Escolar Documentos
Profissional Documentos
Cultura Documentos
by Electrical Heating
B. Hascakir, Middle East Technical University; T. Babadagli, University of Alberta;
and S. Akin, Middle East Technical University
Summary
Electrical heating for heavy-oil recovery is not a new idea, but the
commercialization and wider application of this technique require
detailed analyses to determine optimal application conditions. In
this study, applicability of electrical heating for heavy-oil recovery
from two heavy-oil fields in Turkey (Bati Raman and Camurlu)
was tested numerically. The physical and chemical properties of the
oil samples for the two fields were compiled, and in-situ viscosity
reduction during the heating process was measured with and without using iron powder. Iron powder addition to oil samples causes a
decrease in the polar components (such as carboxylic and phenolic
acids) of oil, and the viscosity of oil can be reduced significantly
because of the magnetic fields created by iron powders. Three
different iron-powder types at three different doses were tested to
observe their impact on oil recovery. Experimental observations
showed that viscosity reductions were accomplished at 88 and 63%
for Bati Raman and Camurlu crude oils, respectively, after 0.5%
iron (Fe) addition, which was determined as the optimum type and
dose for both crude-oil samples. Next, field-scale recovery was
tested numerically using the viscosity values obtained from the
laboratory experiments and physical and chemical properties of
the oil fields compiled from the literature. The power of the system, operation period, and the number of heaters were optimized.
Economic evaluation performed only on the basis of the electricity
cost using the field-scale numerical modeling study showed that
the production of 1 bbl petroleum costs approximately USD 5,
and at the end of 70 days, 320 bbl of petroleum can be produced.
When 0.5% Fe is added, oil production increased to 440 bbl for
the same operational time period.
Introduction
Crude oils whose API gravity is smaller than 20 are called heavy
oil (Conaway 1999). The key to produce oil from these resources
is to reduce oil viscosity, and that is best accomplished by heating
these resources, which can be achieved by thermal methods (i.e.,
hot-fluid injection, in-situ combustion, and thermal stimulation)
(Farouq Ali 2003; Prats 1982). Apart from the common thermal
methods, electromagnetic heating and electrical heating can also
be considered as alternative thermal methods. While steam-based
methods have been more successful economically and technically than others, alternative heating methods were found to be
uneconomical for heavy-oil recovery because of the high operating
costs in the past (Thomas 2007). Because of recent increase in oil
prices, the electrical heating technique could be considered as a
commercial method (Campbell and Laherrre 1998).
Electrical-heating tools and their applications can be divided
into three categories on the basis of the frequency of electrical
current used by the tool (Sahni et al. 2000):
(1) Low-frequency currents are used in resistive/ohmic heating.
(2) High-frequency currents are used in microwave heating
methods.
(3) Induction tools have the ability to use a wide range of lowto medium-frequency currents, depending on heat requirements
and desired temperature.
These methods are applied in the field by using a downhole magnetron or heater (Prats 1982).
Heating with frequencies less than 300 kHz can be described
as electrical-resistance heating (ERH) (Maggard and Wattenbarger
1991). This mode of heating for petroleum recovery has been
known since the late-1960s. Reservoir-simulation models (RangelGerman et al. 2004; Sierra et al. 2001) and experimental models
(Newbold and Perkins 1978; Amba et al. 1964) have been used in
the past to study electrical heating. Electromagnetic heating such as
microwave heating for recovery of heavy oil from thin pay zones,
was studied experimentally (Jha and Chakma 1999; Acar et al.
2007). In order to enhance the electromagnetic heating efficiency,
use of receptors such as activated carbon, iron oxides, and polarized solvents has been proposed (Jackson 2002).
In this study, applicability of electrical heating for heavy-oil
recovery from two heavy-oil fields in Turkey (Bati Raman and
Camurlu) was tested experimentally and numerically. Experimental studies were conducted to study the efficiency of the method.
In addition, to reduce the viscosity of oil, different types of iron
powders were used. Experimental results coupled with the data
available in the literature were used to simulate the process numerically at the field scale.
Theory
As an electromagnetic wave that is radiated from the electrodes
into the oil-bearing formation propagates into the formation, fluids and other reservoir materials impede its passage by providing
resistance to the flow. As a result, the intensity of the propagating
wave is reduced and the energy is converted to heat. There are
key differences between low- and high-frequency heating. At low
frequencies, resistance heating dominates compared to dielectric
heating that dominates at higher frequencies.
Heat transfer from an electromagnetic-wave source to a porous
medium can be described by the energy equation. Evolution of
temperature as a result of electrical energy can then be obtained
by the heat equation, with the following modification:
c p
I
I
T
I I
+ f c pf v f T = c T + P , . . . . . . . . . . . . . . . . . (1)
t
where , cp, and c are the density, specific heat capacity, and
I
thermal conductivity of the medium, respectively; f , cpf , and v f
are the density, specific heat capacity, and superficial velocity,
respectively, of the fluid phase; and P is the electromagnetic dissipated power per unit of volume,
I based on Maxwells equations, is
a function of the electric field E and the effective conductivity ()
of the medium, and is represented by the following expression:
P=
+ tan I 2
E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (2)
2
Units
Bati Raman
Camurlu
Region
South Batman
Mardin-Nusaybin
Limestone
Limestone
Reservoir temperature
129
115
Reservoir pressure
psia
1,750
1,700
Rock compressibility
kPa
5.44*10
5.44*10
J/m . C
2315
2198
J/m.day.C
111888
111888
1310
800
g/mole
1342
1000
46
kPa
53
Average porosity
18
14
Average permeability
md
58
40
21
23
13
12,2
Specific gravity
0,9772
0,985
Average viscosity
cp
592
700
ppm
40000160000
100000
1850
378
*10 STB
132
10000
10
100
Viscosity (cp)))
1000
Camurlu
Bati Raman
Temperature (C)
20
30
40
50
60
70
80
90
100
Fig. 1Viscosity variations for the heavy-oil samples considered in this study (Hasakir and Akin 2006).
=
, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (3)
Power-law model
= K n, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (4)
Bingham model
o =
` , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (5)
and Casson model
TABLE 2CAMURLU CRUDE-OIL VISCOSITY VALUES
AFTER THE ADDITION OF IRON POWDERS*
Experiment Type
Viscosity
at 20C (cp)
Viscosity
at 100C (cp)
Experiment Type
Viscosity
at 20C (cp)
Viscosity
at 100C (cp)
Without catalysts
1,132
113
Without catalysts
2,037
324
150
1,150
156
0.1% Fe2O3
1,039
0.5% Fe2O3
1,299
337
0.5% Fe2O3
1,300
170
1% Fe2O3
1,244
337
1% Fe2O3
270
160
0.1% FeCl3
1,085
145
0.1% FeCl3
361
127
0.5% FeCl3
1,149
173
0.5% FeCl3
304
137
1% FeCl3
1,067
185
1% FeCl3
308
170
0.1% Fe
1,060
191
0.1% Fe
299
136
0.5% Fe
749
85
0.5% Fe
247
125
1% Fe
868
181
1% Fe
505
230
133
0,5
1,5
2,5
3,5
4,5
500
3. y = 252,54x0,2676
R2 = 0,9276
200
300
400
1. y = 0,0767x + 11,24
R2 = 0,9253
100
4. y = 2,0232x + 115,68
R2 = 0,9996
2. y = 0,0638x + 4,7733
R2 = 0,9599
200
400
600
1
800
1000
1200
Fig. 2Determination of Bati Raman crude-oil rheology. Raw oil samples (Curves 3 and 4) both show non-Newtonian characteristics at the room temperature (Curve 3), giving a better fit to the power-law model, and at 100C (Curve 4) a better fit to the
Bingham model. Both iron-added cases showed characteristics very similar to those of Newtonian fluids.
1,5
2,5
25
0.5
-1
for 3 & 4 (s )
0.5
20
(Pa)
Shear Rate
4. y = 0,2051x + 10,681
R2 = 0,9524
10
15
Shear Stress
3. y = 5,1686x + 10,111
R2 = 0,979
1. y = 0,2555x + 1,6254
R2 = 0,9508
0.5
-1
for 1 & 2 (s )
Shear Rate
2. y = 0,2548x + 0,5479
R2 = 0,9613
10
15
20
25
30
35
40
Fig. 3Testing Bati Raman crude-oil rheology using the Casson model.
134
350
Shear Stress (Pa)
300
250
200
2. y = 0,1633x1,0553
R2 = 0,9984
3. y = 1,4003x0,8674
R2 = 0,9723
4. y = 2,0232x + 115,68
R2 = 0,9996
50
100
150
1. y = 1,4515x0,8785
R2 = 0,9641
-1
Shear Rate (s )
50
100
150
200
250
300
350
400
450
500
Fig. 4Determination of Camurlu crude-oil rheology. Raw oil samples both show non-Newtonian characteristics giving a better
fit to the power-law model. Both iron-added cases showed Newtonian characteristics.
of the microstructure of asphaltenes after treatment with electromagnetic irradiations is warranted, but is beyond the scope of this
paper. One interesting feature is that all viscosity values converge
to values that are close to each other. A higher temperature removes
the effect of permanent alteration of asphaltene orientation that
might have caused alteration of the crude oil.
Numerical Simulation
Model Construction. All simulation runs were performed using
the electrical-heating option of a commercial reservoir simulator
20
1. y = 0,7132x + 1,5686
R2 = 0,9729
4. y = 0,3422x 0,1565
R2 = 0,9859
10
Shear Stress
0.5
(Pa)
15
2. y = 0,4782x 0,1492
R2 = 0,9996
3. y = 0,6509x + 1,766
R2 = 0,945
0.5
(s )
Shear Rate
10
1
15
3
20
4
25
Fig. 5Testing Bati Raman crude-oil rheology using the Casson model.
February 2010 SPE Reservoir Evaluation & Engineering
135
Laboratory Scale:
r=0.015 in.
d=10 cm
z=20 cm
Grids 20110
Field Scale:
r=4.5 in.
d=100 cm
z=30 m
Grids 20110
showed that the effect of other experimentally measurable properties, including relative permeability variations on oil production, is
trivial (Hasakir et al. 2008). Figs. 7 and 8 show that high-viscosity
cases and low-temperature values yield better viscosity reduction
for the samples with 0.5% Fe added, owing to a possible magnetic
effect such as those observed for ferrofluids (Odenbach 2003). The
other reservoir-rock and -fluid properties needed for the simulator
are summarized in Table 1 and Fig. 9.
Numerical Results. During the numerical runs, the power given
to the system, the number of heaters used in the process, and the
operation times were optimized. Simulation results are given in
Tables 4 and 5 and in Figs. 10 and 11. The optimization criterion
was determined as the highest oil production for the most economic
case. On the basis of the results, the second run for the Bati Raman
crude oil and the ninth run for the Camurlu crude oil were selected
as optimum conditions. While the production increases after the
addition of 0.5% Fe for Bati Raman crude oil, no significant effect
of iron addition was observed for the Camurlu crude oil. It can
1,0E+03
1,0E-21
Addition
0,0077x
y = 273,72e
2
R =1
0,0274x
y = 6235,1e
2
R =1
1,0E-15
1,0E-09
1,0E-03
Raw
Temperature (C)
0
200
400
600
800
1000
1200
1400
1600
1800
2000
2200
1,0E+02
1,0E-26
1,0E-19
1,0E-12
1,0E-05
Raw
Addition
0,0247x
y = 2637,8e
2
R =1
0,0337x
y = 3831,2e
2
R =1
Temperature (C)
0
200
400
600
800
1000
1200
1400
1600
1800
2000
2200
krw, kro
1
krw
kro
0,8
0,6
0,4
0,2
0
0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0,9
Sw
Fig. 9Water/oil relative permeability curves used in the simulation for heavy-oil samples (Spivak et al. 1989).
Number
of Heaters
Operation
Time (days)
Total
Power (W)
Total
Energy (kWhr)
10
60
29762
42857.28
10
70
34722
58332.96
60
14881
21428.64
10
70
57870
97221.6
10
60
49603
71428.32
10
60
69444
99999.36
10
70
81019
136111.92
10
60
19841
28571.04
10
70
23148
38888.64
10
10
70
11574
19444.32
11
10
60
9921
14286.24
137
Number
of Heaters
Operation
Time (days)
10
60
8930
12859.2
10
70
10417
17500.56
10
60
9921
14286.24
10
70
11574
19444.32
10
60
19841
28571.04
10
70
23148
38888.64
10
60
29762
42857.28
10
70
34722
58332.96
60
14881
21428.64
10
70
17361
29166.48
11
60
29762
42857.28
12
70
34722
58332.96
13
60
19841
28571.04
14
70
23148
38888.64
Total
Energy (kWhr)
40000
Total
Power (W)
300
200
100
10000
Production (bbl)
20000
Power (W)
)))
400
30000
500
10
11
12
13
14
Fig. 10Simulation results for Bati Raman crude oil (1: Raw crude oil; 2: Crude oil containing 0.5% Fe).
138
500
100000
300
100
200
Production (bbl)
20000
40000
Power (W))))
60000
400
80000
10
11
500
Fig. 11Simulation results for Camurlu Crude oil (1: Raw crude oil; 2: Crude oil containing 0.5% Fe).
100
200
300
Production (bbl)
400
Time (days)
0
10
20
30
40
50
60
70
80
Fig. 12Oil production (1: Raw Bati Raman crude oil, 2: Bati Raman crude oil containing 0.5% Fe; 3: Raw Camurlu crude oil, 4:
Camurlu crude oil containing 0.5% Fe).
Addition
# of Heater
Total Operation
Time (days)
Cost of the
Study (USD/bbl)
10
70
320
4.84
Bati Raman
0.5% Fe
10
70
440
3.52
Camurlu
10
70
429
6.88
Camurlu
0.5% Fe
10
70
419
7.04
139
The results also revealed that the effectiveness of the electrical-heating process for both fields is very limited (Fig. 13). Thus,
increasing the heating time neither helps to increase the effectiveness of heating area nor decreases the cost of the process. Seventy
days was observed as an optimum heating/production time period
for each well. Note that each well was defined to produce from a
100-m drainage radius and through 30-m pay thickness (Fig. 6).
To enhance the production further, different options can be considered, including drilling more wells per area, increasing the heating
area effectively using iron powders, or continuing the production
with another process (i.e., flooding), taking advantage of already
reduced oil viscosity.
Fig. 13Temperature profiles obtained during field-scale simulation runs for two different oil types.
140
Note that numerical simulations were performed on homogeneously distributed rock properties such as porosity and permeability.
Heterogeneous structures might have different impacts (positive or
negative) in the effectiveness of heating and heat distribution. This
could be considered as a further research subject.
Obviously, how the iron powders can be introduced into the
reservoir for practical applications is a critical issue. No application
or suggestion is available in the literature. For a reservoir close to
the Earths surface, mining can be an economic alternative for the
recovery of unconventional oil. In this case, the iron powders can
be added during the extraction process, which is a relatively easier
practice. For deep reservoirs in which in-situ recovery techniques
are needed, the iron powders should be injected into the reservoir
with a carrier fluid. In order to avoid emulsion formation in the reservoir, petroleum-based fluids (light crude or solvent) can be used
as carrier fluid instead of water. Using gas could be an alternative,
especially in tight formations such as shales. Oxidizing gases that
add a combustion component to the process or nonoxidizing gases
(i.e., N2, He, or Ar) are possible options, and this requires further
research in terms of injectivity and selection of proper injectant to
transfer the iron powders into the reservoir.
Conclusions
1. As the viscosity/temperature relationship was observed to be
the most critical parameter in modeling of electrical heating of
heavy-oil reservoirs in our previous study (Hasakir et al. 2008),
the viscosity values were measured experimentally. These data
were, therefore, extrapolated to obtain the viscosity values for
high temperature, as required by the simulator used.
2. Experimental data showed that Bati Raman and Camurlu crude
oils are non-Newtonian fluids and that they have a yield point.
3. Since the best viscosity reduction was obtained after the addition
of 0.5% Fe, it is selected as the optimum type and dose of iron
powder for both crudes, and the numerical simulations were
performed for this value of iron concentration and corresponding viscosity reduction.
4. The technical- and economic-feasibility analyses showed that
electrical heating is in an applicable range. Economic evaluation
conducted using the field-scale numerical-modeling study showed
that the electrical cost of the production of 1 bbl of petroleum is
approximately USD 5, and at the end of 70 days, 320 bbl of petroleum can be produced. When 0.5% Fe is added, oil production
increased to 440 bbl for the same operational time period.
5. While the production increases after the addition of 0.5% Fe for
Bati Raman crude oil, no significant effect of iron addition was
observed for the Camurlu case.
Acknowledgments
This work was funded by The Scientific and Technological
Research Council of Turkey and OYP-METU (Faculty Development Program-Middle East Technical University). The numericalmodeling part of the study was performed during B. Hasakirs
stay at the University of Alberta as a visiting PhD degree student.
We gratefully acknowledge this support. We also thank CMG for
providing the simulation software package and its electrical-heating option for this research.
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142