The present disclosure relates to an enhanced oil recovery method. In particular, the present disclosure relates to an enhanced oil recovery method employing slot-drilling.
The combination of horizontal drilling and multistage hydraulic fracturing has resulted in the commercial development of tight formations and shale oil resources. The advancements in drilling and completion technologies have enabled drilling wells with longer lateral lengths and creation of several fracture clusters at several stages in the well. However, the primary recovery in these low-matrix permeability reservoirs is still typically less than 10% of the oil initially in the reservoir. In some examples, shale-oil wells decline 75%-90% within the first three years of production, producing only 5%-9% of the amount of oil initially in the reservoir. Currently, shale EOR systems and methods involve injecting fluids (mostly CO2 or hydrocarbon gas) through multistage hydraulic fractures. The injection can either be continuous (through an injection well) or cyclic (in huff-n-puff mode), also referred to as cyclic gas injection EOR (CGEOR).
Considering the significant costs of injecting fluids into shale-oil reservoirs, petroleum engineers typically perform numerical simulation to identify the optimum EOR mechanism, injection mode, and optimize the operating constraints for the injection and production wells. However, these numerical studies are complicated by the common occurrence of natural fractures in unconventional oil and gas reservoirs. Some current EOR systems and methods include effective matrix/fracture models (such as dual porosity, dual permeability, and continuum models) to address natural fractures or simply neglect the presence of natural fractures. Unlike the effective medium models, discrete models (such as discrete fracture models, embedded discrete fracture model (EDFM), projection-based embedded discrete fracture model (pEDFM)) may account for each individual fracture in a naturally-fractured reservoir.
Regardless of the fracture model employed, the increase in recovery from CGEOR methods is still below a desired recovery. Accordingly, a need exists for an improved enhanced oil recovery system and method.
According to an embodiment of the present disclosure, a method for slot-drill enhanced oil recovery in a formation includes providing a wellbore in a reservoir of the formation, the reservoir having a top and a bottom: cutting a first horizontal slot-drill fracture at the top of the reservoir; cutting a second horizontal slot-drill fracture at the bottom of the reservoir: injecting a fluid into the reservoir via the first horizontal slot-drill fracture at the top of the reservoir; and producing oil from the second horizontal slot-drill fracture at the bottom of the reservoir, wherein the first horizontal slot-drill fracture is parallel to the second horizontal slot-drill fracture.
According to an embodiment of the present disclosure, a method for improving hydrocarbon recovery in an ultra-low permeability reservoir includes injecting a fluid into a first wellbore: producing a hydrocarbon from a second wellbore, wherein the first wellbore and the second wellbore are connected at distal ends thereof with one or more horizontal slot-drilled fractures, and wherein the hydrocarbon is produced from the one or more horizontal slot-drilled fractures.
According to an embodiment of the present disclosure, a method for slot-drill enhanced oil recovery in a formation includes providing a first wellbore having a first distal end and a second wellbore having a second distal end: cutting a horizontal slot-drill fracture in the formation between the first wellbore and the second wellbore; injecting a fluid into the first wellbore; and producing oil from the horizontal slot-drill fracture through the second wellbore, wherein the horizontal slot-drill fracture connects the first distal end of the second distal end.
Features and advantages of the present disclosure will be apparent from the following description of various exemplary embodiments, as illustrated in the accompanying drawings, wherein like reference numbers generally indicate identical, functionally similar, and/or structurally similar elements.
Features, advantages, and embodiments of the present disclosure are set forth or apparent from a consideration of the following detailed description, drawings, and claims. Moreover, it is to be understood that the following detailed description are exemplary and intended to provide further explanation without limiting the scope of the disclosure as claimed.
Various embodiments are discussed in detail below. While specific embodiments are discussed, this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components and configurations may be used without departing from the spirit and scope of the present disclosure.
Enhanced oil recovery (EOR) is essential in shale/tight formations because primary recovery typically produces less than 10% of the original hydrocarbon in-place (OHIP). The system of the present disclosure provides a Slot-Drill EOR technology (SDEOR). The system of the present disclosure may involve injecting gas through a horizontal fracture that is cut into the formation near the top of the reservoir (for example, with a tensioned abrasive cable mounted to the drill string), and producing oil from a second slot-drilled horizontal fracture near the bottom of the reservoir. The reservoirs may be oil reservoirs.
A model, such as, for example, a robust three-dimensional (3D) projection-based embedded discrete fracture model is used to model the natural fractures in the slot-drilled reservoirs accurately and efficiently. Connectivity and uncertainty analyses may be performed to determine a percolation threshold, that is, where natural fractures influence hydrocarbon production appreciably. The system of the present disclosure may yield over a three-fold increase in oil recovery relative to a conventional Cyclic Gas EOR (CGEOR) method. The simulated recovery of the model is high regardless of the presence of natural fractures and/or the type of treatment injected. The treatment may be, for example, a gas and/or a solvent, or other treatments. The gas and/or solvent may be, for example, but not limited to CH4, N2, CO2, flue gas, or combinations thereof. The simulation results indicate that, for example, the continuous gas injection, higher relative oil permeability and the role of gravity-drainage all the oil recovery from the SDEOR to be three times the oil recovery from the CGEOR method.
The system of the present disclosure may provide pairs of parallel slot-drilled fractures to enhance the recovery from challenging and/or unconventional reservoirs, such as the Bakken shale, which has not been successfully enhanced using the CGEOR method. There is a four-fold to eleven-fold improved recovery from the SDEOR relative to primary recovery of the reservoir.
As discussed, numerical simulation is performed to identify the optimum EOR mechanism and injection mode, and to optimize the operating constraints for the injection and production wells. Regardless of the fracture model employed (discussed above), the increase in recovery from CGEOR methods appear to be much less than the SDEOR system and method of the present disclosure. For instance, Moridis et al. (2020) employed a single-porosity effective matrix/fracture model, and showed that the injection of methane gas using the conventional shale EOR method did not result in an appreciable increase in oil recovery (relative to primary production). Various authors (Dahaghi et al., 2010; Eshkalak et al., 2014; Kim et al., 2015; Yu et al., 2014a) have also used the dual continuum models to evaluate CO2 continuous and cyclic injection shale-oil reservoirs. Although these methods are computationally faster, they are unable to account for the heterogeneity in the individual fracture sizes, orientation, distribution, etc. Accordingly, the SDEOR system and method of the present disclosure employs the numerical simulation studies of the conventional shale EOR methods using EDFM. Table 1 summarizes some of these EDFM simulation results, and provides the corresponding references. These tabulated results as well as the other numerical and experimental studies summarized in Tables 1 and 2 of Du and Nojabaei (2019) indicate a wide range in the increased oil recovery factor reported by various authors. In line with previous shale EOR studies, the increase in oil recovery is quantified using the Improved Oil Recovery (IOR) ratio, which is the ratio of the expected ultimate recovery (EUR) from EOR to the EUR from primary recovery.
Considering that EDFM is unable to account for low-conductivity fractures accurately (Tene et al., 2017), the EDFM studies in Table 1 implicitly assume that all the natural fractures are conductive, which is very unlikely in reality. This is because the orientation of each fracture depends on the prevailing stress state when it was created (Shafiei et al., 2018), after which fine-grained/cementing materials could accumulate in these fractures and make them sealing in the prevailing stress state today. In this work, we use the pEDFM in order to evaluate the performance of the proposed technology of the present disclosure in naturally fractured reservoirs with any arbitrary fracture conductivity.
The application of CGEOR in field and pilot studies has yielded mixed results. Several authors agree that CGEOR has been successful in the Eagle Ford shale, with IOR ratios ranging from 1.3 to 1.7 (Grinestaff et al., 2020; Hoffman, 2018). Conversely, several authors also agree (Hoffman et al., 2016) that the application of CGEOR has been unsuccessful in the Bakken shale play. Although Rassenfoss et al. (2017) attributed the lack of an incremental oil recovery to the lower matrix permeability of the Bakken, Hoffman et al. (2016) concluded (from his analysis of several EOR field/pilot tests) that early gas breakthrough (or connectivity of the fracture networks with those from offset wells) rather than poor injectivity was the cause of the negligible increment in recovery. Although field and pilot studies of the CGEOR in the Eagle Ford play indicate an IOR ratio of up to 1.7 if hydrocarbon gases are injected at high rates, Jacobs et al. (2019) pointed out that the success of CGEOR in a shale play depends on its fluid and fracture network properties.
Although SDEOR outperforms CGEOR for all the cases simulated with representative Bakken and Eagle Ford shale parameters, SDEOR has not been validated by field experiments and does not apply to thin shales. This is because the pair of slot-drilled horizontal fractures will be too close to be commercially viable.
Therefore, the present disclosure provides an EOR approach that is applicable in various tight rocks. The SDEOR system and method of the present disclosure may give IOR ratios of up to 4.17 within 8 years of production, even with fluid, matrix, and fracture properties that are representative of the Bakken shale. Accordingly, the SDEOR system and method of the present disclosure can be applied to any shale play, regardless of the rocks brittleness, prevailing stress states, presence or absence of natural fractures, etc. The present disclosure also provides equations for compositional simulation, summarization of how it is discretized and solved using the MATLAB Reservoir Simulation Toolbox (MRST) (Lie, 2019), and summarization of modeling natural fractures using 3D pEDFM and using the Alghalandis Discrete Fracture Network Engineering (ADFNE) code (Alghalandis, 2017) to generate several realizations of natural fracture networks, and perform fracture network connectivity analysis to understand the role of natural fractures in primary and enhanced oil recovery. The present disclosure evaluates the sensitivity of the SDEOR method to the uncertainty in fracture conductivity by simulating several realizations with extreme and stochastic values of fracture conductivity. The present disclosure evaluates the performance of the SDEOR when different gases are injected into a representative Bakken shale play, and systematically studies the controlling EOR mechanisms.
The slot-drill (SD) technology of the present disclosure includes a chain cutter that is pulled through massive rock outcrops. The proposed application of this concept to cut fractures in the subsurface involves the use of one or more wells.
In the SDEOR system and method of the present disclosure, gas is injected into horizontal fractures created close to the top of the reservoir, while oil is produced from parallel horizontal fractures created close to the bottom of the reservoir. To create these horizontal fractures regardless of the prevailing stress states in the reservoir, the present SDEOR system and method employs the use of the slot-drilling completion technique of
In another exemplary SDEOR system and method, both wells may be employed to create two parallel horizontal fractures, as shown in
To evaluate the performance of the SDEOR technology in shale oil reservoirs with realistic fracture networks, a compositional simulation may implement the 3D pEDFM presented in Olorode et al. (2020) and allows models several realizations of stochastic fracture networks created using ADFNE. The next section introduces the governing equations and the fracture model used to simulate these unconventional reservoirs with realistic natural fractures.
Although several models have been proposed to model fluid flow in naturally fractured reservoirs, the present disclosure employs embedded discrete fracture models (EDFM) because they are able to account for the properties and orientation of each individual fracture in a reservoir. The following description includes an introduction of EDFM proceeding to a discussion of its extension to a projection-based EDFM, which unlike EDFM, is able to model low-conductivity fractures accurately. EDFM uses the concept of non-neighboring connections (NNCs) to couple the flow of fluids in a fracture cell to that of its host (or ) matrix cell. The coupling occurs by adding a qinnc term to the semi-discrete form of the governing equation for compositional simulation, as follows:
where qinnc is the mass rate of component i that is exchanged through the NNC (in units of mass per time). It is given as:
where subscript m is an index from 1 to the total number of non-neighboring connections for each cell (Nnnc). The flow potentials of a cell and its non-neighboring cell are written as (pα−ραgz) and (pα−ραgz)nnc, respectively. To determine the transmissibility factor (Tnnc) between any pair of cells that are connected via non-neighboring connections, the present disclosure estimates the area (Annc), permeability (knnc), and distance (dnnc) of the non-neighboring connections. This transmissibility factor is given as:
The equations to estimate Annc, knnc, and dnnc are different for different types of NNC. Moinfar et al. (2014) provides more details on these equations, as well as the expressions for the three types of NNCs in EDFM, which are shown in
where the harmonic average of the projection matrix and fracture cell permeabilities (KpMF) is given as:
Here, dpMF represents the distance between the centroid of the fracture and that of the projection cell, while A⊥x is the area of the fracture projection along each spatial dimension.
The projection-matrix/host-matrix transmissibility (TpMM) is the second modification of the pEDFM, as is given as:
where Δ{right arrow over (x)}e represents the cell size in all three spatial directions (for 3D systems), A is the area of the face between the and the host matrix cells, while Ax is the projection area. Olorode et al. (2020) presents a 3D pEDFM algorithm, and provides further details on its implementation for compositional reservoir simulation.
Considering the significant role natural fractures play in the flow of fluids in tight rocks, a study is performed of fracture network connectivity based on the dimensionless connectivity indices given in Haridy et al. (2019). The main objective of this study is to ensure an unbiased evaluation of the SDEOR method of the present disclosure, regardless of the number, size, and other properties of the natural fractures simulated. Although Haridy et al. (2019) computed the different fracture indices for each cell in the reservoir, the present disclosure extends this approach to compute the connectivity, crossing, and extended connectivity indices for the entire simulation domain as follows:
In these equations, CI, CRi,j,k, and eCIi,j,k are the connectivity, crossing, and extended connectivity indices, respectively. The subscripts i, j, and k are used to indicate that the crossing and extended connectivity indices are computed for the x, y, and z-directions. The connectivity index is computed by looping through all the fracture planes in the domain, counting the number of fracture-fracture intersections, and dividing that by the total number of fracture planes in the reservoir. The crossing index in the x direction (CRi) is computed by looping through all the cell faces in the x-direction, counting the total number of fractures that these faces, and dividing this by the total number of natural fractures in the reservoir simulation domain. The same procedure is repeated for CRj and CRk, except that we only use the y and z faces in these cases, respectively. The extended connectivity index (eCIi,j,k) is computed as the summation of CI and CRi,j,k.
The density of a fracture network can be represented by fracture intensity, which can be characterized using different measures, as in Niven and Deutsch (2010). In this work, fracture intensity (in units of 1/ft) is calculated by summing the areas of all the natural fractures in the reservoir (Ai), and dividing that by the bulk volume of the reservoir (V), as follows:
The level of connectivity of a fracture network can be assessed by computing its “percolation threshold”, which is the interval above which the fracture network begins to contribute significantly towards the production from the fractured reservoir.
The steps required to determine the percolation threshold for a fractured reservoir stimulated using the SDEOR method of the present disclosure are as follows:
1. Set up a reservoir model such that each matrix cell has dimensions exceeding the average length of any given natural facture (NF) plane. Tables 2, B-1, and B-2 list the reservoir, binary interaction coefficients, and compositional data used in the model.
2. Increase the number of NFs in the reservoir, ranging from 8, 16, 32, 64, 128, 256, 512, 750, 1024, to 1500. A few of these realizations are shown in
3. Compute CI, eCli,j,k and fracture intensity (as in Equations [7], [9], and [10]) for each realization.
4. Create a log-log plot of CI and eCIi,j,k against fracture intensity as shown in
5. Determine the percolation threshold at the fracture intensity range, where CI transitions from a non-linear to a linear relationship (Haridy et al., 2019) that increases monotonically. This range is delineated by the two dashed lines 600 in
Following the enumerated steps, the percolation threshold was determined to be at a fracture intensity between 0.005 and 0.014 ft−1. This corresponds to having 70 to 260 natural fractures in the domain. At fracture intensity values above the percolation threshold, adding more stochastic fractures to the reservoir results in a significant change in oil production based on the increased fracture-fracture and fracture-matrix intersections. This change could be positive or negative, depending on value of the fracture conductivity, as demonstrated in the subsequent subsections.
Evaluation of Primary Recovery from Single Slot-Drilled Fracture.
To obtain useful insights on the role of gas injection in SDEOR technology in fractured tight rocks, a simulation is performed of eight years of primary oil production from a producing well that is completed using a slot-drill fracture near the bottom of the reservoir domain. These results provide a reference for the computation of the improved recovery obtained when gas is injected as proposed in SDEOR. Table 2 summarizes the input parameters for the shale-oil reservoir simulated in this section, while Tables B-1 and B-2 summarize the compositional fluid data for the simple three-component mixture simulated in all but the last section of the present disclosure. Although this mixture facilitates the computationally expensive studies in this work, the final section provides a study of the applicability of the SDEOR technology using representative data for a Bakken shale-oil reservoir.
To explain why natural fractures do not contribute appreciably to production when the fracture connectivity is below the percolation threshold, the connectivity indices are computed in Equations [23], [24], and for each cell, as in Haridy et al. (2019).
The next two sections focus on the evaluation of the near-term (8 years) and long-term (60 years) performance of SDEOR technology. The objective is to understand the physical mechanisms that control the short- and long-term performance of SDEOR in fractured tight rocks.
This subsection presents the results of the simulation of 8 years of methane gas injection into a slot-drilled fracture close to the top of the fractured reservoir while simultaneously producing oil from the slot-drilled fracture close to the bottom of the reservoir. To evaluate the robustness of the SDEOR technology in naturally fractured reservoirs, we simulated several realizations of the natural fracture network. This work also accounts for the fact that the permeability/conductivity of natural fractures could vary widely, ranging from sealing to highly conductive fractures, as shown in Table 3.
Study of SDEOR Performance in Reservoirs with Only High-Conductivity Natural Fractures.
The box plots of
To provide further insight into the SDEOR process in fractured shale-oil reservoirs, a profile of methane gas mole fraction is shown in
Study of SDEOR Performance in Reservoirs with Only Low-Conductivity Natural Fractures.
In some examples, a simulation of several realizations of sealing fractures only with a permeability of 1e-5 mD, as shown in Table 3, is performed.
Considering that the fractures in shale-oil reservoirs were formed under different prevailing stress states and at different points in its geologic history, fracture conductivity can vary over a wide range. Some fractures are conductive under the current stress state while others (that were previously active when formed) could be inactive or sealing in the prevailing stress state today. To account for this uncertainty in fracture conductivity, a simulation is performed of a well with 1024 fractures, which have a mix of high- and low-conductivity fractures. The high-conductivity fractures have permeability values that are sampled from a normal distribution with a mean of 82 mD and standard deviation of 52 mD, while the low-conductivity fractures have a mean and standard deviation of 9 nD and 6 nD, respectively. The aperture (wf) of each fracture in the network is computed from the cubic law for fracture permeability (Kf) as follows:
The long-term performance of the proposed SDEOR technology in fractured shale-oil reservoirs by simulating up to 60 years of production was also assessed.
To further show the robustness of the SDEOR method of the present disclosure in the presence of natural fractures ranging from 0 to 1024 and at different times in the life of the reservoir (at 8, 15, 30, and 60 years), we provide a plot of the SDEOR recovery factor in
Table 4 summarizes the performance results of the SDEOR technology by comparing its recovery factor with those from primary production. We also provide the change in recovery factor (relative to primary recovery), as well as the IOR ratio, which can be as high as 8.58 after 60 years of production. To show the game-changing potential of the SDEOR technology in comparison to the application of CGEOR in use today, the next section provides a comparison of both technologies using the same reservoir model.
What follows compares the production performance of the SDEOR technology and the CGEOR method used in multistage hydraulically fractured (MSHF) horizontal wells. The compositional fluid parameters and binary interaction coefficients used in both SDEOR and CGEOR models are provided in Tables B-1 and B-2. To make a meaningful comparison between these two EOR technologies, the total surface area of all the fractures in the CGEOR model shown in
hydraulically fractured wells are similar because both methods model the same total fracture surface area. The other plots in
In
In
In this section, a discussion of the role of different recovery mechanisms in the SDEOR technology of the present disclosure using the reservoir and fluid input parameters in Tables 2, A-1, and A-2, respectively. An understanding of the physical mechanisms that control the performance of the SDEOR process could facilitate the design of an efficient field implementation of this technology. Three recovery mechanisms are discussed herein:
A study of the effect of the pressure difference between the injector and producer (ΔPdiff) on the oil recovery from the SDEOR method of the present disclosure follows.
It is worth noting that while the pressure difference in the SDEOR technology acts continuously between the injector and producer, in CGEOR, the effect of a pressure increase is only felt during the injection and soaking period. This may contribute to the lower oil production observed from the simulations of the CGEOR method.
The role of gravity drainage in the SDEOR technology may be evaluated by simply turning gravity off and on in the simulation, and comparing the corresponding oil production from both cases. The simulation shows that gravity results in more oil recovery at higher matrix permeability values and in systems with dense networks of high-conductivity fractures. Considering that shale-oil reservoirs are typically naturally fractured and with low matrix permeabilities, the results for a shale reservoir with a matrix permeability of 50 μD and 512 natural fractures (which is above the percolation threshold) is employed. The simulation results given in
To evaluate the role of oil viscosity in the SDEOR technology of the present disclosure, the SDEOR technology is simulated by injecting at a constant qinj of 10 Mscf/D and a pwf of 2,500 psia for 30 years. The surface oil viscosity is computed as shown in
In this section, a numerical evaluation of the application of SDEOR in comparison to CGEOR in actual shale plays is discussed. To ensure that the CGEOR cases simulated are not curtailed by sub-optimal operating conditions (in comparison to SDEOR) the simulation for CGEOR includes the cyclic injection of methane gas under efficient operating conditions as follows:
1. Use optimum field injection, soaking, and production durations of 60, 14, and 180 days (2, 0.5, and 6 months), respectively (Kuuskraa et al., 2020).
2. Operate at Pwf above Pb to prevent the vaporization of the oil and ensure optimum CGEOR recovery factor (Sun et al., 2019).
3. Start CGEOR after the cumulative oil production from primary recovery flattens out.
The next two subsections show the results from the simulation of the Eagle Ford and Bakken shale formations. In both cases, primary production is simulated for 3 years, after which, both CGEOR and SDEOR are modeled for 8 more years.
Eagle Ford Shale: To model a volatile oil Eagle Ford shale reservoir, the fluid composition data presented in Tables B-3 and B-4 were used. Most of the reservoir input parameters used are given in Table 2, but to model a representative Eagle Ford shale reservoir, we use Pi, Pwf, and qinj values of 7,000 psia, 2,500 (above Pb=1,560 psia), 400 Mscf/D, and 1 μD, respectively, for both SDEOR and CGEOR cases. We do not simulate any natural fracture in this case because Raterman et al. (2018) did not observe any natural fractures from their extensive sampling of an SRV by drilling multiple lateral wellbores through a region around a stimulated Eagle Ford shale well.
The flattening of the slope of the SDEOR cumulative oil production 2500 corresponds to the time the injected gas breaks through into the bottom producer after 6 years of production. This is confirmed in the right plot in
Performance plots of
The drastic increase in oil recovery from SDEOR in comparison to CGEOR even in shale reservoirs with little or no fractures shows the applicability in such shale plays. The next subsection discusses shale plays such as the Bakken shale (which has lots of complex fractures), where CGEOR has not been successful at increasing the recovery significantly.
Bakken Shale: To model a volatile oil Bakken shale reservoir, the fluid composition data presented in Tables B-5 and B-6 was used. Most of the reservoir input parameters used are given in Table 2, but to model a representative Bakken shale reservoir, we use Pi, Pwf, and qinj values of 6,700 psia, 3,000 (above Pb=1,640 psia), 60 Mscf/D, and 10 μD, respectively, for both SDEOR and CGEOR cases. We simulate 150 sub-vertical natural fracture planes with 1.5 md-ft conductivity, dip ranging from 60° to 90° (with a mean of) 80°, and dip direction between N50° W and S40° E, as interpreted from the formation micro-imager (FMI) logs (Sturm and Gomez, 2009).
Performance plots of
Table 7 summarizes the results of the simulated recoveries from both the Eagle Ford and Bakken shale plays using SDEOR and CGEOR. The IOR ratios for the CGEOR method lies within the published range for the Eagle Ford (1.34-1.62) and Bakken (1.11-1.41) shale plays (Kuuskraa et al., 2020). The consistently superior recovery from the proposed SDEOR technology of the present disclosure (at least three times higher recovery than the CGEOR method in both shale plays) indicates its potential to be a game changer in the recovery of oil from shale-oil reservoirs.
The next subsections discuss the application of the SDEOR technology in the Bakken shale, where CGEOR field pilots have been reported to be unsuccessful and operationally challenging because the injected gas disperses quickly into the natural fracture network without soaking in effectively into the oil-charged matrix (Kuuskraa et al., 2020). The goal is to study the performance of the SDEOR technology in Bakken shale-oil reservoirs under the following unfavorable EOR conditions (Pospisil et al., 2020):
1. The presence of natural fracture networks at low and high conductivities.
2. Operating at Pwf (1,000 psia) below both Pb (1,640 psia) and the minimum miscibility pressure (MMP) for different solvents used (such as CH4, N2, Flue Gas, and CO2).
Study of SDEOR Performance in Bakken Shales with Different Fracture Conductivities.
The injection of methane into a Bakken shale oil reservoir at a constant rate of 20 Mscf/D for 30 years was simulated. To quantify the improve in recovery via SDEOR, primary production without gas injection was also simulated. The SDEOR cases studied include a base case without natural fractures, one with 1024 conductive natural fractures, and another with 1024 non-conductive (NC) natural fractures. As many as 1024 natural fractures were used to ensure that the fracture network connectivity exceeds the percolation threshold.
Results shown in
Study of SDEOR Performance with Different Injectants.
The injection of different gases (CH4, N2, flue gas, and CO2) into the Bakken shale using the SDEOR technology of the present disclosure was simulated.
As shown in the rightmost column in Table 8, although gases were simulated at the same value of injection rate, the corresponding injection pressure for case is different. This is expected in accordance with the Peacemann well model, in which the injection rate is inversely proportional to the viscosity but directly proportional to the pressure difference between the cell and the injection pressures. Therefore, as the gas viscosity increases for the denser gases, the pressure difference will increase, resulting in lower injection pressures at a fixed value of cell pressure. This explains the lower values of delta Pdiff for denser gases because the delta Pdiff is equal to the Pini minus the Pwf, and Pwf is fixed.
Accordingly, as appreciated from the foregoing disclosure, the method and system of the present disclosure provides EOR technology for unconventional reservoirs based on gas injection into a horizontal slot-drilled fracture near the top of the reservoir and oil production from another slot-drilled fracture near the bottom. The method of the present disclosure may outperform the cyclic gas EOR (CGEOR) method by a factor of at least three. The increase in recovery may be due to: (1) the continuous injection and production in the SDEOR technology prevents and/or curtails the effect of a significant reduction in relative oil permeability because of the increasing gas saturation near the well during the cyclic gas injection in CGEOR. (2) the SDEOR technology allows continuous production for 100% of the well life, where as in CGEOR, production is halted during the injection and soaking periods. (3) the SDEOR technology is designed to take advantage of gravity in stabilizing the flow through the fracture network unlike CGEOR, which involves a preferential flow through the poorly known fracture network.
The simulation results presented show that the method of the present disclosure may yield much higher oil recoveries regardless of the presence/absence of natural fractures of high, low or intermediate conductivity. The simulation of SDEOR in the Bakken shale (which has not been successfully enhanced using CGEOR) shows an IOR of at least four when simulating the injection of four different gases (CH4, N2, flue gas, and CO2).
The reservoir simulator computes the mass flow rates of each hydrocarbon component at reservoir conditions. Considering that the simulator was implemented in SI units, these quantities are computed in units of kg/s. To obtain the surface oil and gas rates, the surface phase densities were divided by the corresponding densities at reservoir conditions to obtain the oil and gas formation volume factors. These are then used to convert the subsurface gas and oil rates into the corresponding surface rates. In reality, a well model will be needed to account for the flow regimes and change in pressure due to frictional losses along the wellbore and in the surface facilities. However, the simple approach used is considered adequate for the purpose of comparing the performance of the SDEOR to the CGEOR method.
To obtain slightly more representative surface oil and gas rates without accounting for the pressure drops and flow regimes in the wellbore and surface facilities, the mass rate of each hydrocarbon component was divided by the corresponding molecular mass to obtain the rates in mol/s. These rates were divided by the total mass rate in mol/s to obtain the overall mole fraction, zi. The fluid mixture with overall mole fraction, zi was then flashed to standard conditions of 14.7 psia and 60° F. to obtain the liquid fraction, L and phase mole fractions, xi and yi. We used the definitions xi=niL/nL and L=nL/n to obtain an expression for the surface flow rate of each hydrocarbon component in the oil phase as:
qiL=Lqxi,
where qiL is in units of mol/s and q is the total subsurface flow rate in units of mol/s. The surface flow rate of each hydrocarbon component in the gas phase is obtained in a similar manner:
qiG=Vqyi,
where V is the vapor fraction (V=1−L) and qiG is in units of mol/s. The total oil and gas rates are obtained by summing the flow rate of each component over the corresponding phase. To convert these rates from mol/s to the surface oil and gas rates in stb/d and scf/d, we divide these rates by the corresponding phase molar densities at surface conditions and use the appropriate conversion factors between stb, scf, and m3.
Using the second approach (described in the previous paragraph) for the Eagleford and Bakken shale cases presented in
Considering that the capability of modeling natural fractures individually with EDFM is unavailable in the commercial simulator used to validate our results, we are only able to simulate the cases without natural fractures.
The SD fracture parameters in Table 2 are conservative based on the expected aperture and permeability from the slot-drill technology. For instance, in the slot drill technology patent by Carter (2011), the fracture aperture (WSD) ranges from 9.5 to 76.2 mm. Using the cubic law (wSD2/12) to estimate fracture permeability yields permeability (kSD) values between 7.6E6 and 4.9E8 Darcy. Even if this permeability is scaled by a porosity of 10%, it is still over four orders of magnitude higher than the permeability of 10 D. It is also worth noting that the fracture permeability and aperture described herein are consistent with the parameters shown in Table 1 Odunowo et al., (2014). Their values for SD fracture permeability (kSD), SD fracture porosity (ϕSD), and SD fracture aperture (wSD) are 100 D, 0.33, and 12.7 mm, respectively, whereas our corresponding values are 10 D, 0.33, and 10 mm.
where km and XSD are matrix permeability (0.01 mD), and SD fracture half-length (328 ft), respectively. Table 9 summarizes the FCD values corresponding to each case presented in
As shown, at a dimensionless fracture conductivity of over 50, the fracture is said to be of “infinite conductivity”, where there is no pressure drop in the fracture, and the flow regime is linear (Wattenbarger et al., 1998). So, based on the literature on the slot drill technology, the fractures created using this technology will be of infinite conductivity because our conservative fracture aperture and permeability yield a dimensionless fracture conductivity of 100. To show how the production will decline when the fracture conductivity is finite, we show a case with a dimensionless fracture conductivity of 10.
Accordingly, based on the foregoing disclosure the present disclosure provides a method of using mechanically-created horizontal fractures to enhance oil recovery from ultra-low permeability reservoirs. The method of the present disclosure improves oil recovery in tight/shale oil and gas reservoirs by injecting fluids through fractures which are mechanically cut into these ultra-low matrix permeability resources using the slot-drill technology. This slot-drill technology has the unique flexibility of precisely cutting the fractures at a desired, predetermined location and with a predetermined geometry. The method of the present disclosure involves drilling two wells, each having a horizontal slot-drill fracture, as previously described. One of the wells will serve as an injector, while the other well serves as the producer, depending on the reservoir fluid and the density of the chemicals/fluids to be injected. For example, in shale/tight oil reservoirs, gas (light hydrocarbon gases, CO2, nitrogen, etc.) can be injected from the slot-drilled well at the top, while the oil is produced from the slot-drilled well at the bottom. In another example, when injecting an EOR fluid with a higher density than the reservoir fluid, this will be injected into the horizontal slot-drilled well at the bottom, while the fluid will be produced from the slot-drilled well at the top. Therefore, determination of which of the slot-drill wells to produce or inject from depends on the density of the reservoir fluid in comparison to the density of the injection fluid. If the reservoir fluid is denser than the injection fluid, the top well will be the injector while the bottom well will be the producer. If the reservoir fluid is less dense than the injection fluid, the top well will be the producer, while the bottom well will be the injector.
The mechanical approach to cut the fractures, as described previously herein, is a more environmentally friendly alternative to the current hydraulic fracturing approach, which uses millions of gallons of water per well. A substantial portion of the injected water in hydraulic fracturing is produced and could contaminate the environment if not properly treated and disposed. This has led to the search for waterless fracturing technologies. Furthermore, the system and method of the present disclosure applies to the production of fluids from (or injection of fluids into) very tight rocks. Therefore, the system and method of the present disclosure is a game-changer in the production of steam or hot water from ultra-tight enhanced geothermal reservoirs, which typically require fracturing. The system and method of the present disclosure also applies to CO2 sequestration and hydrogen storage in tight rocks.
Currently, CGEOR is the best EOR method available for shale-oil reservoirs today. It is also the only approach demonstrated to work in the field. However, simulation models show that CGEOR only recovers, at most, 1.7 times of the oil typically recovered during primary recovery. Based on the upper limit of 9% for primary recovery from shale-oil reservoirs, over 80% of the initial oil in shale oil reservoirs are left behind in the subsurface even after CGEOR. Numerical simulations of CGEOR and SDEOR in Eagle Ford and Bakken shale plays indicate that the recovery from CGEOR is curtailed because of two main reasons. First, the relative oil permeability decreases near the hydraulically fractured well during successive gas injection, soaking, and production cycles. Secondly, the well cannot produce during the injection and soaking periods in CGEOR. On the contrary, the SDEOR of the present disclosure involves continuously producing oil and injecting gas from another well.
The method of the present disclosure allows:
1. The precise control and certainty of the fracture location gives control and predictability of the drainage mechanism involved.
2. This predictability allows optimization of the EOR process with dramatical reduction in the level of uncertainty, when compared with EOR in hydraulically-fractured reservoirs, which are very vulnerable to fracture hits, uncertainties in location of injection fractures, etc. This uncertainty can easily result in a direct hydraulic communication between the injecting fractures and producing fractures, leading to EOR failure.
3. The flexibility to cut these slot-drill fractures in any direction allows production of the hydrocarbon to take advantage of gravity drainage. On the contrary, in hydraulic fractures, the fractures typically open against the minimum horizontal stress (in normal and strike-slip faulting regimes), rendering it unlikely and/or impossible to create horizontal fractures with hydraulic fracturing.
4. The ability to cut these slot-drill fractures in any reservoir, regardless of brittleness makes the method of the present disclosure applicable to shale resources that are currently not producible with hydraulic fractures because ductile shales (One example being the Floyd shale) are not very amenable to hydraulic fracturing.
Without accounting for the presence of natural fractures, the governing equations for the mass conservation of each hydrocarbon component, i, in the liquid (l) and vapor (v) phases is shown in Equation 1.
Similarly, the mass conservation equation for water (w) in the aqueous phase is shown as Equation 2.
where φ, ρα, Sα, and qα represent the matrix porosity, mass density, saturation, and volumetric withdrawal/injection rate of phase α, respectively. The symbols Xl and Xg represent the mass fractions of component i in the liquid and vapor phases, while v1 and vv are the Darcy velocities for the liquid and vapor hydrocarbon phases, respectively. Note that the division of the source/sink term in Equations [1] and [2] by bulk volume, V is needed for dimensional consistency.
We obtain the phase velocities in Equations [1] and [2] from Darcy's equation as shown in Equation 3.
where μα and K represent the phase viscosity and absolute matrix permeability, respectively. In the natural variables composition approach (Coats, 1979), which is used in this work, the primary variables are pressure, vapor and liquid composition of all but the last component, and water saturation (p, x11,xg1 . . . , x1n-1, xgn-1, and Sw), respectively. The auxiliary thermodynamic equations and constraints needed for compositional simulation are summarized as follows in Equations [4] to [8].
In these equations, fgi and fli are the fugacities of each component in the gas and liquid phases, respectively. Equation [4] ensures that the fugacity of each component in the vapor phase is equal to that of the same component in the liquid phase (which is required at chemical equilibrium), Equation [5] ensures that the sum of the number of moles of each component in the liquid and gas phases is equal to its corresponding overall composition, while Equations [6], [7], and [8] ensure that all mole fractions and saturations sum up to one.
The Peng-Robinson equation of state (Peng and Robinson, 1976) is used to compute the fugacities and phase compressibility factors (Zg and Zl). Firoozabadi (2015) provides more details on the equation of state, flash procedure, and the equations to compute the fugacities and compressibility factors. To solve the continuous equations in [1] and [2] numerically, a temporal discretization is performed using the backward Euler scheme as shown in Equations 9 and 10.
In the above equations, n+1 represents the current time step, while n represents the previous time step. Note that all other terms without these superscripts are evaluated at the current time step. We then proceed to discretize the flux terms in space using the Finite Volume Method (FVM) with two-point flux approximation (TPFA). The TPFA method involves integrating Equations [9] and over a control volume, after which the divergence theorem is applied. In this work, we use the discrete divergence (div) and gradient (grad) operators, which are discussed in the MATLAB reservoir simulation book (Lie, 2019) and implemented as functions in the MATLAB reservoir simulation toolbox (MRST). The resulting discretized form of Equations [9] and can be written as shown in Equations [11] to [15].
Here, V and Ai,k refer to the cell volumes and face areas, respectively. The symbol, ni,k is the unit normal in the direction from the centroid of cell, i towards the face between cells i and k, while ci,k is the vector from the cell centroid to the face centroid. Additionally, Tik is face transmissibility, while Ti,k is the contribution of a cell to the face transmissibility. This transmissibility (Ti,k) is referred to as a half-transmissibility because a pair of cells contributes to the transmissibility of each face in the TPFA formulation. Note that the temporal and spatial discretizations of the continuous partial differential equations lead to a mass imbalance, which is represented by the residual (R) in Equations [9] through [12]. The Newton-Raphson method involves applying the Taylor expansion to the residual at the current time step and current Newtonian iteration to obtain Equation [16]:
where X denotes the primary variables. The matrix that contains the partial derivatives of the residuals with respect to each of these primary variables
is referred to as the Jacobian matrix. The setup of this matrix is facilitated using automatic differentiation in MRST, and more details on the solution of the system of equations for compositional flow are provided in Moyner et al. (2017). Considering that most shale/tight oil reservoirs are naturally-fractured to some extent, this work will involve simulating the SDEOR method of the present disclosure in such reservoirs with or without natural fractures. The next section explains how the discretized governing equations are modified to model natural fractures accurately and efficiently.
Tables B-1 and B-2 provide the compositional fluid data and binary interaction constants used in the simulations that involve a simple three-component hydrocarbon fluid. Tables B-5 and B-6 provide the corresponding data for a representative Bakken shale-oil reservoir, while Tables B-3 and B-4 provide compositional data inputs for a representative Eagle Ford shale-oil reservoir.
A method for slot-drill enhanced oil recovery in a formation includes providing a wellbore in a reservoir of the formation, the reservoir having a top and a bottom; cutting a first horizontal slot-drill fracture at the top of the reservoir; cutting a second horizontal slot-drill fracture at the bottom of the reservoir, injecting a fluid into the reservoir via the first horizontal slot-drill fracture at the top of the reservoir; and producing oil from the second horizontal slot-drill fracture at the bottom of the reservoir, wherein the first horizontal slot-drill fracture is parallel to the second horizontal slot-drill fracture.
A method for improving hydrocarbon recovery in an ultra-low permeability reservoir includes injecting a fluid into a first wellbore: producing a hydrocarbon from a second wellbore, wherein the first wellbore and the second wellbore are connected at distal ends thereof with one or more horizontal slot-drilled fractures, and wherein the hydrocarbon is produced from the one or more horizontal slot-drilled fractures.
A method for slot-drill enhanced oil recovery in a formation includes providing a first wellbore having a first distal end and a second wellbore having a second distal end; cutting a horizontal slot-drill fracture in the formation between the first wellbore and the second wellbore: injecting a fluid into the first wellbore; and producing oil from the horizontal slot-drill fracture through the second wellbore, wherein the horizontal slot-drill fracture connects the first distal end of the second distal end.
The method of any preceding clause, wherein the first horizontal slot-drill fracture, the second horizontal slot-drill fracture, or both, comprises a plurality of horizontal fractures mechanically created by one or more tensioned, abrasive cables.
The method of any preceding clause, wherein the first horizontal slot-drill fracture, the second horizontal slot-drill fracture, or both, comprises one or more fractures mechanically cut in the formation at predetermined locations in the formation, wherein the predetermined locations are determined via a simulation.
The method of any preceding clause, wherein the reservoir is a tight oil reservoir, shale oil reservoir, gas reservoir, ultra-low permeability reservoir, or combinations thereof.
The method of any preceding clause, wherein the fluid is a light hydrocarbon gas, carbon dioxide, nitrogen, or combinations thereof.
The method of any preceding clause, wherein the first horizontal slot-drill fracture, the second horizontal slot-drill fracture, or both, comprise a plurality of horizontal slot-drill fractures, and wherein, the plurality of first horizontal slot-drill fractures are parallel with the plurality of second horizontal slot-drill fractures.
The method of any preceding clause, wherein oil recovery from the reservoir is three times an oil recovery from a conventional cyclic gas enhanced oil recovery.
The method of any preceding clause, wherein an improved oil recovery of the reservoir is 4.17 within 8 years of production.
The method of any preceding clause, wherein the wellbore comprises two wellbores, and wherein, the injecting occurs in a first wellbore of the two wellbores and the producing occurs in a second wellbore of the two wellbores.
The method of any preceding clause, wherein production of the hydrocarbon is two times greater than production of a hydrocarbon through a well with natural fractures.
The method of any preceding clause, wherein the fluid is injected from a top of the first well, while the hydrocarbon is produced from the one or more horizontal slot-drill fractures at a bottom of the second well.
The method of any preceding clause, wherein the fluid is injected from a bottom of the first well, while the hydrocarbon is produced from the one or more horizontal slot-drill fractures at a top of the second well.
The method of any preceding clause, wherein the method has an oil recovery factor of between 13 and 51.
The method of any preceding clause, wherein the method has an improved oil recovery ratio of between 2 and 9.
The method of any preceding clause, wherein the one or more horizontal slot-drilled fractures comprises at least two parallel horizontal slot-drill fractures.
The method of any preceding clause, wherein the horizontal slot-drill fracture includes at least two parallel horizontal slot-drill fractures.
The method of any preceding clause, wherein after the at least two parallel horizontal slot-drill fractures are created, the first well is plugged at a bottom and is only allowed to inject fluids at the top, and the second well remains open to flow produced oil from a bottom fracture of the at least two parallel horizontal slot-drill fractures.
The method of any preceding clause, wherein the reservoir is a tight oil reservoir, shale oil reservoir, gas reservoir, ultra-low permeability reservoir, or combinations thereof.
The method of any preceding clause, further comprising continuously producing and injecting.
The method of any preceding clause, further comprising continuously producing oil from the second wellbore and injecting the fluid into the first wellbore.
Although the foregoing description is directed to the preferred embodiments, it is noted that other variations and modifications will be apparent to those skilled in the art, and may be made without departing from the spirit or scope of the disclosure Moreover, features described in connection with one embodiment may be used in conjunction with other embodiments, even if not explicitly stated above.
The application claims priority to U.S. Provisional Application No. 63/251,326, filed Oct. 1, 2021, the entire contents of which are hereby incorporated by reference in their entirety.
Filing Document | Filing Date | Country | Kind |
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PCT/US2022/077398 | 9/30/2022 | WO |
Number | Date | Country | |
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63251326 | Oct 2021 | US |