Patent Grant
10487636
This application claims priority from Canadian Patent Application 2,974,712 filed Jul. 27, 2017 entitled ENHANCED METHODS FOR RECOVERING VISCOUS HYDROCARBONS FROM A SUBTERRANEAN FORMATION AS A FOLLOW-UP TO THERMAL RECOVERY PROCESSES, the entirety of which is incorporated by reference herein.
The present disclosure relates generally to methods for recovering viscous hydrocarbons from a subterranean formation and more particularly to methods that utilize a solvent flood vapor stream to recover the viscous hydrocarbons from the subterranean formation subsequent to performing a thermal recovery process within the subterranean formation.
Hydrocarbons often are utilized as fuels and/or as chemical feedstocks for manufacturing industries. Hydrocarbons naturally may be present within subterranean formations, which also may be referred to herein as reservoirs and/or as hydrocarbon reservoirs. Such hydrocarbons may occur in a variety of forms, which broadly may be categorized herein as conventional hydrocarbons and unconventional hydrocarbons. A process utilized to remove a given hydrocarbon from a corresponding subterranean formation may be selected based upon one or more properties of the hydrocarbon and/or of the subterranean formation.
As an example, conventional hydrocarbons generally have a relatively lower viscosity and extend within relatively higher fluid permeability subterranean formations. As such, these conventional hydrocarbons may be pumped from the subterranean formation utilizing a conventional oil well.
As another example, unconventional hydrocarbons generally have a relatively higher viscosity and/or extend within relatively lower fluid permeability subterranean formations. As such, a conventional oil well may be ineffective at producing unconventional hydrocarbons. Instead, unconventional hydrocarbon production techniques may be utilized.
Examples of unconventional hydrocarbon production techniques that may be utilized to produce viscous hydrocarbons from a subterranean formation include thermal recovery processes. Thermal recovery processes generally inject a thermal recovery stream, at an elevated temperature, into the subterranean formation. The thermal recovery stream contacts the viscous hydrocarbons, within the subterranean formation, and heats, dissolves, and/or dilutes the viscous hydrocarbons, thereby generating mobilized viscous hydrocarbons. The mobilized viscous hydrocarbons generally have a lower viscosity than a viscosity of the naturally occurring viscous hydrocarbons at the native temperature and pressure of the subterranean formation and may be pumped and/or flowed from the subterranean formation. A variety of different thermal recovery processes have been utilized, including cyclic steam stimulation processes, solvent-assisted cyclic steam stimulation processes, steam flooding processes, solvent-assisted steam flooding processes, steam-assisted gravity drainage processes, solvent-assisted steam-assisted gravity drainage processes, heated vapor extraction processes, liquid addition to steam to enhance recovery processes, and/or near-azeotropic gravity drainage processes.
Thermal recovery processes may differ in the mode of operation and/or in the composition of the thermal recovery stream. However, all thermal recovery processes rely on injection of the thermal recovery stream into the subterranean formation at the elevated temperature, and thermal contact between the thermal recovery stream and the subterranean formation heats the subterranean formation. Thus, and after performing a given thermal recovery process within a given subterranean formation, a significant amount of thermal energy may be stored within the subterranean formation, and it may be costly to maintain the temperature of the subterranean formation and/or to heat the thermal recovery stream prior to injection of the thermal recovery stream within the subterranean formation.
In addition, as the viscous hydrocarbons are produced from the subterranean formation, an amount of energy required to produce viscous hydrocarbons increases due to increased heat loss within the subterranean formation. Similarly, a ratio of a volume of the thermal recovery stream provided to the subterranean formation to a volume of mobilized viscous hydrocarbons produced from the subterranean formation also increases. Both of these factors decrease economic viability of thermal recovery processes late in the life of a hydrocarbon well and/or after production and recovery of a significant fraction of the original oil-in-place from a given subterranean formation. Thus, there exists a need for improved methods of recovering viscous hydrocarbons from a subterranean formation.
Enhanced methods for recovering viscous hydrocarbons from a subterranean formation as a follow-up to thermal recovery processes. The methods include injecting a solvent flood vapor stream into a first thermal chamber, which extends within the subterranean formation, via a solvent flood injection well that extends within the first thermal chamber. The injecting includes injecting to generate solvent flood-mobilized viscous hydrocarbons within the subterranean formation. The methods also include, at least partially concurrently with the injecting, producing the solvent flood-mobilized viscous hydrocarbons from a second thermal chamber, which extends within the subterranean formation, via a solvent flood production well that extends within the second thermal chamber. The first thermal chamber was formed via a first thermal recovery process that injected a first thermal recovery stream into the subterranean formation, and the second thermal chamber was formed via a second thermal recovery process that injected a second thermal recovery stream into the subterranean formation. The first thermal chamber and the second thermal chamber are in fluid communication with one another and define an interface region therebetween. A solvent flood stream dew point temperature of the solvent flood vapor stream is less than a first thermal recovery stream dew point temperature of the first thermal recovery stream and also is less than a second thermal recovery stream dew point temperature of the second thermal recovery stream.
As illustrated collectively by
As used herein, the phrase “subterranean formation” may refer to any suitable portion of the subsurface region that includes viscous hydrocarbons and/or from which mobilized viscous hydrocarbons may be produced utilizing the methods disclosed herein. In addition to the viscous hydrocarbons, the subterranean formation also may include other subterranean strata, such as sand and/or rocks, as well as lower viscosity hydrocarbons, natural gas, and/or water. The subterranean strata may form, define, and/or be referred to herein as a porous media, and the viscous hydrocarbons may be present, or may extend, within pores of the porous media.
As used herein, the phrase, “viscous hydrocarbons” may refer to any carbon-containing compound and/or compounds that may be naturally occurring within the subterranean formation and/or that may have a viscosity that precludes their production, or at least economic production, utilizing conventional hydrocarbon production techniques and/or conventional hydrocarbon wells. Examples of such viscous hydrocarbons include heavy oils, oil sands, and/or bitumen.
System 10 may include any suitable number and/or combination of hydrocarbon wells 20. As an example, and as illustrated in solid lines in
As discussed in more detail herein, it is within the scope of the present disclosure that system 10 additionally or alternatively may include a plurality of spaced-apart hydrocarbon wells 20 and that
Methods 200 of
An example of such a single-well thermal recovery process is illustrated in
The single-well thermal recovery process that is performed utilizing first hydrocarbon well 31 may produce and/or generate a first thermal chamber 50 within the subterranean formation. Similarly, the single-well thermal recovery process that is performed utilizing second hydrocarbon well 32 may produce and/or generate a second thermal chamber 60 within the subterranean formation. First thermal chamber 50 and second thermal chamber 60 may grow, expand, and/or increase in volume over an operational lifetime of system 10 and/or responsive to repeated cycles of injection and subsequent production. Eventually, and as illustrated in
As used herein, the phrase “thermal chamber,” including first thermal chamber 50 and/or second thermal chamber 60, may refer to any suitable region of the subterranean formation within which injection of a corresponding thermal recovery stream and production of a corresponding mobilized viscous hydrocarbon stream has depleted, at least substantially depleted, and/or depleted a producible fraction of, naturally occurring viscous hydrocarbons.
It is within the scope of the present disclosure that the two single-well thermal recovery processes described above may have any suitable temporal relationship that leads to the formation of communicating thermal chamber 80. As examples, the single-well thermal recovery process performed utilizing first hydrocarbon well 31 and the single-well thermal recovery process performed utilizing second hydrocarbon well 32 may be performed concurrently, at least partially concurrently, sequentially, and/or at least partially sequentially.
Another example of thermal recovery processes includes a well pair thermal recovery process in which a pair of hydrocarbon wells 20 is utilized to concurrently, continuously, and/or at least substantially continuously provide a thermal recovery stream to the subterranean formation and also to receive a mobilized viscous hydrocarbon stream from the subterranean formation. Examples of well pair thermal recovery processes include steam flooding processes, solvent-assisted steam flooding processes, steam-assisted gravity drainage processes, solvent-assisted steam-assisted gravity drainage processes, heated vapor extraction processes, and/or near-azeotropic gravity drainage processes.
An example of such a well pair thermal recovery process also is illustrated in
As illustrated in
Concurrently, at least partially concurrently, sequentially, and/or at least partially sequentially, and as illustrated in
Similar to single-well thermal recovery processes, the thermal chambers may grow with time, eventually forming, producing, and/or generating communicating thermal chamber 80 that is illustrated in
Another example of a well pair thermal recovery process, in the form of a steam flooding process and/or a solvent-assisted steam flooding process, also is illustrated in
As illustrated in
In the example of the flooding processes, corresponding pairs of the spaced-apart hydrocarbon wells may be utilized to produce mobilized viscous hydrocarbons from the subterranean formation. This utilization of the corresponding pairs of spaced-apart hydrocarbon wells may include injection of corresponding thermal recovery streams into corresponding injection wells and production of corresponding mobilized viscous hydrocarbon streams from corresponding production wells. This utilization thus may produce and/or generate corresponding thermal chambers within the subterranean formation. These thermal chambers may grow with time, eventually merging, forming corresponding communicating chambers, and/or defining corresponding interface regions therebetween. As an example, and in addition to formation of first thermal chamber 50, system 10 may include a second injection well and a second production well that together may be utilized to form, define, and/or generate another thermal chamber within the subterranean formation. The first thermal chamber and the other thermal chamber may grow with time, eventually merging, forming the communicating chamber, and/or defining the interface region therebetween.
Regardless of the exact mechanism utilized to form, produce, and/or generate communicating thermal chamber 80, formation of the communicating chamber may heat subterranean formation 44, communicating thermal chamber 80, first thermal chamber 50, and/or second thermal chamber 60 to a chamber temperature that is above a naturally occurring temperature within the subterranean formation. As discussed, maintaining the chamber temperature may be costly, thereby limiting an economic viability of thermal recovery processes. However, formation of such a heated and communicating thermal chamber may permit methods 200 to be utilized to improve an efficiency of production of viscous hydrocarbons from the subterranean formation.
With this in mind,
Performing the thermal recovery process at 205 may include performing any suitable thermal recovery process within the subterranean formation. This may include performing a first thermal recovery process to form, produce, and/or generate a first thermal chamber within the subterranean formation. This also may include performing a second thermal recovery process to form, produce, and/or generate a second thermal chamber within the subterranean formation. The first thermal recovery process may include injection of a first thermal recovery stream into the first thermal chamber and production of a first mobilized viscous hydrocarbon stream from the subterranean formation and/or from the first thermal chamber. Similarly, the second thermal recovery process may include injection of a second thermal recovery stream into the second thermal chamber and production of a second mobilized viscous hydrocarbon stream from the subterranean formation and/or from the second thermal chamber.
When methods 200 include the performing at 205, methods 200 may include continuing the performing at 205 until the first thermal chamber and the second thermal chamber define an interface region therebetween. The interface region may include a region of overlap between the first thermal chamber and the second thermal chamber and/or may permit fluid communication, within the subterranean formation, between the first thermal chamber and the second thermal chamber. The establishment of the interface region and/or the fluid communication between the thermal chambers may be detected and/or confirmed by means of any suitable reservoir surveillance method. Examples of such reservoir surveillance methods include, but are not limited to, 2D and/or 3D seismic surveillance methods, pressure data analysis, temperature data analysis, and/or injection and production data analysis.
Examples of the first thermal recovery process and/or of the second thermal recovery process include a cyclic steam stimulation process, a solvent-assisted cyclic steam stimulation process, a steam flooding process, a solvent-assisted steam flooding process, a steam-assisted gravity drainage process, a solvent-assisted steam-assisted gravity drainage process, a heated vapor extraction process, a liquid addition to steam to enhance recovery process, and/or a near-azeotropic gravity drainage process. Additional examples of the first thermal recovery process and/or of the second thermal recovery process include a steam injection process, a solvent injection process, and/or a solvent-steam mixture injection process.
It is within the scope of the present disclosure that methods 200 are not required to include the performing at 205. Instead, methods 200 may be performed with, via, and/or utilizing a hydrocarbon production system that already includes the first thermal chamber, the second thermal chamber, and the interface region therebetween. As an example, the first thermal recovery process and the second thermal recovery process may be performed and the first thermal chamber and the second thermal chamber may be formed, within the subterranean formation, prior to initiation of methods 200.
It is within the scope of the present disclosure that the interface region may include and/or be a region of overlap between two adjacent thermal chambers, such as interface region 70 that is illustrated in
When methods 200 include the performing at 205, methods 200 also may include the transitioning at 210. The transitioning at 210 may include transitioning from performing the first thermal recovery process in the first thermal chamber and performing the second thermal recovery process in the second thermal chamber to performing the injecting at 215 and the producing at 245. The transitioning at 210, when performed, may be initiated based upon and/or responsive to any suitable transition criteria.
Examples of the transition criteria include establishing and/or detecting fluid communication between the first thermal chamber and the second thermal chamber. Another example of the transition criteria includes production, from the subterranean formation, of at least a threshold fraction of an original oil in place. Examples of the threshold fraction include at least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, and/or at least 80% of the original oil in place.
Injecting the solvent flood vapor stream at 215 may include injecting the solvent flood vapor stream into the first thermal chamber via a solvent flood injection well. The solvent flood vapor stream also may be referred to herein as an injected solvent flood vapor stream. The solvent flood injection well may extend within the first thermal chamber, and the injecting at 215 may include injecting to produce and/or generate solvent flood-mobilized viscous hydrocarbons within the subterranean formation and/or within the first thermal chamber.
The solvent flood injection well may include a hydrocarbon well utilized to form the first thermal chamber. In another embodiment, the solvent flood injection well may be drilled from the surface to intersect the existing first thermal chamber. In another embodiment, the solvent flood injection well is within the first thermal chamber but it may be drilled from the surface before the existence of the first thermal chamber. Injection of the solvent flood vapor stream is illustrated schematically in
The solvent flood vapor stream has a solvent flood vapor stream dew point temperature that is less than a first thermal recovery stream dew point temperature of the first thermal recovery stream and also less than a second thermal recovery stream dew point temperature of the second thermal recovery stream. As such, injection of the solvent flood vapor stream may permit recovery of stored thermal energy from the subterranean formation, from the first thermal chamber, and/or from the second thermal chamber.
Stated another way, and since the solvent flood vapor stream dew point temperature is less than the first thermal recovery stream dew point temperature and also less than the second thermal recovery stream dew point temperature, a temperature of the subterranean formation, such as of the first thermal chamber and/or of the second thermal chamber, may be greater than the solvent flood vapor stream dew point temperature at the pressure of the subterranean formation before commencing the injecting at 215. Thus, the solvent flood vapor stream may be injected at an injection temperature that is less than the temperature of the subterranean formation, thereby permitting the solvent flood vapor stream to absorb the stored thermal energy from the subterranean formation.
The temperature of the injected solvent flood vapor stream may increase by absorbing the stored thermal energy from the subterranean formation. The injected solvent flood vapor stream with increased temperature may flow through the subterranean formation and/or the communicating thermal chambers within to reach parts of the subterranean formation with temperatures lower than the dew point temperature of the solvent flood vapor stream at the operating pressure. The injected solvent flood vapor stream with increased temperature may heat the parts of the subterranean formation with temperatures lower than the dew point temperature of the solvent flood vapor stream by contact and/or by condensation. The injected solvent flood vapor stream may mobilize the viscous hydrocarbons in the parts of the subterranean formation with temperatures lower than the dew point temperature of the solvent flood vapor stream by heating, diluting, and/or dissolving the viscous hydrocarbons.
It is within the scope of the present disclosure that the solvent flood vapor stream dew point temperature may differ from, or be less than, the first thermal recovery stream dew point temperature and the second thermal recovery stream dew point temperature by any suitable value and/or magnitude. As examples, and at a pressure of 101.325 kilopascals, the solvent flood vapor stream dew point temperature may differ from, be less than, or be less than a minimum of the first thermal recovery stream dew point temperature and the second thermal recovery stream dew point temperature by at least 10° C., at least 30° C., at least 50° C., at least 70° C., at least 90° C., at least 110° C., at least 130° C., at least 150° C., at least 170° C., at least 190° C., and/or at least 210° C.
The injecting at 215 may include injecting with, via, and/or utilizing any suitable solvent flood injection well and/or with, via, and/or utilizing any suitable portion and/or region of the solvent flood injection well. As an example, the solvent flood injection well may include an at least substantially horizontal and/or deviated injection well region that extends within the first thermal chamber. Under these conditions, the injecting at 215 may include injecting the solvent flood vapor stream from the at least substantially horizontal and/or deviated injection well region. As another example, the solvent flood injection well may include an at least substantially vertical injection well region that extends within the first thermal chamber. Under these conditions, the injecting at 215 may include injecting the solvent flood vapor stream from the at least substantially vertical injection well region.
The solvent flood vapor stream may include any suitable composition. As an example, the solvent flood vapor stream may include at least a threshold weight percentage of hydrocarbon molecules with a specified number of carbon atoms. Examples of the threshold weight percentage include at least 20 weight percent, at least 30 weight percent, at least 40 weight percent, at least 50 weight percent, at least 60 weight percent, at least 70 weight percent, and/or at least 80 weight percent. Examples of the specified number of carbon atoms include at least 2, at least 3, at least 4, at least 5, at most 9, at most 8, at most 7, at most 6, at most 5, and/or at most 4 carbon atoms. As additional examples, the solvent flood vapor stream may include one or more of a hydrocarbon, an alkane, an alkene, an alkyne, an aliphatic compound, a naphthenic compound, an aromatic compound, an olefinic compound, natural gas condensate, liquefied petroleum gas, a naphtha product, a crude oil refinery stream, a mixture of a hydrocarbon solvent and steam in any suitable relative proportions, and/or a near-azeotropic mixture of the hydrocarbon solvent and steam.
The solvent flood vapor stream may be injected at any suitable injection temperature. The injection temperature may be equal to the dew point temperature of the solvent flood vapor stream for a target operating pressure within the subterranean formation and/or for a target injection pressure of the solvent flood vapor stream. The solvent flood vapor stream may be injected with some degrees of superheat relative to the dew point temperature of the solvent flood vapor stream at the operating pressure and/or at the injection pressure. Examples of the degrees of superheat include at least 1° C., at least 5° C., at least 10° C., at least 20° C., at least 30° C., or at least 40° C. The solvent flood vapor stream may be injected at any suitable injection pressure. As an example, the injection pressure may be equal to or greater than the subterranean formation pressure before commencing the injecting at 215.
The solvent flood vapor stream may be received as vapor or liquid at a wellhead of the solvent flood injection well for injection. The liquid may be vaporized at the wellhead utilizing a vaporization facility to prepare the solvent flood vapor stream for injection. The vaporization facility may be specific to each wellhead of a group of spaced-apart wellheads or may be a centralized vaporization facility that provides the solvent flood vapor stream to a group of spaced-apart wellheads. The vaporization facility may be a part of a central processing facility.
The solvent flood vapor stream may be injected as an unheated solvent flood vapor stream. As an example, the unheated solvent flood vapor stream may include a vapor stream at ambient temperature, or a vaporized liquid stream at ambient temperature, prepared by flashing a liquid stream to vapor from higher pressure to a lower pressure.
The solvent flood vapor stream may be injected as a heated solvent flood vapor stream. As an example, the heated solvent flood vapor stream may include a vapor stream at a temperature higher than ambient temperature, or a vaporized liquid stream at a temperature higher than ambient temperature, that is prepared by evaporating a liquid stream to vapor by providing heat and/or increasing temperature.
The injecting at 215 may include injecting to produce, to facilitate, and/or to maintain the target operating pressure within the subterranean formation. In addition, and when the solvent flood vapor stream includes the near-azeotropic mixture of the hydrocarbon solvent and steam, a hydrocarbon solvent molar fraction of the hydrocarbon solvent within the solvent flood vapor stream may be within a threshold molar fraction range of an azeotropic hydrocarbon solvent molar fraction of the solvent flood vapor stream at the target operating pressure. Examples of the threshold molar fraction range include at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, at least 95%, at most 100%, at most 95%, at most 90%, at most 85%, and/or at most 80% of the azeotropic hydrocarbon solvent molar fraction of the solvent flood vapor stream at the target operating pressure.
The injecting at 215 additionally or alternatively may include injecting to produce, facilitate, and/or maintain a pressure differential between the solvent flood injection well and a solvent flood production well. This pressure differential, which may include a greater pressure proximal the solvent flood injection well when compared to the solvent flood production well, may facilitate the producing at 245 and/or may provide a motive force for flow of the solvent flood-mobilized viscous hydrocarbons from the subterranean formation during the producing at 245.
It is within the scope of the present disclosure that methods 200 may be performed with, via, and/or utilizing any suitable number of solvent flood injection wells. As an example, the solvent flood injection well may be a first solvent flood injection well of a plurality of spaced-apart solvent flood injection wells. Each of the plurality of solvent flood injection wells may extend within a corresponding thermal chamber that extends within the subterranean formation. Under these conditions, the injecting at 215 may include injecting the solvent flood vapor stream into the subterranean formation via each of the plurality of spaced-apart solvent flood injection wells. Stated another way, the injecting at 215 may include injecting the solvent flood vapor stream into each corresponding thermal chamber that is associated with each of the plurality of spaced-apart solvent flood injection wells.
Generating solvent flood-mobilized viscous hydrocarbons at 220 may include generating the solvent flood-mobilized viscous hydrocarbons responsive to and/or as a result of the injecting at 215. The generating at 220 may include generating the solvent flood-mobilized viscous hydrocarbons within the subterranean formation and/or in any suitable manner. As an example, the generating at 220 may include heating the viscous hydrocarbons with the solvent flood vapor stream to generate the solvent flood-mobilized viscous hydrocarbons. As another example, the generating at 220 may include diluting the viscous hydrocarbons with condensed portions of the solvent flood vapor stream to generate the solvent flood-mobilized viscous hydrocarbons. As yet another example, the generating at 220 may include dissolving the viscous hydrocarbons in and/or within the condensed portions of the solvent flood vapor stream to generate the solvent flood-mobilized viscous hydrocarbons.
Heating the solvent flood vapor stream at 225 may include heating the solvent flood vapor stream with, within, and/or via thermal contact with the subterranean formation, the first thermal chamber, and/or the second thermal chamber. As an example, and as discussed, the first thermal chamber and/or the second thermal chamber may have and/or define respective chamber temperatures that are greater than a solvent flood vapor stream injection temperature of the solvent flood vapor stream. As such, injection of the solvent flood vapor stream into the subterranean formation causes, produces and/or generates heating of the solvent flood vapor stream to an increased temperature.
Cooling the thermal chamber at 230 may include cooling the first thermal chamber and/or cooling the second thermal chamber via contact between the first thermal chamber and/or the second thermal chamber and the solvent flood vapor stream. As discussed, the solvent flood vapor stream injection temperature may be less than the chamber temperature of the first thermal chamber and/or of the second thermal chamber. As such, injection of the solvent flood vapor stream into the subterranean formation causes, produces and/or generates cooling of the first thermal chamber and/or of the second thermal chamber.
Ceasing injection of the solvent flood vapor stream at 235 may include ceasing the injecting at 215. This may include ceasing the injecting at 215 subsequent to performing the producing at 245 for at least a threshold production time period and/or prior to performing and/or initiating the injecting at 240.
Injecting the gas flood stream at 240 may include injecting the gas flood stream into the subterranean formation, or initiating injection of the gas flood stream into the subterranean formation, subsequent to performing the injecting at 215, subsequent to performing the injecting at 215 for at least a threshold injection time period, and/or subsequent to production of a target fraction of an original oil in place from the subterranean formation. The injecting at 240 may, but is not required to, include injecting the gas flood stream into the subterranean formation with, via, and/or utilizing the solvent flood injection well. Additionally or alternatively, the injecting at 240 may include injecting to permit, facilitate, and/or provide a motive force for production of the solvent flood mobilized viscous hydrocarbons, for production of the solvent flood vapor stream from the subterranean formation, and/or to produce and/or recover at least a fraction of the solvent flood vapor stream from the subterranean formation, such as during the producing at 245. The solvent flood vapor stream and/or at least a fraction of the solvent flood vapor stream may be produced and/or recovered from the subterranean formation in vapor and/or liquid phase.
The gas flood stream may include any suitable gas, gaseous, and/or non-condensable fluid stream. As examples, the gas flood stream may include one or more of natural gas, carbon dioxide, nitrogen, a flue gas, methane, ethane, and/or propane.
Producing solvent flood-mobilized viscous hydrocarbons at 245 may include producing the solvent flood-mobilized viscous hydrocarbons from a second thermal chamber that extends within the subterranean formation and/or via a solvent flood production well that extends within the second thermal chamber. The producing at 245 is concurrent, or at least partially concurrent, with the injecting at 215. Stated another way, the injecting at 215 and the producing at 245 have and/or exhibit at least a threshold amount of temporal overlap.
The solvent flood production well may consist of a hydrocarbon well utilized to form the second thermal chamber. In another embodiment, the solvent flood production well may be drilled from the surface to intersect the existing second thermal chamber. In another embodiment, the solvent flood production well is within the second thermal chamber but it may be drilled from the surface before the existence of the second thermal chamber. Production of the solvent flood-mobilized viscous hydrocarbons is illustrated schematically in
It is within the scope of the present disclosure that, in addition to the solvent flood-mobilized viscous hydrocarbons, the producing at 245 also may include producing one or more other fluids from the subterranean formation. As examples, the producing at 245 may include producing at least a fraction of the first thermal recovery stream, at least a fraction of the second thermal recovery stream, water, at least a fraction of the first mobilized viscous hydrocarbon stream, at least a fraction of the second mobilized viscous hydrocarbon stream, and/or at least a fraction of the solvent flood vapor stream in liquid and/or in vapor phases.
The injecting at 215 and the producing at 245 may include sweeping solvent flood-mobilized viscous hydrocarbons from the first thermal chamber and/or into the second thermal chamber. Stated another way, the producing at 245 may include flowing a fraction of the solvent flood-mobilized viscous hydrocarbons from the first thermal chamber and into the second thermal chamber prior to production of the solvent flood-mobilized viscous hydrocarbons.
As discussed herein, hydrocarbon production systems that may be utilized to perform methods 200 may include any suitable number of hydrocarbon wells, and any suitable subset of these hydrocarbon wells may be utilized as solvent flood injection wells and/or as solvent flood production wells during methods 200. As such, it is within the scope of the present disclosure that one or more intermediate thermal chambers may extend between the first thermal chamber and the second thermal chamber. These one or more intermediate thermal chambers may function as the interface region between the first thermal chamber and the second thermal chamber and/or may provide the fluid communication between the first thermal chamber and the second thermal chamber. Under these conditions, the producing at 245 further may include sweeping and/or flowing at least a subset of the solvent flood-mobilized viscous hydrocarbons through the one or more intermediate thermal chambers as the subset of the solvent flood-mobilized viscous hydrocarbons flows toward and/or into the solvent flood production well.
It also is within the scope of the present disclosure that methods 200 may be performed with, via, and/or utilizing any suitable number of solvent flood production wells. As an example, the solvent flood production well may be a first solvent flood production well of a plurality of spaced-apart solvent flood production wells. Each of the plurality of solvent flood production wells may extend within a corresponding thermal chamber that extends within the subterranean formation. Under these conditions, the producing at 245 may include producing the solvent flood-mobilized viscous hydrocarbons from the subterranean formation via each of the plurality of spaced-apart solvent flood production wells. Stated another way, the producing at 245 may include producing the solvent flood-mobilized viscous hydrocarbons from each corresponding thermal chamber that is associated with each of the plurality of spaced-apart solvent flood production wells.
The producing at 245 may include producing with, via, and/or utilizing any suitable solvent flood production well and/or with, via, and/or utilizing any suitable portion and/or region of the solvent flood production well. As an example, the solvent flood production well may include an at least substantially horizontal and/or deviated production well region that extends within the second thermal chamber. Under these conditions, the producing at 245 may include producing the solvent flood-mobilized viscous hydrocarbons with, via, and/or utilizing the at least substantially horizontal and/or deviated production well region. As another example, the solvent flood production well may include an at least substantially vertical production well region that extends within the second thermal chamber. Under these conditions, the producing at 245 may include producing the solvent flood-mobilized viscous hydrocarbons with, via, and/or utilizing the at least substantially horizontal production well region.
Reversing injection and production at 250 may be performed and/or initiated subsequent to performing the injecting at 215, subsequent to performing the injecting at 215 for at least the threshold injection time period, subsequent to performing the producing at 245, and/or subsequent to performing the producing at 245 for at least the threshold production time period. The reversing at 250 may include reversing the injecting at 215 and the producing at 245 in any suitable manner. As an example, the reversing at 250 may include reversing the injecting at 215 by injecting the solvent flood vapor stream into the second thermal chamber via a hydrocarbon well that extends within the second thermal chamber, such as the solvent flood production well. As another example, the reversing at 250 may include reversing the producing at 245 by producing the solvent flood-mobilized viscous hydrocarbons from the first thermal chamber via a hydrocarbon well that extends within the first thermal chamber, such as the solvent flood injection well.
In addition, transitioning from the thermal recovery process utilizing only steam as the thermal recovery stream to injection of the solvent flood vapor stream and production of the solvent flood-mobilized viscous hydrocarbons may result in an increase in a viscous hydrocarbon production rate from the subterranean formation. This increase in viscous hydrocarbon production rate is illustrated in solid lines in
Both the decrease in energy consumption and the increase in viscous hydrocarbon production rate may improve the overall economics of methods 200 when compared to other thermal recovery processes without the enhancement of the solvent flood vapor stream follow-up. Thus, methods 200 may permit economic production of additional viscous hydrocarbons from the subterranean formation and/or may provide a longer economic service life for a given hydrocarbon production system.
In the present disclosure, several of the illustrative, non-exclusive examples have been discussed and/or presented in the context of flow diagrams, or flow charts, in which the methods are shown and described as a series of blocks, or steps. Unless specifically set forth in the accompanying description, it is within the scope of the present disclosure that the order of the blocks may vary from the illustrated order in the flow diagram, including with two or more of the blocks (or steps) occurring in a different order and/or concurrently.
As used herein, the term “and/or” placed between a first entity and a second entity means one of (1) the first entity, (2) the second entity, and (3) the first entity and the second entity. Multiple entities listed with “and/or” should be construed in the same manner, i.e., “one or more” of the entities so conjoined. Other entities may optionally be present other than the entities specifically identified by the “and/or” clause, whether related or unrelated to those entities specifically identified. Thus, as a non-limiting example, a reference to “A and/or B,” when used in conjunction with open-ended language such as “comprising” may refer, in one embodiment, to A only (optionally including entities other than B); in another embodiment, to B only (optionally including entities other than A); in yet another embodiment, to both A and B (optionally including other entities). These entities may refer to elements, actions, structures, steps, operations, values, and the like.
As used herein, the phrase “at least one,” in reference to a list of one or more entities should be understood to mean at least one entity selected from any one or more of the entity in the list of entities, but not necessarily including at least one of each and every entity specifically listed within the list of entities and not excluding any combinations of entities in the list of entities. This definition also allows that entities may optionally be present other than the entities specifically identified within the list of entities to which the phrase “at least one” refers, whether related or unrelated to those entities specifically identified. Thus, as a non-limiting example, “at least one of A and B” (or, equivalently, “at least one of A or B,” or, equivalently “at least one of A and/or B”) may refer, in one embodiment, to at least one, optionally including more than one, A, with no B present (and optionally including entities other than B); in another embodiment, to at least one, optionally including more than one, B, with no A present (and optionally including entities other than A); in yet another embodiment, to at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other entities). In other words, the phrases “at least one,” “one or more,” and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C,” “at least one of A, B, or C,” “one or more of A, B, and C,” “one or more of A, B, or C” and “A, B, and/or C” may mean A alone, B alone, C alone, A and B together, A and C together, B and C together, A, B and C together, and optionally any of the above in combination with at least one other entity.
In the event that any patents, patent applications, or other references are incorporated by reference herein and (1) define a term in a manner that is inconsistent with and/or (2) are otherwise inconsistent with, either the non-incorporated portion of the present disclosure or any of the other incorporated references, the non-incorporated portion of the present disclosure shall control, and the term or incorporated disclosure therein shall only control with respect to the reference in which the term is defined and/or the incorporated disclosure was present originally.
As used herein the terms “adapted” and “configured” mean that the element, component, or other subject matter is designed and/or intended to perform a given function. Thus, the use of the terms “adapted” and “configured” should not be construed to mean that a given element, component, or other subject matter is simply “capable of” performing a given function but that the element, component, and/or other subject matter is specifically selected, created, implemented, utilized, programmed, and/or designed for the purpose of performing the function. It also is within the scope of the present disclosure that elements, components, and/or other recited subject matter that is recited as being adapted to perform a particular function may additionally or alternatively be described as being configured to perform that function, and vice versa.
As used herein, the phrase, “for example,” the phrase, “as an example,” and/or simply the term “example,” when used with reference to one or more components, features, details, structures, embodiments, and/or methods according to the present disclosure, are intended to convey that the described component, feature, detail, structure, embodiment, and/or method is an illustrative, non-exclusive example of components, features, details, structures, embodiments, and/or methods according to the present disclosure. Thus, the described component, feature, detail, structure, embodiment, and/or method is not intended to be limiting, required, or exclusive/exhaustive; and other components, features, details, structures, embodiments, and/or methods, including structurally and/or functionally similar and/or equivalent components, features, details, structures, embodiments, and/or methods, are also within the scope of the present disclosure.
Additional embodiments of the invention herein are as follows:
A method for recovering viscous hydrocarbons from a subterranean formation, the method comprising:
injecting a solvent flood vapor stream into a first thermal chamber that extends within the subterranean formation via a solvent flood injection well that extends within the first thermal chamber to generate solvent flood-mobilized viscous hydrocarbons within the subterranean formation; and
at least partially concurrently with the injecting the solvent flood vapor stream, producing the solvent flood-mobilized viscous hydrocarbons from a second thermal chamber that extends within the subterranean formation via a solvent flood production well that extends within the second thermal chamber, wherein:
(i) the first thermal chamber was formed via a first thermal recovery process that injected a first thermal recovery stream into the first thermal chamber and produced a first mobilized viscous hydrocarbon stream from the subterranean formation;
(ii) the second thermal chamber was formed via a second thermal recovery process that injected a second thermal recovery stream into the second thermal chamber and produced a second mobilized viscous hydrocarbon stream from the subterranean formation;
(iii) the first thermal chamber and the second thermal chamber define an interface region therebetween, wherein the interface region permits fluid communication between the first thermal chamber and the second thermal chamber; and
(iv) a solvent flood vapor stream dew point temperature of the solvent flood vapor stream is less than a first thermal recovery stream dew point temperature of the first thermal recovery stream and also is less than a second thermal recovery stream dew point temperature of the second thermal recovery stream.
The method of embodiment 1, wherein the solvent flood injection well includes at least one of:
(i) an at least substantially horizontal injection well region, which extends within the first thermal chamber, wherein the injecting the solvent flood vapor stream includes injecting from the at least substantially horizontal injection well region; and
(ii) an at least substantially vertical injection well region, which extends within the first thermal chamber, wherein the injecting the solvent flood vapor stream includes injecting from the at least substantially vertical injection well region.
The method of any one of embodiments 1-2, wherein the injecting the solvent flood vapor stream includes generating the solvent flood-mobilized viscous hydrocarbons within the subterranean formation.
The method of embodiment 3, wherein the generating includes at least one of:
(i) heating the viscous hydrocarbons with the solvent flood vapor stream to generate the solvent flood-mobilized viscous hydrocarbons;
(ii) diluting the viscous hydrocarbons with a condensed portion of the solvent flood vapor stream to generate the solvent flood-mobilized viscous hydrocarbons; and
(iii) dissolving the viscous hydrocarbons in the condensed portion of the solvent flood vapor stream to generate the solvent flood-mobilized viscous hydrocarbons.
The method of any one of embodiments 1-4, wherein the solvent flood vapor stream includes a plurality of solvent flood hydrocarbon molecules, and is comprised of at least 50 weight percent of hydrocarbons with 2-6 carbon atoms.
The method of any one of embodiments 1-5, wherein the solvent flood vapor stream includes at least one of:
(i) a hydrocarbon;
(ii) an alkane;
(iii) an alkene;
(iv) an alkyne;
(v) an aliphatic compound;
(vi) a naphthenic compound;
(vii) an aromatic compound;
(viii) an olefinic compound;
(ix) natural gas condensate;
(x) liquefied petroleum gas;
(xi) a naphtha product; and
(xii) a crude oil refinery stream.
The method of any one of embodiments 1-6, wherein a difference between the solvent flood vapor stream dew point temperature and a minimum of the first thermal recovery stream dew point temperature and the second thermal recovery stream dew point temperature is at least one of:
(i) at least 10° C. at 101.325 kilopascals;
(ii) at least 30° C. at 101.325 kilopascals;
(iii) at least 50° C. at 101.325 kilopascals;
(iv) at least 70° C. at 101.325 kilopascals;
(v) at least 90° C. at 101.325 kilopascals;
(vi) at least 110° C. at 101.325 kilopascals;
(vii) at least 130° C. at 101.325 kilopascals;
(viii) at least 150° C. at 101.325 kilopascals;
(ix) at least 170° C. at 101.325 kilopascals;
(x) at least 190° C. at 101.325 kilopascals; and
(xi) at least 210° C. at 101.325 kilopascals.
The method of any one of embodiments 1-7, wherein the injecting the solvent flood vapor stream includes at least one of:
(i) injecting an unheated solvent flood vapor stream;
(ii) injecting a heated solvent flood vapor stream;
(iii) injecting the solvent flood vapor stream at the solvent flood vapor stream dew point temperature for a target operating pressure within the subterranean formation; and
(iv) injecting the solvent flood vapor stream with some degrees of superheat relative to the solvent flood vapor stream dew point temperature for the target operating pressure within the subterranean formation.
The method of any one of embodiments 1-8, wherein the solvent flood vapor stream includes a mixture of a hydrocarbon solvent and steam.
The method of any one of embodiments 1-9, wherein the solvent flood vapor stream includes a near-azeotropic mixture of hydrocarbon solvent and steam.
The method of any one of embodiments 1-10, wherein a hydrocarbon solvent molar fraction in the solvent flood vapor stream is 70-100% of an azeotropic hydrocarbon solvent molar fraction of the solvent flood vapor stream at a target operating pressure within the subterranean formation.
The method of any one of embodiments 1-11, wherein the solvent flood injection well is a first solvent flood injection well of a plurality of spaced-apart solvent flood injection wells, wherein each solvent flood injection well of the plurality of spaced-apart solvent flood injection wells extends within a corresponding thermal chamber that extends within the subterranean formation, and further wherein the injecting the solvent flood vapor stream includes injecting the solvent flood vapor stream into the subterranean formation via each solvent flood injection well of the plurality of spaced-apart solvent flood injection wells.
The method of any one of embodiments 1-12, wherein, during the injecting the solvent flood vapor stream, the first thermal chamber and the second thermal chamber define respective chamber temperatures that are greater than a solvent flood vapor stream injection temperature of the solvent flood vapor stream.
The method of any one of embodiments 1-13, wherein the method further includes heating the solvent flood vapor stream via thermal contact between the solvent flood vapor stream and at least one of the first thermal chamber and the second thermal chamber.
The method of any one of embodiments 1-14, wherein the method further includes cooling at least one of the first thermal chamber and the second thermal chamber via thermal contact with the solvent flood vapor stream.
The method of any one of embodiments 1-15, wherein the producing the solvent flood-mobilized viscous hydrocarbons further includes producing, via the solvent flood production well, at least one of:
(i) at least a fraction of the first thermal recovery stream;
(ii) at least a fraction of the second thermal recovery stream;
(iii) water; and
(iv) at least a fraction of the solvent flood vapor stream.
The method of any one of embodiments 1-16, wherein the producing the solvent flood-mobilized viscous hydrocarbons includes flowing a fraction of the solvent flood-mobilized viscous hydrocarbons into the second thermal chamber from the first thermal chamber.
The method of any one of embodiments 1-17, wherein, at least partially concurrently with the injecting the solvent flood vapor stream, the method further includes producing at least a fraction of at least one of the first mobilized viscous hydrocarbon stream and the second mobilized viscous hydrocarbon stream.
The method of any one of embodiments 1-18, wherein the solvent flood production well is a first solvent flood production well of a plurality of spaced-apart solvent flood production wells, wherein each solvent flood production well of the plurality of spaced-apart solvent flood production wells extends within a corresponding thermal chamber that extends within the subterranean formation, and further wherein the producing the solvent flood-mobilized viscous hydrocarbons includes producing the solvent flood-mobilized viscous hydrocarbons via each solvent flood production well of the plurality of spaced-apart solvent flood production wells.
The method of any one of embodiments 1-19, wherein the solvent flood production well includes at least one of:
(i) an at least substantially horizontal production well region, which extends within the second thermal chamber, wherein the producing the solvent flood-mobilized viscous hydrocarbons includes producing via the at least substantially horizontal production well region; and
(ii) an at least substantially vertical production well region, which extends within the second thermal chamber, wherein the producing the solvent flood-mobilized viscous hydrocarbons includes producing from the at least substantially vertical production well region.
The method of any one of embodiments 1-20, wherein the method further includes performing at least a portion of at least one of the first thermal recovery process and the second thermal recovery process.
The method of embodiment 21, wherein at least one of the first thermal recovery process and the second thermal recovery process includes at least one of:
(i) a cyclic steam stimulation process;
(ii) a solvent-assisted cyclic steam stimulation process;
(iii) a steam flooding process;
(iv) a solvent-assisted steam flooding process;
(v) a steam-assisted gravity drainage process;
(vi) a solvent-assisted steam-assisted gravity drainage process;
(vii) a heated vapor extraction process;
(viii) a liquid addition to steam to enhance recovery process; and
(ix) a near-azeotropic gravity drainage process.
The method of any one of embodiments 21-22, wherein at least one of the first thermal recovery process and the second thermal recovery process includes at least one of:
(i) a steam injection process;
(ii) a solvent injection process; and
(iii) a solvent-steam mixture injection process.
The method of any one of embodiments 21-23, wherein the method further includes transitioning from performing at least one of the first thermal recovery process in the first thermal chamber and performing the second thermal recovery process in the second thermal chamber to performing the injecting the solvent flood vapor stream into the first thermal chamber and the producing the solvent flood-mobilized viscous hydrocarbons from the second thermal chamber.
The method of embodiment 24, wherein the method includes initiating the transitioning responsive to a transition criteria.
The method of embodiment 25, wherein the transition criteria includes at least one of:
(i) establishing fluid communication between the first thermal chamber and the second thermal chamber; and
(ii) detecting fluid communication between the first thermal chamber and the second thermal chamber.
The method of any one of embodiments 25-26, wherein the transition criteria includes at least one of:
(i) production of at least 10% of original oil in place from the subterranean formation;
(ii) production of at least 20% of original oil in place from the subterranean formation;
(iii) production of at least 30% of original oil in place from the subterranean formation;
(iv) production of at least 40% of original oil in place from the subterranean formation;
(v) production of at least 50% of original oil in place from the subterranean formation;
(vi) production of at least 60% of original oil in place from the subterranean formation;
(vii) production of at least 70% of original oil in place from the subterranean formation; and
(viii) production of at least 80% of original oil in place from the subterranean formation.
The method of any one of embodiments 1-27, wherein, subsequent to the injecting the solvent flood vapor stream, the method further includes:
(i) injecting a flood gas stream into the subterranean formation via the solvent flood injection well; and
(ii) during the injecting the flood gas stream, producing the solvent flood-mobilized viscous hydrocarbons from the solvent flood production well.
The method of embodiment 28, wherein the injecting the flood gas stream includes injecting at least one of:
(i) a non-condensable gas;
(ii) natural gas;
(iii) carbon dioxide;
(iv) nitrogen;
(v) a flue gas;
(vi) methane;
(vii) ethane; and
(viii) propane.
The method of any one of embodiments 28-29, wherein the injecting the flood gas stream facilitates the producing the solvent flood-mobilized viscous hydrocarbons.
The method of any one of embodiments 28-30, wherein at least one of:
(i) during the injecting the flood gas stream, the producing the solvent flood-mobilized viscous hydrocarbons includes producing at least a fraction of the solvent flood vapor stream; and
(ii) the injecting the flood gas stream includes injecting the flood gas stream to recover at least a fraction of the solvent flood vapor stream from the subterranean formation.
The method of any one of embodiments 28-31, wherein the method includes ceasing the injecting the solvent flood vapor stream prior to initiating the injecting the flood gas stream.
The method of any one of embodiments 28-32, wherein the method includes initiating the injecting the flood gas stream subsequent to producing a target fraction of original oil in place from the subterranean formation.
The method of any one of embodiments 1-33, wherein, subsequent to performing the injecting the solvent flood vapor stream and the producing the solvent flood-mobilized viscous hydrocarbons, the method further includes reversing the injecting and reversing the producing, wherein:
(i) the reversing the injecting includes injecting the solvent flood vapor stream into the second thermal chamber; and
(ii) the reversing the producing includes producing the solvent flood-mobilized viscous hydrocarbons from the first thermal chamber.
The method of any one of embodiments 1-34, wherein the injecting the solvent flood vapor stream includes maintaining a pressure differential between the solvent flood injection well and the solvent flood production well to facilitate the producing the solvent flood-mobilized viscous hydrocarbons.
The methods disclosed herein are applicable to the oil and gas industries.
It is believed that the disclosure set forth above encompasses multiple distinct inventions with independent utility. While each of these inventions has been disclosed in its preferred form, the specific embodiments thereof as disclosed and illustrated herein are not to be considered in a limiting sense as numerous variations are possible. The subject matter of the inventions includes all novel and non-obvious combinations and subcombinations of the various elements, features, functions and/or properties disclosed herein. Similarly, where the claims recite “a” or “a first” element or the equivalent thereof, such claims should be understood to include incorporation of one or more such elements, neither requiring nor excluding two or more such elements.
It is believed that the following claims particularly point out certain combinations and subcombinations that are directed to one of the disclosed inventions and are novel and non-obvious. Inventions embodied in other combinations and subcombinations of features, functions, elements and/or properties may be claimed through amendment of the present claims or presentation of new claims in this or a related application. Such amended or new claims, whether they are directed to a different invention or directed to the same invention, whether different, broader, narrower, or equal in scope to the original claims, are also regarded as included within the subject matter of the inventions of the present disclosure.
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