WO2013103518A1 - Amélioration de la récupération de pétrole lourd par utilisation de valorisation du bitume de fond de puits avec drainage par gravité assisté à la vapeur - Google Patents

Amélioration de la récupération de pétrole lourd par utilisation de valorisation du bitume de fond de puits avec drainage par gravité assisté à la vapeur Download PDF

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Publication number
WO2013103518A1
WO2013103518A1 PCT/US2012/070324 US2012070324W WO2013103518A1 WO 2013103518 A1 WO2013103518 A1 WO 2013103518A1 US 2012070324 W US2012070324 W US 2012070324W WO 2013103518 A1 WO2013103518 A1 WO 2013103518A1
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WO
WIPO (PCT)
Prior art keywords
catalyst
production well
steam
heavy oil
cracking catalyst
Prior art date
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PCT/US2012/070324
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English (en)
Inventor
Frank Michael BAYLES
Original Assignee
Conocophillips Company
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Publication date
Application filed by Conocophillips Company filed Critical Conocophillips Company
Publication of WO2013103518A1 publication Critical patent/WO2013103518A1/fr

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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
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G1/00—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
    • C10G1/04—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal by extraction
    • C10G1/047—Hot water or cold water extraction processes
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G11/00—Catalytic cracking, in the absence of hydrogen, of hydrocarbon oils
    • C10G11/14—Catalytic cracking, in the absence of hydrogen, of hydrocarbon oils with preheated moving solid catalysts
    • C10G11/16—Catalytic cracking, in the absence of hydrogen, of hydrocarbon oils with preheated moving solid catalysts according to the "moving bed" method
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
    • C10G2300/10—Feedstock materials
    • C10G2300/1033—Oil well production fluids
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
    • C10G2300/40—Characteristics of the process deviating from typical ways of processing
    • C10G2300/4037—In-situ processes
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
    • C10G2300/40—Characteristics of the process deviating from typical ways of processing
    • C10G2300/4056—Retrofitting operations

Definitions

  • the present invention relates generally to methods and systems for enhanced recovery of heavy oils. More particularly, but not by way of limitation, embodiments of the present invention include methods and systems for enhancing recovery of heavy oils using selective catalytic downhole upgrading of a portion of the heavy oil in combination with steam-assisted gravity drainage technology.
  • the term, “heavy oil” includes any heavy hydrocarbons having greater than 10 carbon atoms per molecule. Further, the term “heavy oil” includes heavy hydrocarbons having a viscosity in the range of from about 100 to about 100,000 centipoise at 100°F, and an API gravity from about 5 to about 22° API; or can be a bitumen having a viscosity less than about 100,000 centipoise, and an API gravity less than or equal to about 22° API.
  • diluents such as solvents or lighter hydrocarbons introduced into a formation
  • solvents can be quite expensive. Indeed, not only are solvents quite expensive, the use of diluents also suffers from costly solvent losses (i.e. solvent lost to the formation that is not subsequently recovered). Thus, the process economics of using diluents are highly sensitive to both solvent cost and solvent losses. Often, the use of solvents to recover heavy oils is prohibitively expensive.
  • hydrocarbons produced are usually a lower quality crude oil that requires upgrading either at the production site or at a refinery. Because heavy oils are so viscous, they cannot often be transported from the production site without adding diluents.
  • upgrading facilities due to the capital intensive nature of an upgrading facility, upgrading facilities only become economical when used to service large quantities of crude oil (e.g. greater than about 100,000 barrels of crude oil a day). Therefore, upgrading facilities are typically not economical for those wells producing less than about 100,000 barrels of crude oil a day.
  • Certain conventional methods contemplate in-situ upgrading in which an upgrading catalyst is injected into a subterranean formation to allow the crude oil therein to be upgraded. Unfortunately, this conventional method suffers from the disadvantage of large catalyst losses to the formation. Also, it is difficult to control the distribution and contact duration of the catalyst in the formation to maximize the impact of the catalyst with the heavy oil. Further, unlike surface upgrading facilities, this method does not allow reuse of any of the upgrading catalyst injected to the formation.
  • the present invention relates generally to methods and systems for enhanced recovery of heavy oils. More particularly, but not by way of limitation, embodiments of the present invention include methods and systems for enhancing recovery of heavy oils using selective catalyst downhole upgrading scheme in combination with steam-assisted gravity drainage technology.
  • One example of a method for enhancing heavy oil recovery from a subterranean formation comprises the steps of: providing a production well intersecting a subterranean formation, wherein the production well is in fluid communication with an injection well to form a well pair among one or more steam- assisted gravity drainage production well pairs for recovering heavy oil from a bitumen formation; (a) providing a cracking catalyst; (b) heating the cracking catalyst to a catalyst pre-heated temperature; (c) introducing the cracking catalyst into the production well at a catalyst injection point above a producing interval; (d) allowing the heavy oil to be produced through the production well; (e) allowing the heavy oil to be upgraded in the production well in the presence of the cracking catalyst to form an upgraded mixture; wherein the catalyst pre-heated temperature is sufficient to provide a reaction temperature of about 500°F to about 550°F during step (e); (f) introducing the upgraded mixture to a separator to separate the upgraded mixture into a hydrocarbon-enriched stream and a catalyst slurry; (
  • One example of a method for enhancing heavy oil recovery from a subterranean formation comprises the steps of: providing a production well intersecting a subterranean formation, wherein the production well is in fluid communication with an injection well to form a well pair among one or more steam- assisted gravity drainage production well pairs for recovering heavy oil from a bitumen formation; (a) providing a cracking catalyst; (b) heating the cracking catalyst; (c) introducing the cracking catalyst into the production well at a catalyst injection point above a producing interval; (d) allowing the heavy oil to be produced through the production well; (e) allowing the heavy oil to be upgraded in the production well in the presence of the cracking catalyst to form an upgraded mixture; (f) introducing the upgraded mixture to a separator to separate the upgraded mixture into a hydrocarbon-enriched stream and a catalyst slurry; (h) separating the catalyst slurry into two streams, a gasification feed and recovered catalyst; (i) recycling the recovered catalyst to the catalyst injection point; (j) introducing the gas
  • Figure 1 illustrates an example of an enhanced heavy oil recovery system using a downhole upgrading catalyst in combination with a SAGD process in accordance with one embodiment of the present invention.
  • the present invention relates generally to methods and systems for enhanced recovery of heavy oils. More particularly, but not by way of limitation, embodiments of the present invention include methods and systems for enhancing recovery of heavy oils using selective catalytic downhole upgrading of heavy oil in combination with steam-assisted gravity drainage technology.
  • methods and systems for enhancing recovery of heavy oils comprise the steps of extracting heavy oil using a SAGD process and upgrading the heavy oil in a production well with a cracking catalyst.
  • cracking catalyst is introduced into the production well, allowing the extracted hydrocarbons to intimately interface with the cracking catalyst so as to upgrade the hydrocarbons in the production well.
  • the upgraded hydrocarbons thus produced are separated from the cracking catalyst in a separator.
  • This upgraded stream has a lower molecular weight which significantly reduces the viscosity of the produced heavy oil at similar temperatures.
  • a gasifier is provided to gasify a portion of the slurry that contains unconverted heavy oil and cracking catalyst.
  • the produced syngas is then used to produce steam for use in the SAGD extraction process.
  • the energy efficiency of the SAGD process is improved by leveraging syngas produced from the gasifier to produce steam.
  • this enhanced process avoids catalyst losses to the formation as the catalyst that is injected into the production well is recovered and available for reuse.
  • the specific activity of the catalyst can be controlled by mixing the recycled catalyst with fresh catalyst.
  • FIG. 1 illustrates an example of an enhanced heavy oil recovery system using a selective catalyst downhole upgrading scheme in combination with a SAGD process in accordance with one embodiment of the present invention.
  • enhanced heavy oil recovery system 100 comprises SAGD well pair 122, separator 130, slurry catalyst tank 140, fresh catalyst tank 150, process heater 160, gasifier 170, and steam generator 180.
  • Production well 1 12 and steam injection well 120 intersect subterranean formation 105 for extracting heavy oil from production interval 1 14. Portions of production well 112 and steam injection well 120 together forms a SAGD well pair 122, which traverses through production interval 1 14.
  • SAGD well pairs comprise a pair of horizontal wells drilled into an oil reservoir, one a few meters above the other (e.g. about 4 to about 6 meters). The upper well injects steam, possibly mixed with solvents, and the lower one collects the heated crude oil or bitumen that flows out of the formation, along with any water from the condensation of injected steam.
  • the basis of the process is that the injected steam forms a "steam chamber" that grows vertically and horizontally in the formation.
  • the heat from the steam reduces the viscosity of the heavy crude oil or bitumen which allows it to flow down into the lower wellbore.
  • the steam and gases rise due to their low density compared to the heavy crude oil below, ensuring that steam is not produced at the lower production well.
  • Production as high as 70% to 80% of oil in place is common in suitable reservoirs.
  • the SAGD process may be used to extract heavy oil for production to surface 1 10 via production well 112. It is recognized that a plurality of SAGD well pairs may be used to extract heavy oil from subterranean formation 105 as desired.
  • the heavy oil thus produced is of low quality and requires additional viscosity reduction, usually around an API of at least about 19 to about 22°, to allow transportation of the heavy oil to its final destination. While this can be accomplished by adding diluent to the extracted hydrocarbons, this method is often not economical. Additionally, as described in the Background Section, upgrading facilities are capital intensive and therefore may not always be economical, especially for smaller production wells. Accordingly, the methods herein contemplate introducing heated cracking catalyst 162 to production well 112 at catalyst injection point 1 16. In this way, extracted heavy oil may be upgraded in the presence of heated cracking catalyst 162 as the heavy oil and cracking catalyst 162 flow through downhole reaction interval 118. In certain embodiments, the ratio of heated cracking catalyst 162 to heavy oil varies from three to seven on a weight basis.
  • Cracking catalysts suitable for use with this invention include any catalysts capable of upgrading the heavy oil to lighter compounds at production temperatures and pressures. To achieve adequate cracking at temperatures found in production systems, a high activity catalyst is required. Examples of suitable cracking catalysts include high surface area catalysts, such as, nanocatalysts. In some embodiments, the cracking catalyst includes particle sizes ranging from about 50 micrometers to about 100 micrometers. In some embodiments, the particle size of the cracking catalyst is selected to maximize surface area for enhanced upgrading reaction of the heavy oil.
  • Catalyst injection point 116 may be located at any distance from producing interval 114 to prevent catalyst loss to the formation. Examples of suitable distances include, but are not limited to, about 50 feet from producing interval 1 14 and about 40 feet to about 100 feet from producing interval 1 14. In certain embodiments, the length and diameter of the production well is preferably of dimensions to provide a sufficient reaction residence time to allow the extracted hydrocarbons to be sufficiently upgraded. Downhole reaction interval 1 18 may be any length suitable for providing sufficient reaction residence time to allow the heavy oil to be upgraded as desired.
  • the main criteria for determining upgrading success are reduction in viscosity.
  • the degree of viscosity reduction is based on the economics of the cost of upgrading versus the decrease in cost of any diluent necessary to allow pipeline transportation of the heavy oil.
  • the range is from maximum diluent (traditional approach) to no diluent.
  • Examples of suitable selective catalytic downhole reaction interval lengths include, but are not limited to, at least about 500 feet and lengths from about 500 feet to about 1,200 feet.
  • Examples of suitable reaction residence times include, but are not limited to, about two seconds to about 2 minutes to several minutes.
  • Upgraded mixture 129 exits subterranean formation via production well 112 at surface 1 10.
  • Upgraded mixture 129 comprises both upgraded hydrocarbons combined with catalyst slurry.
  • Upgraded mixture 129 is introduced to separator 130 to separate upgraded mixture 129 into hydrocarbon-enriched stream 132 and recovered catalyst 134.
  • separator 130 is any process equipment suitable for separating hydrocarbon-enriched stream 132 from recovered catalyst 134. Examples of suitable separators include, but are not limited to, fractionators, flash drums, or any combination thereof.
  • recovered catalyst 134 flows to optional slurry catalyst tank 140. The recovered catalyst may be split into recycled catalyst 142a and gasification feed 144.
  • hydrocarbon- enriched stream 132 has a higher API (i.e. a lower viscosity) than the heavy oil in-situ in the formation, hydrocarbon-enriched stream 132 may be transported to a final destination, for example, to storage or to a refinery for further processing.
  • Recycled catalyst 142a combines with fresh catalyst 152 from fresh catalyst tank 150 to form cracking catalyst mixture 154 and is fed to process heater 160.
  • process heater 160 heats cracking catalyst mixture 154 to form heated cracking catalyst 162.
  • Process heater 160 heats heated cracking catalyst 162 to a temperature to achieve an overall reaction temperature of about 500°F to about 550°F.
  • all or a portion of recycled catalyst 142a may bypass process heater 160 via diverted catalyst 142b. In this way, catalyst slurry may be recycled to allow catalyst reuse for upgrading the extracted heavy oil from subterranean formation 105. This recycling of catalyst avoids the catalyst losses inherent to those conventional methods that inject catalyst directly into the subterranean formations.
  • introducing the catalyst in the confined space of production well 112 allows the catalyst to be actively concentrated on the extracted heavy oil and further allows the reaction conditions to be more precisely controlled or varied, which is not possible when injecting catalyst directly into a formation.
  • gasification feed 144 comprises a portion of recovered catalyst 134.
  • Gasification feed is introduced to gasifier 170.
  • Gasification is a process that converts organic or fossil based carbonaceous materials into carbon monoxide, hydrogen, carbon dioxide and methane. This process is achieved by reacting material at high temperatures (e.g. greater than about 700°C), without combustion, with a controlled amount of oxygen and/or steam.
  • the resulting gas mixture is often referred to as syngas (from synthesis gas or synthetic gas) or producer gas and is itself a fuel.
  • One of the advantages of gasification is that using the syngas is potentially more efficient than direct combustion of the original fuel, because it can be combusted at higher temperatures, so that the thermodynamic upper limit to the efficiency defined by Carnot's rule is higher or not applicable.
  • the high- temperature combustion refines out corrosive ash elements such as chloride and potassium, allowing clean gas production from otherwise problematic fuels.
  • gasification of gasification feed 144 in gasifier 170 produces syngas 172 and waste stream 174.
  • Syngas 172 may be used as a fuel to produce steam in steam generator 180 or to produce heat in process heater 160 by combusting syngas 172.
  • Steam generator 180 may comprise a direct steam generator, an indirect steam generator, or a combination thereof for generating steam 182.
  • Waste stream 174 is also produced by gasifier 170. Waste stream 174 is typically disposed of.
  • syngas 170 may be diverted for use in process heater 160 to reduce energy requirements needed to heat cracking catalyst mixture 154 to form heated cracking catalyst 162. This use of syngas 170 in process heater 160 reduces the overall energy required to heat cracking catalyst mixture 154 and therefore further economizes energy usage of the upgrading process.
  • a higher quality upgraded product can be produced by separating the hydrogen from the syngas and directing it to the well bore. Introducing hydrogen in the catalytic upgrading will result in a more stable product than with non-hydrogen upgrading.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Mining & Mineral Resources (AREA)
  • Geology (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Organic Chemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Environmental & Geological Engineering (AREA)
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Abstract

La présente invention concerne des procédés pour la récupération de pétroles lourds par une utilisation catalytique sélective pour la valorisation de fond de puits avec la technologie de drainage par gravité assisté à la vapeur (SAGD). Certains modes de réalisation comprennent l'extraction de pétrole lourd à l'aide d'un procédé SAGD et la valorisation du pétrole lourd dans un puits de production avec un catalyseur de craquage. Le catalyseur de craquage est introduit dans le puits de production, permettant aux hydrocarbures extraits à venir en interface avec le catalyseur de craquage pour la valorisation des hydrocarbures. Les hydrocarbures valorisés sont ensuite séparés du catalyseur de craquage. Ce flux valorisé a un poids moléculaire inférieur, ce qui permet de réduire considérablement la viscosité des hydrocarbures produits. Un réacteur de gazéification est prévu pour gazéifier une partie de la boue contenant le pétrole lourd non converti et le catalyseur de craquage pour produire du gaz de synthèse. Le gaz de synthèse peut ensuite être utilisé pour produire de la vapeur d'eau destinée à être utilisée dans le procédé d'extraction SAGD, améliorant son rendement énergétique. En outre, les pertes de catalyseur sont évitées puisque le catalyseur injecté dans le puits est récupéré et mis à disposition pour une réutilisation.
PCT/US2012/070324 2012-01-03 2012-12-18 Amélioration de la récupération de pétrole lourd par utilisation de valorisation du bitume de fond de puits avec drainage par gravité assisté à la vapeur WO2013103518A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US201261582627P 2012-01-03 2012-01-03
US61/582,627 2012-01-03
US13/717,894 2012-12-18
US13/717,894 US20130168094A1 (en) 2012-01-03 2012-12-18 Enhanced heavy oil recovery using downhole bitumen upgrading with steam assisted gravity drainage

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WO2013103518A1 true WO2013103518A1 (fr) 2013-07-11

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Publication number Priority date Publication date Assignee Title
CN103351886B (zh) * 2013-07-09 2015-09-23 杨林江 一种从天然沥青中提炼石油基质沥青的方法

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US3412011A (en) * 1966-09-02 1968-11-19 Phillips Petroleum Co Catalytic cracking and in situ combustion process for producing hydrocarbons
US20030131582A1 (en) * 2001-12-03 2003-07-17 Anderson Roger E. Coal and syngas fueled power generation systems featuring zero atmospheric emissions
US20070032692A1 (en) * 2005-08-08 2007-02-08 Chevron U.S.A. Inc. Catalyst and process for selective hydroconversion of normal paraffins to normal paraffin-rich lighter products
US20100212893A1 (en) * 2006-11-14 2010-08-26 Behdad Moini Araghi Catalytic down-hole upgrading of heavy oil and oil sand bitumens
US20110168394A1 (en) * 2005-10-24 2011-07-14 Shell Oil Company Methods of producing alkylated hydrocarbons from an in situ heat treatment process liquid

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US3412011A (en) * 1966-09-02 1968-11-19 Phillips Petroleum Co Catalytic cracking and in situ combustion process for producing hydrocarbons
US20030131582A1 (en) * 2001-12-03 2003-07-17 Anderson Roger E. Coal and syngas fueled power generation systems featuring zero atmospheric emissions
US20070032692A1 (en) * 2005-08-08 2007-02-08 Chevron U.S.A. Inc. Catalyst and process for selective hydroconversion of normal paraffins to normal paraffin-rich lighter products
US20110168394A1 (en) * 2005-10-24 2011-07-14 Shell Oil Company Methods of producing alkylated hydrocarbons from an in situ heat treatment process liquid
US20100212893A1 (en) * 2006-11-14 2010-08-26 Behdad Moini Araghi Catalytic down-hole upgrading of heavy oil and oil sand bitumens

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