Development of the Surfactant-Based Chemical EOR Formula for Low Permeability Reservoirs

Based on the results of the foam flooding for our low permeability reservoirs, we have explored the possibility of using low interfacial tension (IFT) surfactants to improve oil recovery. The objective of this work is to develop a robust low-tension surfactant formula through lab experiments to investigate several key factors for surfactant-based chemical flooding. Microemulsion phase behavior and aqueous solubility experiments at reservoir temperature were performed to develop the surfactant formula. After reviewing surfactant processes in literature and evaluating over 200 formulas using commercially available surfactants, we found that we may have long ignored the challenges of achieving aqueous stability and optimal microemulsion phase behavior for surfactant formulations in low salinity environments. A surfactant formula with a low IFT does not always result in a good microemulsion phase behavior. Therefore, a novel synergistic blend with two surfactants in the formulation was developed with a cost-effective nonionic surfactant. The formula exhibits an increased aqueous solubility, a lower optimum salinity, and an ultra-low IFT in the range of 10-4 mN/m. There were challenges of using a spinning drop tensiometer to measure the IFT of the black crude oil and the injection water at reservoir conditions. We managed the process and studied the IFTs of formulas with good Winsor type III phase behavior results. Several microemulsion phase behavior test methods were investigated, and a practical and rapid test method is proposed to be used in the field under operational conditions. Reservoir core flooding experiments including SP (surfactant-polymer) and LTG (low-tension-gas) were conducted to evaluate the oil recovery. SP flooding with a selected polymer for mobility control and a co-solvent recovered 76% of the waterflood residual oil. Furthermore, 98% residual crude oil recovery was achieved by LTG flooding through using an additional foaming agent and nitrogen. These results demonstrate a favorable mobilization and displacement of the residual oil for low permeability reservoirs. In summary, microemulsion phase behavior and aqueous solubility tests were used to develop coreflood formulations for low salinity, low temperature conditions. The formulation achieved significant oil recovery for both SP flooding and LTG flooding. Key factors for the low-tension surfactant-based chemical flooding are good microemulsion phase behavior, a reasonably aqueous stability, and a decent low IFT.

New Insights into Surfactant Adsorption Estimation During ASP Flooding in Carbonates Under Harsh Conditions Using Surface Complexation Modeling

Several laboratory experiments demonstrated that the use of sodium hydroxide could increase the solution pH and reduce the adsorption of anionic surfactants. However, a better understanding of rock-oil-brine interactions and their effect on surfactant adsorption during alkaline-surfactant-polymer (ASP) flooding is needed for realistic and representative estimations of surfactant adsorption levels. Therefore, this study presents a novel approach to capture these interactions and better predict their effect on surfactant adsorption as well as effluent concentrations of surfactant and various aqueous species. Currently, surface complexation models (SCM) consider rock-brine, oil-brine, and surfactant-brine reactions. In this work, four new surface complexation reactions with intrinsic stability constants that honor oil-surfactant interactions have been proposed for the first time and then validated against experimental data reported in the literature. In addition, we analyzed the effect of various parameters on surface adsorption under harsh conditions of high-temperature and high-salinity using the proposed surface complexation model (SCM). The results showed that the developed surfactant-based SCM is robust and accurate for estimating surfactant adsorption and its concentration in the effluent during chemical floods. The model was validated against two sets of ASP corefloods from the literature including single-phase and two-phase dynamic surfactant adsorption studies. The findings highlighted that oil-surfactant surface complexation reactions are important and should be captured for more representative and accurate estimation of surfactant adsorption during chemical flooding. Moreover, the detail and comprehensive analysis showed that surfactant adsorption increases and its concentration in the effluent decreases with the increase in temperature of the chemical flood, which could be due to the increase in kinetic energy of the species. It was also showed that a decrease in water total salinity decreases the surfactant adsorption on the rock surface, which is related to the increase in the repulsive forces between the adsorbed species. Additionally, with the increase in surfactant concentration in the chemical flood, the effluent surfactant concertation increases, with a slight increase in surfactant adsorption. This slight increase in adsorption can be neglected compared to the injected and produced masses of the surfactant that are proportional. Moreover, the effect of sulfate spiking is significant where the increase in sulfate concentration reduces the surfactant adsorption. Furthermore, it is worth highlighting that the lowest surfactant adsorption levels were achieved through injected water dilution; less than 0.1 mg/g of rock. This is the first study to test a novel formulation of surface complexation modeling considering oil-surfactant effect on surfactant adsorption properties. The proposed framework to estimate surfactant adsorption is conducted for high-temperature and high-salinity reservoir condition. Thus, it could be used in numerical reservoir simulators to estimate oil recovery due to wettability alteration by chemical flooding in carbonates, which will be investigated in our future work. The surfactant adsorption mechanisms during chemical flooding is very case-dependent and hence, the findings of this study cannot be generalized.

Adsorption Inhibitor Role in a Constant Salinity Surfactant-Polymer CSSP Flooding Design for an Offshore Field Application

A base chemical flooding formulation using alkaline-surfactant-polymer (ASP) has been developed for application in offshore environments. The formulation uses combination of conventional alkali (sodium carbonate) with amphoteric surfactant. The field is currently under waterflooding using sea water as injection water. However, since alkali is incompatible with divalent ions in sea water, an alternative formulation using seawater with no additional water treatment is also being developed and considered for application. The alternative formulation uses combination of alkyl propoxy sulfate (APS) and alkyl ethoxy sulfate (AES). Coreflood recovery performance of both formulations is similar. Without alkali, high surfactant adsorption becomes major concern for the alternative formulation. Thus, an adsorption inhibitor (AI) agent – polyacrylic acid type, is being considered as an additive to address this concern. While AI showed potential in reducing surfactant adsorption and improving oil recovery efficiency, it can also increase overall cost for the surfactant in sea water chemical formulation. Hence, the merit to apply AI was not clearly observed.

Chemical Flooding in Western Canada – Successes and Operational Challenges

Over the last 30 years, chemical flooding of oil reservoirs has been broadly adopted as a technique for enhanced and incremental oil recovery around the world. Western Canadian oil producers have embraced polymer flooding to recover heavy oil, but have applied other forms of chemical flooding more sparingly. This study examines 31 chemical floods - ASP, AP, SP, alkali, and nanosurfactant floods - from mostly heavy oil fields (20 heavy oil, 10 medium oil, and one light oil). The success of the chemical floods was related to over forty reservoir and operating parameters, including water quality. We also discuss the operational challenges common in western Canada. Chemical flooding projects were identified through searches of government documents. Production and injection data were gathered using Accumap software; and reservoir and operating parameters were gathered from government documents and literature. Incremental recovery was calculated by performing decline curve analysis of the waterflooding production. The incremental recovery was the difference between the actual production during chemical flooding, and the predicted production had waterflooding continued rather than shifting to chemical flooding. Multivariate analysis was used to determine the most important parameters to the success of the chemical floods. The incremental recoveries ranged from 0 to 22% of original oil-in-place (OOIP), or 0 to 44% of OOIP per pore volume. Twenty-three of the 31 floods improved their water-oil ratios (WOR) after the start of chemical flooding. Water quality was a significant issue to the success of the chemical floods, leading to problems that were not anticipated in the planning and development stages. Some case histories are discussed to better illustrate the best practices for chemical recovery of heavy and medium oils. Water sources, management, treatment and chemistry all pose significant challenges that are often not fully assessed before starting the chemical flood projects. The review highlights challenges common to chemical flooding of heavy oil, and discusses common effects experienced as a result of water and chemistry compromises.

Experimental Microemulsion Flooding Study to Increase Low Viscosity Oil Recovery Using Glass Micromodel

The growing demand for clean energy can be met by improving the recovery of current resources. One of the effective methods in recovering the unswept reserves is chemical flooding. Microemulsion flooding is an alternative for surfactant flooding in a chemical-enhanced oil recovery method and can entirely sweep the remaining oil in porous media. The efficiency of microemulsion flooding is guaranteed through phase behavior analysis and customization regarding the actual field conditions. Reviewing the literature, there is a lack of experience that compared the macroscopic and microscopic efficiency of microemulsion flooding, especially in low viscous oil reservoirs. In the current study, one-quarter five-spot glass micromodel was implemented for investigating the effect of different parameters on microemulsion efficiency, including surfactant types, injection rate, and micromodel pattern. Image analysis techniques were applied to represent the phase saturations throughout the microemulsion flooding tests. The results confirm the appropriate efficiency of microemulsion flooding in improving the ultimate recovery. LABS microemulsion has the highest efficiency, and the increment of the injection rate has an adverse effect on oil recovery. According to the pore structure’s tests, it seems that permeability has little impact on recovery. The results of this study can be used in enhanced oil recovery designs in low-viscosity oil fields. It shows the impact of crucial parameters in microemulsion flooding.

Coreflood Model Calibration for Alkali Surfactant Polymer Process from a High Salinity Reservoir to Design an ASP Pilot

This paper aims to address calibration of a coreflood Alkali Surfactant Polymer (ASP) formulation experiment through parametrization of fluid-fluid and rock-fluid interactions considering cation exchange capacity and by rock to guide an ASP pilot design. First of all, a series of chemical formulation experiments were studied in cores drilled from clastic reservoir so that displacement lab tests were run on linear and radial cores to determine the potential for oil recovery by ASP flooding and recommended the chemical formulation and flooding schemes, in terms of oil recovery. Therefore, to simulate the process, those tests performed with radial core injection were taken, because this type of test has a better representation of the fluid flow in reservoir, the fluids are injected by a perforation in the center of the core, moving in a radial direction the fluids inside the porous medium. Subsequently, displaced fluids are collected on the periphery of the core carrier and stored in graduated test tubes. The recommended test was carried out to the phase of numerical simulation and historical matching. Reservoir simulation is one of the most important tools available to predict behavior under chemical flooding conditions and to study sensitivities based on cost-effective process implementation. Then, a radial core simulation model was designed from formulation data with porosity of 42.6%, a pore volume (PV) of 344.45 ml, radius of 7.17 cm and weight of 1225.84 g. The initial oil saturation was 0.748 PV (257.58 ml), with a critical water saturation of 0.252 PV (86.78 ml). For the simulation model historical matching, adjustments were made until an acceptable comparison was obtained with laboratory test production data through parameterization of relative permeability curves, chemical adsorption parameters, polymer viscosity, among others; resulting in an accumulated effluents production mass 37% greater for alkali than obtained in the historical, regarding to surfactant the deviation was 8% considered acceptable and for the polymer the adjustment was very close. For the injector well bottom pressure, the viscosity ratio of the mixture was considered based on the polymer concentration and the effect of the shear rate on the viscosity of the polymer as well as the effect of salinity in the alkali case. Finally, a calibrated coreflood numerical simulation model was obtained for ASP flooding to design an ASP Pilot with a residual oil saturation of 0.09 PV (31 ml) meaning 64% more recovered oil compared to a waterflooding case.