthalene, or a combination of more than one of any of the foregoing. In some aspects, the methods include delivering a solvent to the reservoir.
10161 In another implementation, there is provided a method for recovering hydrocarbons from a hydrocarbon-containing reservoir. The method includes delivering a nanocatalyst to the reservoir by injection through a wellbore in the reservoir; allowing a pre-determined period of time to pass such that particles of the nanocatalyst are dispersed into the reservoir via a mobile water phase present in the reservoir; directing electromagnetic radiation to the nanocatalyst to activate the nanocatalyst; and, when the activated nanocatalyst has induced at least one chemical reaction which at least partially upgrades the hydrocarbons, recovering the at least partially upgraded hydrocarbons from the reservoir.
[017] In some aspects of the methods, the reservoir is an oil sands reservoir.
In some aspects of the methods, the hydrocarbons include bitumen. In some aspects of the methods, the hydrocarbons include heavy oil. In some aspects of the methods, the hydrocarbons include bitumen and heavy oil. In some aspects of the methods, the at least partially upgraded hydrocarbons are recovered from the reservoir using steam injection (SAGD or CSS) recovery.
[018] In some aspects of the methods, partially upgrading the hydrocarbons includes reducing the viscosity of the hydrocarbons. In some aspects of the methods, partially upgrading the hydrocarbons comprises pyrolysis, aquathermolysis (hydrous pyrolysis), gasification, hydrocracking, hydrogenation, desulphurization, denitrogenation, demetallation, or deasphalting, or a combination of more than one of any of the foregoing.
10191 In some aspects, the methods include refreshing the nanocatalyst in the reservoir by at least one of re-injection into the wellbore, injection through a secondary injector, and injection along an antenna. In some aspects, the methods include renewing the nanocatalyst in situ through application of steam or solvent wash.
[020] In another implementation, there is provided a reservoir treated with a catalyst for recovery of at least partially upgraded hydrocarbons. The catalyst is distributed through a mobile water phase present in the reservoir and is activatable by electromagnetic radiation. In some aspects, the reservoir is an oil sands reservoir. In some aspects, the hydrocarbons include bitumen. In some aspects, the hydrocarbons include heavy oil. In some aspects, the hydrocarbons include bitumen and heavy oil.
[021] The methods described in this specification are advantageous over other in-situ upgrading methods, such as those using thermally-activated catalysts. For example, the present methods distinguish the energy source for activating the catalyst and catalyzing the reactions from the energy source for heating the bitumen, thereby increasing efficiency of catalytic upgrading of bitumen and reducing steam consumption. Activation of a catalyst and initiation of a catalytic reaction are endothermic and require energy. Where thermal activation is employed, the catalyst uses heat for activation from steam that is also injected to mobilize bitumen during a steam-assisted recovery operation. In that case, although the catalyst is added to enhance bitumen recovery, this addition of catalyst can initially slow down heating of bitumen or increase consumption of steam, due to the extra heat load of catalyst activation or catalysis initiation.
[022] The present methods can also reduce certain negative effects of mobile water in the reservoir during thermal recovery. While it is known that hydrocarbons do not couple well with electromagnetic radiation due to lack of a dipole moment, water can be an excellent candidate for dielectric heating or electromagnetic heating. During radio-frequency radiation of a bitumen reservoir, for example, water in the reservoir is locally heated and can induce thermal cracking of bitumen. In such cases, the mobile water phase in the reservoir can function as another energy source for upgrading bitumen and heavy oils in accordance with the present methods. A
synergistic effect can also arise from the combination of: (a) dispersing the catalyst in the water phase; and (b) activating the catalyst with radiation. As noted above, water can absorb radiation and provide heat to the surroundings. Thus, water can facilitate activation of the catalyst in addition to electromagnetic radiation.
1023] The details of one or more implementations are set forth in the description below. Other features and advantages will be apparent from the specification and the claims.
BRIEF DESCRIPTION OF THE DRAWING
1024] Features and advantages of embodiments of the present application will become apparent from the following detailed description and the appended drawing, in which:
[025] FIG. 1 is a flowchart exemplifying implementation of the methods described herein for treating a hydrocarbon reservoir with a catalyst to recover upgraded oil or upgraded bitumen.
DETAILED DESCRIPTION
[026] The present description relates to treatment of an underground reservoir for upgrading hydrocarbons, particularly bitumen and heavy oil, in situ. The treatment includes distributing or dispersing a catalyst that is activatable (i.e., capable of or susceptible to activation) by electromagnetic radiation into a mobile water phase present in the reservoir.
The mobile water phase within the reservoir can include mobile water films that wet the sand grains within the reservoir rock. The water films are sufficiently connected throughout the reservoir volume due to grain-to-grain contacts; the hydrocarbon phase is present in the pore space between the water films.
10271 Mobile water in a hydrocarbon reservoir is generally considered to be disadvantageous to thermal recovery processes. However, as the methods described herein illustrate, a mobile water phase can be utilized for in-situ upgrading and recovery of hydrocarbons, including bitumen and/or heavy oil. A mobile water phase flows through the tiny interconnected pore spaces in the reservoir matrix. This continuous water network provides means for transporting the catalyst, especially in nanocatalyst form, throughout the reservoir at cold reservoir conditions.
1028] The following requirements for existing in-situ upgrading processes have been identified: (i) provision of a catalyst; (ii) achievement of appropriate reaction temperature; and (iii) mobilization of hydrocarbons over the catalyst. Most in-situ technologies currently attempt to carry out catalytic reactions in the production well in order to gain better control over the requirements. CAPRITM (catalytic upgrading process in-situ) (Archon Technologies Ltd.) is an example.
10291 The present methods take a different approach with respect to the following factors:
scale of upgrading, timing of distribution and activation of the catalyst, and delivery of activation energy. First, a catalyst is broadly distributed throughout the reservoir, instead of being contained or localized within the production well. Second, the catalyst is provided to the reservoir prior to mobilization of the hydrocarbons, and activated concurrently with or prior to mobilization of the hydrocarbons. Third, activation energy is delivered to the catalyst by electromagnetic radiation, rather than thermal heating. Therefore, when mobilization of hydrocarbons commences in the reservoir using one of the recovery processes (e. g. , SAGD, CHOPS, solvent injection), catalytic reactions can be carried out simultaneously in the reservoir. As a result, permanent partial upgrading in situ and improved recovery of hydrocarbons can be achieved at lower energy consumption.
[030] Throughout this specification, numerous terms and expressions are used in accordance with their ordinary meanings. Provided below are definitions of some additional terms and expressions that are used in the description that follows.
[031] "Hydrocarbon" and "hydrocarbons", as used herein, refer to hydrocarbon molecules that contain carbon atoms and, in many cases, attached hydrogen atoms. Examples include bitumen and heavy oil.
[032] "Bitumen" and "heavy oil" are normally distinguished from other petroleums based on their relative densities and/or viscosities, which often depend on context.
Commonly-accepted definitions classify "heavy oil" as petroleum (the density of which is between 920 and 1,000 kg/m3) and "bitumen" as oil produced from bituminous sand formations (the density of which is greater than 1,000 kg/m3). For purposes of this specification, the terms "bitumen" and "heavy oil" are used interchangeably such that each one includes the other. For example, where the term "bitumen" is used alone, it includes within its scope "heavy oil".
[033] As used herein, "reservoir" refers to a subsurface formation that is primarily composed of a matrix of unconsolidated sand, with hydrocarbons occurring in the porous matrix.
[034] The "mobile water phase" is a continuous water network that can be formed by interstitial water present in the porous matrix of a hydrocarbon reservoir and can allow reservoir water to flow throughout the reservoir.
[035] As used herein, "electromagnetic radiation" refers to radiation encompassing microwave and radio-frequency radiation, particularly with frequencies anywhere in the range of about 60 Hz to about 1,000 GHz.
[036] The "metal-based catalyst" described herein is a catalyst that includes at least one metal element and optionally one or more components of non-metal elements (e.g., C, N, 0, Si, P. S, etc.). For example, the metal-based catalyst can be a pure metal catalyst or a metal-oxide catalyst (e.g., nickel or nickel oxide). The "metal-based catalyst" described herein includes a catalyst with a support (e.g., Pt/y-A1203, Al/y-A1203, etc.).
[037] The "natural reservoir temperature" or "reservoir temperature" is an ambient temperature of a cold or unheated reservoir.
[038] The terms "upgrading" and "at least partially upgrading", which are used interchangeably herein, refer to any treatment of oil or bitumen that increases its value. The minimum objective is to reduce the viscosity of oil, and the maximum objective is to obtain a crude oil substitute of higher quality. Upgrading includes a number of processes, such as pyrolysis, aquathermolysis (hydrous pyrolysis), gasification, hydrocracking, hydrogenation, desulphurization, denitrogenation, demetallation, and deasphalting, or a combination of more than one of the foregoing.
[039] "Cracking" means the breaking down of larger hydrocarbon chains into smaller-chained compounds. In other words, a long-chain hydrocarbon will break up into smaller-chain hydrocarbons.
[040] The term "hydrogenation" is used herein to refer to an addition or substitution reaction in which hydrogen is consumed; a non-limiting example of hydrogenation is hydrocracking.
[041] "Hydrocracking" means a hydrogenation reaction which utilizes hydrogen as a reagent and chemically converts hydrocarbons to relatively lighter hydrocarbons.
Additional reactions, including olefin and aromatic saturation and heteroatom (e.g., oxygen, nitrogen, sulfur, halogen) removal, can also occur during hydrocracking.
[042] The term "in situ" refers to the environment of a subsurface hydrocarbon reservoir.
10431 "Nanoscale" or "nano" means smaller than microscopic in scale. The term "nanocatalyst" is used herein to refer to a particulate catalyst, the particle size of which is less than 1,000 nm.
[044] FIG. 1 illustrates an implementation of the present methods for treating a hydrocarbon reservoir in which heavy oil or bitumen is recovered by SAGD techniques (100).
In this implementation, a catalyst is injected into at least one of an injection well and a production well drilled in a hydrocarbon reservoir (110). The catalyst reaches the reservoir through the well(s), and is dispersed into a mobile water phase within the reservoir (130).
Optionally, a hydrogen source and/or a solvent can be injected along with the catalyst through the injection well (120).
After a period of time, the catalyst is sufficiently distributed within the reservoir. To activate the catalyst, electromagnetic (EM) radiation is directed to the catalyst in the reservoir (140).
After sufficient exposure to radiation, one or more catalytic reactions initiate in-situ upgrading of the bitumen (150). In the SAGD recovery process, steam is injected into the reservoir through the injection well to mobilize the hydrocarbons (160). The timing of the steam injection can be varied and flexible. Steam injection can commence shortly before step 140, anytime between step 140 and step 150, or shortly after step 150; any appropriate timing or duration of steam injection can be determined by a skilled person. Upgraded oil or upgraded bitumen is recovered from the reservoir through a production well (170). The process (100) can be repeated from step 110 if a second recovery operation is desired.
1045] Specific examples of the present methods are described below. Details are provided for the purpose of illustration, and the methods can be practiced without some or all of the features discussed herein. For clarity, technical materials that are known in the fields relevant to the present methods are not discussed in detail.
A. Delivery of Catalyst to Hydrocarbon Reservoir [046] The present methods utilize a catalyst that can be activated by electromagnetic radiation.
The catalyst can be a metal-based catalyst, such as a vanadium-, sodium-, or platinum-based catalyst. The catalyst can also be a supported catalyst, such as alumina-supported platinum or alumina-supported aluminum. Examples of the catalyst include, without limitation, ammonium Y zeolite, aluminum-based crystallite (e.g., Al/y-A1203), zirconium oxide (Zr02), and cordierite (Mg2A14Si5018).
[047] The catalyst can be delivered to the reservoir through a variety of methods commonly known in the art. Typical methods used in the art include injecting a liquid containing catalytic particles (e.g., aqueous dispersion) through a wellbore drilled in the reservoir. The wellbore can be for an injection or production well for a hydrocarbon recovery process.
[048] In general, the catalyst is first dispersed in an aqueous (water) phase on the surface prior to introduction into the reservoir. The catalyst is then injected into the reservoir in the water phase. The catalyst flows through mobile water films that wet the sand grains in the reservoir.
Since the water is mobile, the catalyst that is dispersed within the aqueous phase moves freely through the water films in the reservoir under pressure or gravity. In this manner, the catalyst moves and spreads throughout the reservoir, thereby improving its ability to contact the
9 hydrocarbons in the reservoir.
[049] Once the catalyst is injected to the reservoir, the catalytic particles distribute or disperse through a mobile water phase in the reservoir. The catalyst particles are small enough that they can permeate through the porous matrix of the reservoir without significant retention.
Preferably, the size of the catalytic particles is at nanoscale. Nanoparticles have high mobility in porous media and can easily transport through the matrix pores of relatively tight hydrocarbon reservoirs.
[050] In one implementation, injection of the catalyst can be carried out prior to production of hydrocarbons from the reservoir. In other implementations, injection of the catalyst can also be carried out during the production phase. In the latter case, the catalyst is injected into the reservoir before commencing recovery or during recovery of remaining hydrocarbons from the reservoir.
[051] By way of example, an aqueous dispersion of the catalyst is injected into the reservoir for a period of time prior to direction of electromagnetic radiation into the reservoir. In this manner, the catalyst is positioned throughout the reservoir in the water films prior to hydrocarbon production. In such a case, the method catalyzes upgrading of the hydrocarbons in the reservoir throughout the volume of the reservoir that is irradiated by the electromagnetic energy. Hydrocarbons further from the well undergo longer exposure to the catalyst (which is activated by the electromagnetic energy) before being produced; thus, the degree of hydrocarbon upgrading increases as the reservoir is produced ¨ as long as the hydrocarbons produced were exposed to the catalyst.
10521 In another example, the aqueous dispersion of the catalyst is injected into the reservoir concurrent with direction of electromagnetic radiation into the reservoir. In this example, the upgrading zone within the reservoir grows as the recovery process evolves. The aqueous dispersion of the catalyst can also be injected into the reservoir prior to direction of electromagnetic radiation into the reservoir, but then continue after the electromagnetic irradiation has occurred.
[053] A sufficient or pre-determined period of time can be allowed to pass to permit distribution or dispersal of the catalytic particles through a mobile water phase in the reservoir to an extent sufficient to accomplish purposes described herein. Using techniques known to one of skill in the art, an appropriate or sufficient period of time can be determined on the basis of the desired degree or type of in-situ upgrading, the size of the hydrocarbon bearing zone, porosity and permeability of the reservoir, physical/chemical properties of the catalyst, and/or any other factors considered relevant by the skilled person.
[054] In addition to the catalyst, the reservoir can be provided with a hydrogen source, such as organic or inorganic peroxide, tetralin (1,2,3,4-tetrahydronaphthalene), decalin (decahydronaphthalene), naphthalene, dimethyl ether (DME), light hydrocarbons (e.g., C3-C10), and the like, or a combination of more than one of any of the foregoing, in order to facilitate in-situ chemical reactions with bitumen (e.g., hydrocracking, hydrodesulfurization, etc.). The hydrogen source can be injected to the reservoir, for example, through at least one injection and/or production well.
[055] Furthermore, the reservoir can be provided with a solvent, such as toluene, diesel, propane, butane, pentane, hexane, heptane, xylene, diluent, condensate, and the like, or any component or mixture thereof, in order to improve reservoir conformance and hydrocarbon recovery. The solvent can also be injected to the reservoir, for example, through at least one injection and/or production well.
B. Pre-production Process 10561 A pre-production process can be commenced as required for a given hydrocarbon-recovery methodology. Exemplary recovery methodologies include, without limitation, steam assisted gravity drainage (SAGD), cold heavy oil production with sand (CHOPS), cyclic steam stimulation (CSS), and solvent injection. In the case of SAGD, high pressure steam is continuously injected into the upper wellbore to create a steam chamber in the oil reservoir, so that heavy oil can be heated and mobilized for production. In the case of CHOPS, sand ingress or influx is initiated such that a mixture of sand and oil can be sustained throughout primary oil production.
C. Directing Electromagnetic Radiation 1057] Electromagnetic radiation or frequencies can come from a frequency generator that is located above or below ground. An antenna system can be set up and directed towards the reservoir to deliver electromagnetic radiation to the catalyst spread in the mobile water phase.
The antenna system can be a single vertical or horizontal antenna, phased array of mixed geometry, or some other configuration. The antenna system can also be placed above or below ground (e.g., placed in a well), or in a combination thereof A skilled operator can determine the optimal placement and/or configuration of a given antenna system to maximize activation of the catalyst in the reservoir.
10581 Electromagnetic radiation has a frequency anywhere between 60 Hz and 1,000 GHz.
This frequency range includes both radio and microwave frequencies. One skilled in the art can match the appropriate electromagnetic frequency and intensity of radiation to the selected catalyst(s) in order to achieve effective catalysis.
10591 The catalyst can be activated and catalysis initiated before, concurrently with, or after the pre-production process is commenced.
D. In-situ Upgrading and Recovery of Hydrocarbons 1060] After sufficient exposure to radiation, upgrading of the bitumen or oil in contact with the activated catalyst will commence. The in-situ catalytic reactions crack large molecules in the hydrocarbons into smaller molecules, thereby decreasing viscosity. The reactions can also include, without limitation, pyrolysis, aquathermolysis (hydrous pyrolysis), gasification, hydrocracking, hydrogenation, desulphurization, denitrogenation, demetallation, or deasphalting, or a combination of more than one of any of the foregoing.
10611 The catalytic upgrading of hydrocarbons involves heat, the presence of a catalyst, the hydrocarbons themselves, and other components that can enable hydrogen production. In the case of petroleum reservoirs, the components enabling hydrogen production are the petroleum itself and water. In the absence of oxygen, the reactions that occur at elevated temperatures within the reservoir include pyrolysis (thermal cracking), aquathermolysis (hydrous pyrolysis or thermal cracking reactions in the presence of water), and gasification reactions.
[062] When the catalyst is irradiated with electromagnetic waves, for example, the water phase heats up and, due to elevated temperatures, the hydrocarbons undergo pyrolysis and aquathermolysis. In the presence of the catalyst, these reactions are enabled at lower temperatures than would be the case if the catalyst were not present. The reactions crack the hydrocarbons into smaller molecular weight species. As a result of interactions between the hydrocarbons and water, hydrogen, hydrogen sulphide, and carbon oxides are produced during aquathermolysis reactions. Additionally, as a result of gasification reactions which arise due to heating, the water-gas shift reaction will convert excess steam and carbon monoxide into additional hydrogen. Consequently, all of the required conditions for upgrading are present, including the catalyst, the heat, the hydrocarbons, and the hydrogen.
[063] Nanocatalysts are beneficial in the present methods. Nanoscale particles have a large surface-to-volume ratio, and, therefore, exhibit increased contact area and enhanced catalytic activity. Smaller-sized particles can achieve efficiency of the chemical aspects of the upgrading process. By way of example, nanoscale catalysts show asphaltene adsorption properties that enhance catalytic cracking of heavy oil within a reservoir.
[064] In the presence of a hydrogen source, hydrocracking can occur. As noted above, the hydrogen source can be provided to the reservoir externally or by a water-splitting reaction in the reservoir. Bitumen typically contains various metallic components which can add to the catalytic effect, if precipitated in situ.
[065] The hydrocarbon product resulting from the present methods can include medium-heavy oil, which typically exhibits a density of 870 to 920 kg/m3. Such medium-heavy oil is usually mobile at reservoir conditions.
E. Refreshing or Renewing the Catalyst [066] The catalyst can be refreshed in the reservoir as needed by re-injection into one of the injection or production wells, through a second injector, or along the antenna. In addition, the catalyst can be renewed in situ through application of steam or solvent wash.
10671 Although the present specification has described particular embodiments and examples of the methods and treatments discussed herein, it will be apparent to persons skilled in the art that modifications can be made to the embodiments without departing from the scope of the appended claims.
[049] Once the catalyst is injected to the reservoir, the catalytic particles distribute or disperse through a mobile water phase in the reservoir. The catalyst particles are small enough that they can permeate through the porous matrix of the reservoir without significant retention.
Preferably, the size of the catalytic particles is at nanoscale. Nanoparticles have high mobility in porous media and can easily transport through the matrix pores of relatively tight hydrocarbon reservoirs.
[050] In one implementation, injection of the catalyst can be carried out prior to production of hydrocarbons from the reservoir. In other implementations, injection of the catalyst can also be carried out during the production phase. In the latter case, the catalyst is injected into the reservoir before commencing recovery or during recovery of remaining hydrocarbons from the reservoir.
[051] By way of example, an aqueous dispersion of the catalyst is injected into the reservoir for a period of time prior to direction of electromagnetic radiation into the reservoir. In this manner, the catalyst is positioned throughout the reservoir in the water films prior to hydrocarbon production. In such a case, the method catalyzes upgrading of the hydrocarbons in the reservoir throughout the volume of the reservoir that is irradiated by the electromagnetic energy. Hydrocarbons further from the well undergo longer exposure to the catalyst (which is activated by the electromagnetic energy) before being produced; thus, the degree of hydrocarbon upgrading increases as the reservoir is produced ¨ as long as the hydrocarbons produced were exposed to the catalyst.
10521 In another example, the aqueous dispersion of the catalyst is injected into the reservoir concurrent with direction of electromagnetic radiation into the reservoir. In this example, the upgrading zone within the reservoir grows as the recovery process evolves. The aqueous dispersion of the catalyst can also be injected into the reservoir prior to direction of electromagnetic radiation into the reservoir, but then continue after the electromagnetic irradiation has occurred.
[053] A sufficient or pre-determined period of time can be allowed to pass to permit distribution or dispersal of the catalytic particles through a mobile water phase in the reservoir to an extent sufficient to accomplish purposes described herein. Using techniques known to one of skill in the art, an appropriate or sufficient period of time can be determined on the basis of the desired degree or type of in-situ upgrading, the size of the hydrocarbon bearing zone, porosity and permeability of the reservoir, physical/chemical properties of the catalyst, and/or any other factors considered relevant by the skilled person.
[054] In addition to the catalyst, the reservoir can be provided with a hydrogen source, such as organic or inorganic peroxide, tetralin (1,2,3,4-tetrahydronaphthalene), decalin (decahydronaphthalene), naphthalene, dimethyl ether (DME), light hydrocarbons (e.g., C3-C10), and the like, or a combination of more than one of any of the foregoing, in order to facilitate in-situ chemical reactions with bitumen (e.g., hydrocracking, hydrodesulfurization, etc.). The hydrogen source can be injected to the reservoir, for example, through at least one injection and/or production well.
[055] Furthermore, the reservoir can be provided with a solvent, such as toluene, diesel, propane, butane, pentane, hexane, heptane, xylene, diluent, condensate, and the like, or any component or mixture thereof, in order to improve reservoir conformance and hydrocarbon recovery. The solvent can also be injected to the reservoir, for example, through at least one injection and/or production well.
B. Pre-production Process 10561 A pre-production process can be commenced as required for a given hydrocarbon-recovery methodology. Exemplary recovery methodologies include, without limitation, steam assisted gravity drainage (SAGD), cold heavy oil production with sand (CHOPS), cyclic steam stimulation (CSS), and solvent injection. In the case of SAGD, high pressure steam is continuously injected into the upper wellbore to create a steam chamber in the oil reservoir, so that heavy oil can be heated and mobilized for production. In the case of CHOPS, sand ingress or influx is initiated such that a mixture of sand and oil can be sustained throughout primary oil production.
C. Directing Electromagnetic Radiation 1057] Electromagnetic radiation or frequencies can come from a frequency generator that is located above or below ground. An antenna system can be set up and directed towards the reservoir to deliver electromagnetic radiation to the catalyst spread in the mobile water phase.
The antenna system can be a single vertical or horizontal antenna, phased array of mixed geometry, or some other configuration. The antenna system can also be placed above or below ground (e.g., placed in a well), or in a combination thereof A skilled operator can determine the optimal placement and/or configuration of a given antenna system to maximize activation of the catalyst in the reservoir.
10581 Electromagnetic radiation has a frequency anywhere between 60 Hz and 1,000 GHz.
This frequency range includes both radio and microwave frequencies. One skilled in the art can match the appropriate electromagnetic frequency and intensity of radiation to the selected catalyst(s) in order to achieve effective catalysis.
10591 The catalyst can be activated and catalysis initiated before, concurrently with, or after the pre-production process is commenced.
D. In-situ Upgrading and Recovery of Hydrocarbons 1060] After sufficient exposure to radiation, upgrading of the bitumen or oil in contact with the activated catalyst will commence. The in-situ catalytic reactions crack large molecules in the hydrocarbons into smaller molecules, thereby decreasing viscosity. The reactions can also include, without limitation, pyrolysis, aquathermolysis (hydrous pyrolysis), gasification, hydrocracking, hydrogenation, desulphurization, denitrogenation, demetallation, or deasphalting, or a combination of more than one of any of the foregoing.
10611 The catalytic upgrading of hydrocarbons involves heat, the presence of a catalyst, the hydrocarbons themselves, and other components that can enable hydrogen production. In the case of petroleum reservoirs, the components enabling hydrogen production are the petroleum itself and water. In the absence of oxygen, the reactions that occur at elevated temperatures within the reservoir include pyrolysis (thermal cracking), aquathermolysis (hydrous pyrolysis or thermal cracking reactions in the presence of water), and gasification reactions.
[062] When the catalyst is irradiated with electromagnetic waves, for example, the water phase heats up and, due to elevated temperatures, the hydrocarbons undergo pyrolysis and aquathermolysis. In the presence of the catalyst, these reactions are enabled at lower temperatures than would be the case if the catalyst were not present. The reactions crack the hydrocarbons into smaller molecular weight species. As a result of interactions between the hydrocarbons and water, hydrogen, hydrogen sulphide, and carbon oxides are produced during aquathermolysis reactions. Additionally, as a result of gasification reactions which arise due to heating, the water-gas shift reaction will convert excess steam and carbon monoxide into additional hydrogen. Consequently, all of the required conditions for upgrading are present, including the catalyst, the heat, the hydrocarbons, and the hydrogen.
[063] Nanocatalysts are beneficial in the present methods. Nanoscale particles have a large surface-to-volume ratio, and, therefore, exhibit increased contact area and enhanced catalytic activity. Smaller-sized particles can achieve efficiency of the chemical aspects of the upgrading process. By way of example, nanoscale catalysts show asphaltene adsorption properties that enhance catalytic cracking of heavy oil within a reservoir.
[064] In the presence of a hydrogen source, hydrocracking can occur. As noted above, the hydrogen source can be provided to the reservoir externally or by a water-splitting reaction in the reservoir. Bitumen typically contains various metallic components which can add to the catalytic effect, if precipitated in situ.
[065] The hydrocarbon product resulting from the present methods can include medium-heavy oil, which typically exhibits a density of 870 to 920 kg/m3. Such medium-heavy oil is usually mobile at reservoir conditions.
E. Refreshing or Renewing the Catalyst [066] The catalyst can be refreshed in the reservoir as needed by re-injection into one of the injection or production wells, through a second injector, or along the antenna. In addition, the catalyst can be renewed in situ through application of steam or solvent wash.
10671 Although the present specification has described particular embodiments and examples of the methods and treatments discussed herein, it will be apparent to persons skilled in the art that modifications can be made to the embodiments without departing from the scope of the appended claims.
Claims (46)
1. A method for treating a reservoir to recover hydrocarbons, comprising:
delivering a catalyst into the reservoir using a mobile water phase present in the reservoir;
and directing electromagnetic radiation to the catalyst to activate the catalyst, wherein the activated catalyst initiates at least one catalytic reaction.
delivering a catalyst into the reservoir using a mobile water phase present in the reservoir;
and directing electromagnetic radiation to the catalyst to activate the catalyst, wherein the activated catalyst initiates at least one catalytic reaction.
2. The method of claim 1, wherein the reservoir is an oil sands reservoir.
3. The method of claim 1 or 2, wherein the hydrocarbons comprise bitumen.
4. The method of claim 1 or 2, wherein the hydrocarbons comprise heavy oil.
5. The method of any one of claims 1 to 4, wherein the catalyst is a nanocatalyst.
6. The method of any one of claims 1 to 4, wherein the catalyst is a metal-based catalyst.
7. The method of claim 6, wherein the catalyst includes vanadium, sodium, aluminum, or platinum.
8. The method of claim 6, wherein the catalyst is Al/.gamma.-Al2O3, ammonium Y zeolite, zirconium dioxide (ZrO2), or cordierite.
9. The method of claim 8, wherein the cordierite is Mg2Al4Si5O18.
10. The method of any one of claims 1 to 9, wherein the catalytic reaction operates to at least partially upgrade the hydrocarbons in the reservoir.
11. The method of claim 10, wherein at least partially upgrading the hydrocarbons comprises reducing the viscosity of the hydrocarbons.
12. The method of claim 10, wherein at least partially upgrading the hydrocarbons comprises pyrolysis, aquathermolysis, gasification, hydrocracking, hydrogenation, desulphurization, denitrogenation, demetallation, or deasphalting.
13. The method of claim 12, wherein at least partially upgrading the hydrocarbons comprises hydrocracking the hydrocarbons.
14. The method of claim 12, wherein at least partially upgrading the hydrocarbons comprises hydrogenation of the hydrocarbons.
15. The method of claim 12, wherein at least partially upgrading the hydrocarbons comprises desulphurization of the hydrocarbons.
16. The method of claim 12, wherein at least partially upgrading the hydrocarbons comprises denitrogenation of the hydrocarbons.
17. The method of claim 12, wherein at least partially upgrading the hydrocarbons comprises demetallation of the hydrocarbons.
18. The method of any one of claims 1 to 17, wherein an interconnected pore network of the reservoir contains the mobile water phase.
19. The method of any one of claims 1 to 18, wherein the catalyst is delivered to the reservoir by injection through a wellbore.
20. The method of claim 19, wherein a time period between the injection of the catalyst to the reservoir and the activation of the catalyst by the electromagnetic radiation permits distribution of particles of the catalyst within the reservoir via the mobile water phase.
21. The method of claim 20, wherein up to one year passes between the injection and the activation.
22. The method of any one of claims 1 to 21, wherein the electromagnetic radiation has a frequency in the range of about 60 Hz to about 1,000 GHz.
23. The method of any one of claims 1 to 22, wherein the electromagnetic radiation is directed to the catalyst using an antenna.
24. The method of claim 23, wherein the antenna is a vertical or horizontal antenna or a phased array of mixed geometry.
25. The method of any one of claims 1 to 24, further comprising delivering a hydrogen source to the reservoir.
26. The method of claim 25, wherein the hydrogen source is peroxide, dimethyl ether (DME), light hydrocarbon, tetralin, decalin, or naphthalene.
27. The method of any one of claims 1 to 26, further comprising delivering a solvent to the reservoir.
28. A method for recovering hydrocarbons from a hydrocarbon-containing reservoir, comprising:
delivering a nanocatalyst to the reservoir by injection through a wellbore in the reservoir;
allowing a pre-determined period of time to pass such that particles of the nanocatalyst are dispersed into the reservoir via a mobile water phase present in the reservoir;
directing electromagnetic radiation to the nanocatalyst to activate the nanocatalyst; and when the activated nanocatalyst has induced at least one chemical reaction which at least partially upgrades the hydrocarbons, recovering the at least partially upgraded hydrocarbons from the reservoir.
delivering a nanocatalyst to the reservoir by injection through a wellbore in the reservoir;
allowing a pre-determined period of time to pass such that particles of the nanocatalyst are dispersed into the reservoir via a mobile water phase present in the reservoir;
directing electromagnetic radiation to the nanocatalyst to activate the nanocatalyst; and when the activated nanocatalyst has induced at least one chemical reaction which at least partially upgrades the hydrocarbons, recovering the at least partially upgraded hydrocarbons from the reservoir.
29. The method of claim 28, wherein the reservoir is an oil sands reservoir.
30. The method of claim 28 or 29, wherein the hydrocarbons comprise bitumen.
31. The method of claim 28 or 29, wherein the hydrocarbons comprise heavy oil.
32. The method of any one of claim 28 to 31, wherein the at least partially upgraded hydrocarbons are recovered from the reservoir using steam injection recovery.
33. The method of claim 32, wherein the steam injection recovery is steam-assisted gravity-drainage (SAGD) or cyclic-steam stimulation (CSS).
34. The method of any one of claims 28 to 33, wherein at least partially upgrading the hydrocarbons comprises reducing the viscosity of the hydrocarbons.
35. The method of any one of claims 28 to 33, wherein at least partially upgrading the hydrocarbons comprises pyrolysis, aquathermolysis (hydrous pyrolysis), gasification, hydrocracking, hydrogenation, desulphurization, denitrogenation, demetallation, or deasphalting.
36. The method of claim 35, wherein at least partially upgrading the hydrocarbons comprises hydrocracking the hydrocarbons.
37. The method of claim 35, wherein at least partially upgrading the hydrocarbons comprises hydrogenation of the hydrocarbons.
38. The method of claim 35, wherein at least partially upgrading the hydrocarbons comprises desulphurization of the hydrocarbons.
39. The method of claim 35, wherein at least partially upgrading the hydrocarbons comprises denitrogenation of the hydrocarbons.
40. The method of claim 35, wherein at least partially upgrading the hydrocarbons comprises demetallation of the hydrocarbons.
41. The method of any one of claims 28 to 40, further comprising refreshing the nanocatalyst in the reservoir by at least one of re-injection into the wellbore, injection through a secondary injector, and injection along an antenna.
42. The method of claim 41, further comprising renewing the nanocatalyst in situ through application of steam or solvent wash.
43. A reservoir comprising a catalyst for recovery of at least partially upgraded hydrocarbons, wherein the catalyst is distributed through a mobile water phase present in the reservoir and the catalyst is activatable by electromagnetic radiation.
44. The reservoir of claim 43, wherein the reservoir is an oil sands reservoir.
45. The reservoir of claim 43 or 44, wherein the hydrocarbons comprise bitumen.
46. The reservoir of claim 43 or 44, wherein the hydrocarbons comprise heavy oil.
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