Experimental Design and Evaluation of Surfactant Polymer for a Heavy Oil Field in South of Sultanate of Oman

Heavy oil reservoirs remain challenging for surfactant-based EOR. In particular, selecting fine-tuned and cost effective chemical formulations requires extensive laboratory work and a solid methodology. This paper reports a laboratory feasibility study, aiming at designing a surfactant-polymer pilot for a heavy oil field with an oil viscosity of ~500cP in the South of Sultanate of Oman, where polymer flooding has already been successfully trialed. A major driver was to design a simple chemical EOR method, to minimize the risk of operational issues (e.g. scaling) and ensure smooth logistics on the field. To that end, a dedicated alkaline-free and solvent-free surfactant polymer (SP) formulation has been designed, with its sole three components, polymer, surfactant and co-surfactant, being readily available industrial chemicals. This part of the work has been reported in a previous paper. A comprehensive set of oil recovery coreflood tests has then been carried out with two objectives: validate the intrinsic performances of the SP formulation in terms of residual oil mobilization and establish an optimal injection strategy to maximize oil recovery with minimal surfactant dosage. The 10 coreflood tests performed involved: Bentheimer sandstone, for baseline assessments on large plugs with minimized experimental uncertainties; homogeneous artificial sand and clays granular packs built to have representative mineralogical composition, for tuning of the injection parameters; native reservoir rock plugs, unstacked in order to avoid any bias, to validate the injection strategy in fully representative conditions. All surfactant injections were performed after long polymer injections, to mimic the operational conditions in the field. Under injection of "infinite" slugs of the SP formulation, all tests have led to tertiary recoveries of more than 88% of the remaining oil after waterflood with final oil saturations of less than 5%. When short slugs of SP formulation were injected, tertiary recoveries were larger than 70% ROIP with final oil saturations less than 10%. The final optimized test on a reservoir rock plug, which was selected after an extensive review of the petrophysical and mineralogical properties of the available reservoir cores, led to a tertiary recovery of 90% ROIP with a final oil saturation of 2%, after injection of 0.35 PV of SP formulation at 6 g/L total surfactant concentration, with surfactant losses of 0.14 mg-surfactant/g(rock). Further optimization will allow accelerating oil bank arrival and reducing the large PV of chase polymer needed to mobilize the liberated oil. An additional part of the work consisted in generating the parameters needed for reservoir scale simulation. This required dedicated laboratory assays and history matching simulations of which the results are presented and discussed. These outcomes validate, at lab scale, the feasibility of a surfactant polymer process for the heavy oil field investigated. As there has been no published field test of SP injection in heavy oil, this work may also open the way to a new range of field applications.