Simulation of O/W Emulsion Flow in Alkaline/Surfactant Flood For Heavy Oil Recovery
Simulation of O/W Emulsion Flow in Alkaline/Surfactant Flood For Heavy Oil Recovery
Simulation of O/W Emulsion Flow in Alkaline/Surfactant Flood For Heavy Oil Recovery
Flow in Alkaline/Surfactant
Flood for Heavy Oil Recovery
J. Wang*, M. Dong, University of Calgary
* now with Core Laboratories Canada Lid.
Sandpacks
Alkaline/surfactant flood tests were performed in sandpacks to 0.001
demonstrate the effectiveness of sweep efficiency improvement 0 0.2 0.4 0.6 0.8 1
through the in-situ formed O/W emulsions, and more importantly, Combined Alkaline Concentration, wt%
to provide experimental data for history matching in the further
numerical simulation study. The heavy oil sample and the forma- FIGURE 1: Interfacial tensions of heavy oil/brine as a function of
combined alkaline concentration. Weight ratio of Na2CO3/NaOH being
tion brine used in this study were from a heavy oil reservoir in 1:1, and surfactant concentration in brine being 100 mg/L.
Saskatchewan, Canada. The oil sample was centrifuged at 10,000
rpm under 35°C for 2 hours to remove water and solids. The vis- of the sandpacks was around 36.3% and the absolute permeability
cosity and density of the oil sample at 25°C were determined to be ranged from 5.5 – 7.0 µm2.
1,370 mPa.s and 961.8 kg/m3, respectively. The acid number of the The wet-packed sandpack was flooded with the heavy oil to es-
oil sample was 1.32 mg KOH/g-oil. The salinity of the formation tablish initial water saturation. The oil injection was conducted
brine was 27,286 mg/L in terms of total dissolved solids (TDS), at the velocity of 0.4 m/d and continued until water production
with 410 mg/L of Ca2+ and 256 mg/L of Mg2+. ceased (water cut less than 1.0%). The initial water saturation was
Emulsification tests(7) showed that the oil ��������������������
sample could
�������������
be dis- determined on the basis of mass balance. After that, waterflooding
persed into the formation brine by the synergy of alkali and surfac- was conducted by injecting formation brine at a constant injection
tant. The combined application of NaOH and Na2CO3 was chosen flow rate. Waterflooding was continued until oil production be-
as the alkaline agent from the screening tests. An anionic surfac- came negligible (oil cut less than 1.0%), and then A/S flooding was
tant, alkyl ether sulphate (Stepan, Canada), was selected as the ad- started. A 0.3 pore volume (PV) preflush slug (0.10 wt% Na2CO3
ditive because it provided the better emulsification result for the in brine) was used before the injection of alkaline/surfactant slug
studied heavy oil/brine system. Oil/water interfacial tensions were in order to reduce surfactant loss and to provide a Ca2+-free cir-
measured using a spinning-drop tensiometer (Model 510, Temco, cumstance for emulsification of oil. Following the injection of a
USA). Figure 1 presents the IFT as a function of the combined chemical slug, an extended waterflood was carried out until the oil
alkaline concentration with the weight ratio of Na2CO3/NaOH
production became negligible.
being 1:1, in the presence of 100 mg/L surfactant. A minimum
The parameters of ���������������������������������������
the �����������������������������������
sandpacks and the results of water-
IFT was observed at around 0.4 wt% combined alkalis. With the
flooding and chemical flooding are summarized in Table 1. Ini-
consideration of chemical loss, 0.6 wt% combined alkalis and 300
ppm surfactant were used in sandpack flood tests. tial oil saturation ranged from 69.3 – 87.0%, and waterflooding oil
recovery varied from 29.0 – 34.1% OOIP. Varied injection flow
Three alkaline/surfactant flooding tests were carried out in this rates, chemical slug sizes and sandpack lengths were used in these
study. The sandpack holder used in alkaline flood tests was 4.25
three A/S flooding tests, and all tests showed significant improve-
cm in diameter. Two of the three sandpacks were 14.2 cm in length
ment in oil recovery after the chemical ���������������������������
flooding�������������������
. The injection ve-
and the other one had a length of 90.4 cm in order to investigate
the effect of sandpack length on oil recovery. Both ends of the locity was 0.4 m/d for Run1 and Run 3, and 0.8 m/d for Run 2. The
sandpack holder were equipped with flow distributors, upon which chemical slug sizes were 0.5 PV for Run 1 and Run 3, and 1.2 PV
200-mesh stainless steel screens were spot-welded to prevent fine for Run 2. The same sandpack length was used in Run 1 and Run
sand from flowing out and to provide more even distribution of the 2, while a longer sandpack with more than six times of that length
injected fluid. Ottawa sand was wet-packed in the sandpack holder. was used in Run 3. Test results showed there was no evident dif-
The packing procedure was as follows: 60−100 mesh sand was ference in tertiary oil recovery for these three tests, which ranged
poured into the sandpack holder, which was vertically mounted from 22.4% – 24.4% OOIP. This indicates that the injection rate
on a vibrator and filled with formation brine. The sandpack holder has an insignificant effect on oil recovery in the studied flow-rate
was fully filled at a time and was vibrated for 1 hour. The porosity range. With approximately a same tertiary oil recovery, the 0.5 PV
Run number 1 2 3
Sandpack Length, cm 14.2 14.2 90.4
Porosity, % 36.6 36.8 35.4
Permeability, µm2 5.5 6.5 7.0
Initial oil saturation, % 69.6 69.3 87.0
Waterflooding recovery, %OOIP 29.0 34.1 34.0
Injection velocity, m/d 0.4 0.8 0.4
0.3 wt% Na2CO3 0.3 wt% Na2CO3 0.3 wt% Na2CO3
Chemical formula + 0.3 wt% NaOH + 0.3 wt% NaOH + 0.3 wt% NaOH
+ 300 ppm Surfactant + 300 ppm Surfactant + 300 ppm Surfactant
Chemical slug size, PV 0.5 1.2 0.5
Tertiary recovery, %OOIP 22.4 24.4 23.4
Final oil recovery, %OOIP 51.4 58.5 57.4
FIGURE 2: Experimental and simulated cumulative oil production and Water + Chemical + Dead Oil → O / W Emulsion ................................. (1)
pressure drop for test Run 1 of A/S flooding in sandpack.
chemical slug size is more economical compared to the 1.2 PV of The capture of emulsion drops by porous media was represented
chemical slug. The oil recovery efficiency was not reduced with by a chemical reaction:
the increase in sandpack length, which indicated a great potential
for upscaling the laboratory tests to field applications. O / W Emulsion → Trapped Oil ............................................................ (2)
The curves of cumulative oil production and pressure drop of
these three flood tests are presented in Figures 2 through 4 (in In the grids with a higher alkaline concentration, more emul-
squares). It can be seen that the increase in oil recovery during sion is produced. The trapped oil was generated when the in-situ
A/S slug injection is accompanied by an increase in pressure drop. formed O/W emulsion drops were trapped, and then the local water
The mechanism involves the ultralow IFT and formation and flow phase permeability was decreased by adding a resistance factor (>
of O/W emulsions. The injected chemicals react with the organic 1.0). Trapping is more likely happen in lower permeability region.
acids in the oil, leading to a significant reduction in IFT, and emul- To represent this trapping tendency, the reaction rate parameter
sification of heavy oil in brine. Some oil is entrained in the con- used in the reaction in Equation (2) was a function of permeability,
tinuous water phase and flows out in the form of O/W emulsion. which was higher in lower permeability region(17).
The flowing emulsion droplets may be trapped when arriving at The measured oil/water interfacial tension (Figure 1) was input
smaller pore throats, which will lower the local mobility of water into the simulation. Langmuir isotherm curve was used to describe
phase and divert the injected water to un-swept regions. This en- the chemical adsorption. Tests performed in sandpacks by Liu(18)
trapment mechanism accounts for the increase in pressure drop and showed that the maximum NaOH loss on sand was approximately
improvement in oil recovery. 2.0 µmol/g-sand. This value was used to estimate the maximum
adsorption value in the simulation.
Oil/water two-phase relative permeability curves used for
History Match of Sandpack Flood Tests matching three sandpack flood tests are shown in Figures 5
through 7. To represent the effect of IFT reduction on two-phase
Based on the experimental studies, laboratory-scale numer- flow, the relative permeability was interpolated as a function of
ical simulations were conducted to match the production histories capillary number. Two sets of relative permeability curves, cor-
of the sandpack flood tests. CMG STARS was used to simulate responding to high IFT (during waterflooding) and low IFT cases,
the alkaline/surfactant flooding processes. The in-situ formation were used in the simulation. The capillary numbers for these two
of O/W emulsion was represented by a reaction of oil, water and cases were 2.5×10–7 and 3.2×10–3, respectively. Both oil-phase
chemicals. Filtration Theory was used to simulate the emulsion and water-phase relative permeabilities increased during chemical
capture in porous media. A grid system of 25×25×1 was used flooding. The water-phase permeability in the grids where emul-
to represent the 14.2-cm-long sandpacks in the tests, with the sion drops were trapped was decreased by including a water phase
gridblock size of 0.568 cm×0.567 cm×1 cm. The longer sand- resistance factor. The reaction rates, resistance factors and relative
pack was modelled using a grid system of 100×5×1, with the Cumulative Oil Production, Experimental
Cumulative Oil Production, Simulated
Cumulative Oil Production, Experimental Injection Pressure, Experimental
40 Cumulative Oil Production, Simulated 300 250 Injection Pressure, Simulated
500
Injection Pressure, Experimental
Cumulative Oil Production, cm3
Waterflooding
Cumulative Oil Production, cm3
200
Injection Pressure, kPa
Injection Pressure, kPa
30 250 400
Waterflooding Waterflooding
150
Waterflooding
20 200 Chemical 300
Chemical Slug Slug
100
10 150 200
50
0 100 0 100
0.00 0.20 0.40 0.60 0.80 1.00 1.20 0.0 2.0 4.0 6.0 8.0
Time, days Time, days
FIGURE 3: Experimental and simulated cumulative oil production and FIGURE 4: Experimental and simulated cumulative oil production and
pressure drop for test Run 2 of A/S flooding in sandpack. pressure drop for test Run 3 of A/S flooding in sandpack.
48 Journal of Canadian Petroleum Technology
1
Waterflooding
Ca = 3.2E-3
0.8
Kro
0.6
Kr
0.4
Krw
0.2
0.6
0.4
Based on the history matching of the alkaline/surfactant flooding
tests, field-scale numerical reservoir simulations were conducted
Krw to investigate the potential of field application of the EOR process.
Field simulations were performed on a rectangular area of 450 m
0.2 long and 400 m wide with a pay thickness of 4.5 m. Parallel hori-
zontal wells spaced 200 m were used as injectors and producers.
Table 2 lists the production parameters of the field model. A grid
system of 21×10×5 was used to represent this reservoir model,
0
0 0.2 0.4 0.6 0.8 1
with the gridblock size of 20 m×50 m×0.9 m. Figure 8 is a 3D
view of the reservoir model with colour scale showing the perme-
Sw
ability distribution. Uniformly distributed permeabilities, ranging
FIGURE 6: Simulation used oil-water two-phase relative permeability from 1.0 µm2 to 10.0 µm2, were assigned to these 1,050 grids with
curves for test Run 2 of A/S flooding. the average permeability of 5.57 µm2.
1 The reservoir model shown in Figure 8 was used to study var-
ious production scenarios, including varied time lengths of wa-
terflooding before chemical injection, and varied time lengths of
chemical injection (chemical slug sizes). Components, chemicals
Waterflooding
0.8 Ca = 3.2E-3
Kro
80
0.6
Oil Recovery Factor SCTR
Waterflooding 3 years
60 Waterflooding 2 years
Kr
Waterflooding 1 year
0.4
40
Krw
0.2
20
0 0
0 0.2 0.4 0.6 0.8 1 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
Sw Time, date
FIGURE 7: Simulation used oil-water two-phase relative permeability
curves for test Run 3 of A/S flooding. FIGURE 9: Effect of waterflooding time on oil recovery.
June 2010, Volume 49, No. 6 49
Table 2: Parameters of field-scale model.
and reactions were the same as those used for the simulation of the injection resulted in a higher oil recovery. However, when the
test Run 2 in the previous section. chemical injection time was longer than 8 months, the oil recovery
The effect of waterflooding time on oil recovery is shown in did not show evident increase with increasing chemical injection
Figure 9, which compares the oil recoveries for the cases with time. Although this time may vary for specific reservoir condi-
waterflooding period of 1, 2 and 3 years. There was no primary tions, the simulation results indicate that there exists an optimum
production prior to initial waterflood for all these three cases. chemical slug size.
Chemical flooding was continued for 8 months, and then switched The previously described reservoir simulation model was used
to extended waterflood. The production well was shut off when the to study the variations in oil recovery, reservoir pressure and
water cut was higher than 98%. The simulation results showed that water cut after chemical injection. Reservoir production started
for the case with longer time of waterflood, the oil recovery was at 1 January 2000, and there was no primary production. Wa-
lower at first; however, the final oil recovery was relatively higher. terflooding was continued for 3 years before chemical flooding.
This may indicate that a certain length of time of waterflood before After 8 months of chemical injection (corresponding to 0.15 PV
chemical injection would benefit for the final oil recovery. chemical slug injection), waterflood was resumed until water cut
The effect of chemical slug size on oil recovery was studied in production well was higher than 98%. The simulated oil re-
by simulating and comparing five cases with varied time lengths covery, average reservoir pressure and water cut in production
of chemical injection ranging from 0 – 12 months. There was well are plotted as a function of time, and shown in Figure 11.
no primary production, and waterflood was continued for three The oil recovery with only waterflood (no chemical injection) is
years for all these cases. The production well was shut-off when also plotted in this figure for comparison. It can be seen that after
the water cut was higher than 98%. The simulation results are chemical injection reservoir pressure was increased, and water cut in
shown in Figure 10. It can be seen that a longer time of chemical
80
Chemical injection 1 year
Chemical injection 8 months
Oil Recovery Factor SCTR
40
20
0
2002 2004 2006 2008 2010 2012
Time, date
FIGURE 10: Effect of chemical slug size on oil recovery.
80
8,000
60
6,000
40
4,000
20
0 2,000
2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
Time, date
FIGURE 12: Oil saturation distributions in the middle layer of the
FIGURE 11: Simulation results for A/S flooding in homogeneous reservoir model. Chemical slug was injected during 1 January – 31
reservoir. Chemical slug was injected during 1 January – 31 August August 2003. (a) At the end of initial waterflood; (b) 11 months of
2003. extended waterflood after chemical injection.
50 Journal of Canadian Petroleum Technology
production well was effectively decreased. Oil recovery was greatly
improved by the chemical flooding. The tertiary oil recovery was
as high as the waterflood’s recovery; that is, oil recovery was
doubled after chemical flooding. Comparing to the final oil re-
covery in the case without chemical injection, the oil recovery im-
provement by chemical flooding was approximately 20% OOIP.
Figure 12 compares the oil saturation distribution in the middle
layer of the reservoir at the time just before chemical injection (or
at the end of waterflooding) and at one time point of extended wa-
terflood after chemical injection. It shows that oil bank was formed
in the displacement front after the chemical injection. The corre-
sponding pressure distribution in this layer of the reservoir is
shown in Figure 13. It shows that the pressure around the injec-
tion well and the pressure gradient in the displacement front are in-
creased during the chemical flooding process.
Conclusions
Three alkaline/surfactant flooding tests were conducted in sand-
packs using a heavy oil to demonstrate the effectiveness of sweep
efficiency improvement by the in-situ generated O/W emulsions,
as well as to provide experimental data for numerical simulation
study. Numerical simulation was performed to match production
history by including the in-situ generation and flow of the O/W
emulsions. Using the parameters obtained in history matching,
field-scale simulations were conducted. On the basis of experi-
mental and simulation results, the following conclusions were
drawn:
1. A properly designed alkaline flooding for heavy oil recovery
could effectively improve sweep efficiency through in-situ
generated O/W emulsion. The formation of O/W emulsion
lowered the mobility of water phase, diverted the injected
water to un-swept regions and improved oil recovery. The
injection flow rate had insignificant effect on oil recovery in
the studied range corresponding to the flow velocity of 0.4 to
0.8 m/d. The oil recovery efficiency was not reduced with the FIGURE 13: Reservoir pressure distributions in the middle layer of
increase in sandpack length, which showed a great potential the reservoir model. Chemical slug was injected during 1 January –
for upscaling the laboratory tests to field applications. 31 August 2003. (a) At the end of initial waterflood; (b) 11 months of
extended waterflood after chemical injection.
2. Laboratory-scale numerical simulations, including the ad-
sorption of chemicals, interfacial tension reduction, and in-
3. Farouq Ali, S.M., Figueroa, J.M., Azuaje, E.A., and Farquharson,
situ generation and flow of emulsions fairly simulated the
R.G. 1979. Recovery of Lloydminster and Morichal crudes by
pressure response and oil recovery improvement in chemical
caustic, acid and emulsion floods. J Can Pet Technol 18 (January–
flooding tests in sandpacks. The entrapment of oil drops was
March): 53–59.
represented by decreased local water phase permeability.
4. Bryan, J. and Kantzas, A. 2007. Enhanced Heavy-Oil Recovery by
3. Field-scale simulations showed promising results of chem-
ical flooding for heavy oils. It was indicated that a certain Alkali-Surfactant Flooding. Paper SPE 110738 presented at the SPE
length of time for water injection would benefit for the final Annual Technical Conference and Exhibition, Anaheim, California,
oil recovery, and there existed an optimum chemical slug USA, 11–14 November. doi: 10.2118/110738-MS.
size. For the studied case in this study, 0.15 PV of chemical 5. Dong, M. 2004. Displacement of Heavy Oil through Interfacial Insta-
slug would achieve more economical results, and nearly a bility—A Study of an EOR Method for Murphy East Bodo Heavy Oil
doubled oil recovery was obtained by the application of alka- Reservoir. Technical report, Petroleum Technology Research Centre
line/surfactant flooding. (PTRC), Regina, Saskatchewan, Canada.
6. Dong, M., Liu, Q., Ma, S., and Zhou, W. 2005. Displacement of
Heavy Oil Through Interfacial Instability: A Study of an EOR
Acknowledgements Method for CNRL Brintnell Heavy Oil Reservoir. Technical report,
Petroleum Technology Research Centre (PTRC), Regina, Saskatch-
The authors acknowledge with thanks the Petroleum Technology ewan, Canada.
Research Centre (PTRC), the Natural Sciences and Engineering 7. Liu, Q., Dong, M., Yue, X., and Hou, J. 2006. Synergy of alkali
Research Council of Canada (NSERC) and Canada Foundation for and surfactant in emulsification of heavy oil in brine. Colloids and
Innovation (CFI) for the financial support of this study. Surfaces A: Physicochemical and Engineering Aspects 273 (1–3):
219–228. doi:10.1016/j.colsurfa.2005.10.016.
References 8. Liu, Q., Dong, M., and Ma, S. 2006. Alkaline/Surfactant Flood Po-
tential in Western Canadian Heavy Oil Reservoirs. Paper SPE 99791
1. Johnson, C.E. Jr. 1976. Status of Caustic and Emulsion Methods. presented at the SPE/DOE Symposium on Improved Oil Recovery,
J Pet Technol 28 (1): 85–92. SPE-5561-PA. doi: 10.2118/5561-PA. Tulsa, 22–26 April. doi: 10.2118/99791-MS.
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10. Alvarado, D.A. and Marsden, S.S. Jr. 1979. Flow Of Oil-in-Water
Emulsions Through Tubes and Porous Media. SPE J. 19 (6): 369– Authors’ Biographies
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11. Abou-Kassem, J.H. and Farouq Ali, S.M. 1995. Modelling of Emul- Jinxun Wang is currently a project engi-
sion Flow in Porous Media. J Can Pet Technol 34 (6): 30–38. neer with Core Laboratories Canada Ltd.
12. McAuliffe, C.D. 1973. Oil-in-Water Emulsions and Their Flow Prop- He is a Ph.D. candidate in chemical engi-
erties in Porous Media. J Pet Technol 25 (6): 727–733. SPE-4369-PA. neering at the University of Calgary. His re-
doi: 10.2118/4369-PA. search interests include multiphase flow in
13. Devereux, O.F. 1974. Emulsion flow in porous solids: I. a flow model. porous media, enhanced oil recovery, res-
The Chemical Engineering Journal 7 (2): 121–128. doi:10.1016/0300- ervoir simulation and phase behaviour of
9467(74)85005-7. reservoir fluids. He holds B.Sc. and M.Sc.
14. Soo, H. and Radke, C.J. 1984. The Flow Mechanism Of Dilute, degrees in petroleum engineering. Wang is
Stable Emulsions In Porous Media. Ind. Eng. Chem. Fundamen. 23 a member of SPE.
(3): 342–347. doi:10.1021/i100015a014.
15. Soo, H. and Radke, C.J. 1986. A filtration model for the flow of dilute
stable emulsions in porous media—I. Theory. Chemical Engineering
Science 41 (2): 263–272. doi:10.1016/0009-2509(86)87007-5. Mingzhe Dong is a professor in the De-
16. Soo, H., Williams, M.C., and Radke, C.J. 1986. A filtration model partment of Chemical and Petroleum Engi-
for the flow of dilute stable emulsions in porous media—II. Param- neering at the University of Calgary. Prior
eter evaluation and estimation. Chemical Engineering Science 41 (2): to the appointment at the University of Cal-
273–281. doi:10.1016/0009-2509(86)87008-7. gary in 2007, he held a faculty position in
17. STARS User Guide. 2007. Calgary, Alberta: Computer Modelling
the Faculty of Engineering at the Univer-
Group (CMG).
sity of Regina (2001 – 2007). His research
18. Liu, Q. 2006. Interfacial Phenomena in Enhanced Heavy Oil Re-
interests include multiphase flow in porous
covery by Alkaline Flood. Ph.D thesis, University of Regina, Regina,
media, enhanced oil recovery, phase behav-
Saskatchewan.
iour in gas injection, reservoir simulation,
and interfacial phenomena in oil recovery
This paper (2009-066) was accepted for presentation at the 10th Canadian processes. He holds a B.A.Sc. degree from
International Petroleum Conference (the 60th Annual Technical Meeting Northwest University, Xi’an; an M.A.Sc.
of the Petroleum Society), Calgary, 16-18 June, 2009, and revised for degree from the University of Petroleum, Beijing; and a Ph.D.
publication. Original manuscript received for review 24 March 2009. degree from the University of Waterloo, Ontario, all in chemical
Revised paper received for review 18 April 2010. Paper peer approved 20 engineering. He is a member of SPE and APEGGA and is a regis-
April 2010 as SPE Paper 138969. tered professional engineer in the province of Alberta.