Method and system for Co.SUB.2 .enhanced oil recovery
11702915 · 2023-07-18
Assignee
Inventors
- Michael Drescher (Trondheim, NO)
- Torbjørn Fiveland (Skien, NO)
- Olav Kristiansen (Trondheim, NO)
- Thomas Levy (Skien, NO)
- Knut Arild Maråk (Trondheim, NO)
- Bengt Olav Neeraas (Trondheim, NO)
- Per Ivar Karstad (Jonsvatnet, NO)
Cpc classification
E21B43/40
FIXED CONSTRUCTIONS
Y02P90/70
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
Abstract
Methods of Enhanced Oil Recovery (EOR) from an oil reservoir by CO.sub.2 flooding are disclosed. One method comprises producing a well stream from the reservoir; separating the well stream into a liquid phase and a gas phase with a first gas/liquid separator, wherein the gas phase comprises both CO.sub.2 gas and hydrocarbon gas; cooling the gas phase with a first cooler; compressing the gas phase using a first compressor into a compressed stream; mixing the compressed stream with an external source of CO.sub.2 to form an injection stream; and injecting the injection stream into the reservoir. Systems for EOR from an oil reservoir by CO.sub.2 flooding are also disclosed.
Claims
1. A method of Enhanced Oil Recovery (EOR) from an oil reservoir by CO.sub.2 flooding, comprising: producing a well stream from an oil reservoir; separating the well stream into a liquid phase and a gas phase with a first gas/liquid separator, wherein the gas phase comprises both CO.sub.2 gas and hydrocarbon gas; cooling the gas phase with a first cooler; compressing the gas phase using a first compressor into a compressed stream; mixing the compressed stream with an external source of CO.sub.2 in a mixer to form an injection stream; cooling the injection stream with a second cooler arranged downstream of the mixer; and injecting the injection stream into the reservoir.
2. The method as claimed in claim 1, wherein the gas phase is cooled prior to compression.
3. The method as claimed in claim 1, wherein the first cooler is an active cooler.
4. The method as claimed in claim 1, wherein the gas phase separated by the first gas/liquid separator comprises water vapour in addition to CO.sub.2 and hydrocarbon gas.
5. The method as claimed in claim 1, wherein the well stream is choked to a pre-defined pressure prior to separating the well stream into a liquid phase and a gas phase.
6. The method as claimed in claim 1, wherein prior to separating the well stream into a liquid phase and a gas phase, the well stream is heated.
7. The method as claimed in claim 1, wherein the oil reservoir is an offshore reservoir.
8. The method as claimed in claim 7, wherein the method is carried out subsea; or wherein at least the steps of separating the well stream, cooling the gas phase with the first cooler and compressing the gas phase are carried out above sea level; or wherein the step of separating the well stream is carried out subsea, and the steps of cooling the gas phase with the first cooler and compressing the gas phase are carried out above the sea.
9. The method as claimed in claim 1, wherein after compressing the gas phase, part of the compressed gas phase is recycled into the well stream upstream the gas/liquid separator or into the gas phase downstream the gas/liquid separator.
10. The method as claimed in claim 1, wherein after compressing the gas phase, part of the compressed gas phase forms an anti-surge flow which is directed into the gas phase downstream the gas/liquid separator and upstream the cooler.
11. The method as claimed in claim 1, wherein the cooled injection stream is pumped by a booster or injection pump.
12. The method as claimed in claim 1, wherein the gas phase is compressed in two stages using two compressors.
13. The method as claimed in claim 1, wherein the injection stream comprises 85 to 95 mole % CO.sub.2.
14. The method as claimed in claim 1, wherein the liquid phase is transported to an oil processing facility.
15. An enhanced oil recovery system, comprising: a producer arranged to produce a well stream from a reservoir; a first gas/liquid separator arranged to separate the well stream into a liquid phase and a gas phase comprising both CO.sub.2 gas and hydrocarbon gas; a first cooler arranged to cool the gas phase; a first compressor arranged to compress the gas phase into a compressed stream; a mixer arranged to mix the compressed stream with an external source of CO.sub.2 to form an injection stream; a second cooler downstream of the mixer to cool the injection stream; and injection piping arranged to inject the injection stream into the reservoir.
16. The system as claimed in claim 15, wherein the first cooler is arranged upstream of the first compressor to cool the gas phase prior to compression.
17. The system as claimed in claim 15, wherein the first cooler is an active cooler.
18. The system as claimed in claim 15, further comprising a choke arranged upstream the first gas/liquid separator to choke the well stream to a pre-defined pressure.
19. The system as claimed in claim 15, further comprising a heat exchanger arranged upstream the first gas/liquid separator to heat the well stream.
20. The system as claimed in claim 15, wherein the system is located subsea; or wherein the first gas/liquid separator, first cooler and first compressor is located above sea level; or wherein the first gas/liquid separator is located subsea whilst the first cooler and first compressor are located above the sea.
21. The system as claimed in claim 15, further comprising a recycle line connecting between downstream the first compressor and either upstream the gas/liquid separator or downstream the gas/liquid separator, the recycle line being arranged to recycle part of the compressed gas phase into either the well stream upstream the gas/liquid separator, or the gas phase downstream the gas/liquid separator.
22. The system as claimed in claim 15, further comprising an anti-surge line connecting between downstream the first compressor and a point downstream the gas/liquid separator and upstream the first cooler, the anti-surge line being arranged to provide an anti-surge flow of compressed gas phase into the gas phase downstream the gas/liquid separator and upstream the first cooler.
23. The system as claimed in claim 15, further comprising a booster pump or injection pump arranged downstream the second cooler to pump the injection stream.
24. The system as claimed in claim 15, further comprising corrosion-resistant piping arranged to transport the liquid phase to an oil processing facility.
25. A method used in Enhanced Oil Recovery (EOR) from an oil reservoir by CO.sub.2 flooding, comprising: producing a well stream from the reservoir; separating the well stream into a liquid phase and a gas phase with a gas/liquid separator; compressing the gas phase using a compressor; injecting a first part of the compressed gas phase into the reservoir; and recycling a second part of the compressed gas phase into the well stream upstream the gas/liquid separator so as to provide stable conditions for operation of the separator in the presence of a dynamic well stream gas flow rate.
Description
(1) Preferred embodiments of the present invention will now be described by way of example only and with reference to the accompanying drawings, in which:
(2)
(3)
(4)
(5)
(6)
(7) It will be noted that the described embodiments relate to offshore CO.sub.2 EOR processes, however the skilled person will appreciate that the embodiments may equally be employed in onshore fields.
(8)
(9) If CO.sub.2 breakthrough has occurred, i.e. CO.sub.2 gas is now being back-produced, then the well stream, numbered 4b, is directed to subsea process unit 8. This may be considered as a second phase of operation. Embodiments of this process unit will be described later with reference to
(10)
(11)
(12) If CO.sub.2 breakthrough has occurred, i.e. CO.sub.2 gas is now being back-produced, then the well stream, numbered 4b, is directed to gas/liquid separator 16, which separates the well stream 4b into a liquid phase 9 comprising oil and water and a gas phase 18 comprising CO.sub.2 and hydrocarbon gas and dissolved water.
(13) The liquid phase 9 is directed to the oil processing facility 17. The gas phase 18 is supplied to a topside process unit 19 above the surface, for example on a platform or a floater. This topside process unit 19 carries out various further process steps, resulting in a gas phase 11 comprising CO.sub.2 and hydrocarbon gas which is mixed with imported CO.sub.2 12 from an external source, to form injection stream 13. Further process steps are carried out on this stream 13 (not shown) and it is then provided via injection well-head 14 to injection piping/injector 15, which injects the stream 13 into the reservoir 2.
(14) As with
(15) Optionally, in the embodiment of
(16)
(17) In the system of
(18) If, as is likely, the pressure of the external CO.sub.2 source is not sufficient for direct injection into the reservoir, a booster pump 36 is provided to increase the pressure prior to injection. The booster pump 36 delivers sufficient pressure to inject the CO.sub.2 into the reservoir. The pressure required will depend on the pressure in the reservoir at the injection point, the necessary excess pressure to drive the CO.sub.2 into the reservoir, the static pressure increase from the injection template to the injection point, and the frictional pressure drop in the injection pipe.
(19)
(20) Once CO.sub.2 breakthrough has occurred, i.e. CO.sub.2 gas is now being back-produced, then the well stream 4 is directed to various process equipment which together form a “subsea process unit” 8. The point at which the well stream 4 should be directed to the subsea process unit 8 may be determined based on the composition of the well stream. For example, a certain gas composition, particularly a certain CO.sub.2/methane ratio may be expected once CO.sub.2 breakthrough has occurred. In this initial phase after CO.sub.2 breakthrough, the methane content in the gas will be high and the CO.sub.2 content low. Also, the total gas flow will be low, compared with later life.
(21) First, the well stream 4 is choked by choke 25 to a pre-defined pressure, and is then directed to gas/liquid separator 16. The selection of the pressure level provided by the choke 25 will decide the partial pressure/content of CO.sub.2 in the gas-phase and the CO.sub.2 content in the liquid phase produced by the gas/liquid separator 16. A lower pressure will reduce the CO.sub.2 content in the liquid. The separation pressure will also influence the compressor requirements (compressor 30, discussed later) and the power required for the gas to be injected, and will decide if the liquid phase 9 sent to the oil processing facility needs to be pressure boosted or not. If pressure boosting is required, a pump will be provided for liquid phase 9 (not shown in
(22) Moreover, the separation pressure will determine whether carbon steel can be used in the piping downstream the separator 16 (i.e. the piping connecting with the oil processing facility) or whether corrosion resistant materials are required. The higher the pressure, the more CO.sub.2 there will be in the liquid phase 9. Due to the corrosive effect of CO.sub.2, if the CO.sub.2 in the liquid phase 9 is too high, some pipeline materials such as carbon steel will suffer from corrosion to an unacceptable extent. Thus, at higher pressures, the larger amounts of CO.sub.2 in the liquid phase 9 requires the downstream piping to be manufactured from corrosion resistant material, such as stainless steel. In the embodiment of
(23) However, in another embodiment, the separation pressure could be lowered to a level where corrosion resistant materials are not necessary, and thus the downstream piping could be made of carbon steel. A pump would then be required to increase the pressure of the liquid phase 9 after leaving the separator. Such embodiments are described later with reference to
(24) Corrosion-resistant materials will always be required in the EOR process facility (i.e. the whole system of
(25) Continuing the discussion of
(26) In
(27) The well stream gas flow rate after CO.sub.2 breakthrough will be highly dynamic (mainly increasing) especially in the first period of operation, before a more stable situation is reached. To give an example, if the operational time for the CO.sub.2 EOR facility is 10 years after CO.sub.2 breakthrough, the largest dynamics would happen in the first 1 to 2 years. To handle this dynamic situation, a compressor recycle is provided. As can be seen, a recycle flow 32 from downstream the compressor 30 is directed into the well stream 4 upstream the gas liquid separator 16. This provides more stable conditions for the separator operation, as it allows the separator to operate within narrower gas and liquid load ranges during the lifetime of the oil reservoir 2, which simplifies the operation and control of the separator. Alternatively, the compressor recycle flow 32 can be mixed into the gas 26 downstream the gas/liquid separator 16.
(28) To protect the compressor against surge, an anti-surge line 31 is also provided. Gas from downstream the compressor 30 is directed into the separated gas 26 upstream from the cooler 27. Alternatively, gas from downstream the compressor 30 may be mixed with the well stream 4 upstream the gas/liquid separator 16. It will be appreciated that in one embodiment, a combined compressor recycle and anti-surge line may be provided.
(29) Downstream the compressor 30, the gas phase 11 is mixed at mixer 33 with CO.sub.2 12 from an external supply. The pressure of the external CO.sub.2 and the compressed gas phase 11 needs to be balanced. In a first phase after CO.sub.2 breakthrough, the gas flow 11 from the compressor will be low and contain high concentrations of methane. This gas needs to be condensed prior to injection into the reservoir 2. However, a very high pressure from the compressor would be required for condensation by sea-water alone, and there would be a high risk of hydrate formation. However, by mixing the gas 11 with the external CO.sub.2 12, the gas 11 will condense/dissolve in the external CO.sub.2 during the mixing process or in subsequent cooling by cooler 34. Thus, the compression requirement is lower.
(30) The process temperatures are controlled by both sea-water coolers 34, 27 to avoid hydrate formation. It is desirable to reach a lower temperature after the mixing and cooling, to increase the density of the fluid, preferably liquid, leaving the cooler 34, but at the same time stay above the hydrate formation temperature. Therefore, the cooler 34 is preferably an active cooler, with sea water circulation by a sea water pump 35. In an alternative embodiment, the gas 11 is cooled prior to (rather than after) being mixed with the external CO.sub.2 12.
(31) The pressure of the fluid leaving the cooler 34 is increased by booster pump 36, then the resulting fluid 13′ comprising a high proportion of CO.sub.2 is injected into the reservoir 2 via injection well head 14 and injection piping 15, yielding enhanced oil recovery. Typically, the proportion of CO.sub.2 in the injection fluid 13′ will be between 85-95 mole % of the total fluid (though this will be case specific). The CO.sub.2 is ultimately back-produced via production tubing 3 and recycled through the process again.
(32) After some time, the gas flow rate from the reservoir 2 will stabilise and contain more and more CO.sub.2, up to 80-90 mole % or more. When the gas flow rate increases, the required amount of external CO.sub.2 12 reduces.
(33) Whilst in the embodiment of
(34) Example process data for an implementation of the embodiment of
(35) It will be appreciated that these values are approximate, and are for one particular example only.
(36)
(37) Gas/liquid separator 16, as in
(38) The liquid phase 45 will still be corrosive to some extent though, as some CO.sub.2 will still be dissolved in it, so a corrosion control method such as the injection of a film forming corrosion inhibitor may be used to limit the corrosion rate of the pipeline and process equipment.
(39) The gas stream 47 is, if required, cooled by cooler 48, here shown as an active cooler with sea-water circulation by sea water pump 49. However in other embodiments a passive cooler may be used. The pressure is likely to be low enough that hydrates are not an issue, so active cooling may be less essential.
(40) The flow rate of the gas stream 47 from the gas/liquid separator 44 is substantially lower than that of the gas stream 26 from the gas/liquid separator 16. To bring the latter up to the same or similar flow rate/pressure as the former, more than one compressor is required if the required pressure ratio for the compression is too high for one compressor. Thus, the cooled gas stream 51 from the cooler 48 is compressed by compressor 52 to form compressed stream 53, followed by compressor 54 to form further compressed stream 55. If the total pressure ratio is low enough, intermediate cooling between the compressors is not needed, but may be required for higher pressure ratios. The compressors are preferably both liquid tolerant compressors, or at least the compressor 52 should be a liquid tolerant compressor. Optionally, dry gas compressors may be used, and if so then upstream separators/scrubbers will be needed.
(41) The compressors 52 and 53 are smaller than compressor 30, and the power requirement is typically less than 10% of that of the compressor 30. The operational conditions of compressors 52 and 53 will likely be constant enough to avoid the need for compressor recycle, but if not a compressor recycle system similar to shown in
(42) To protect the compressors 52 and 53 against surge, and anti-surge line 56 is provided. Gas from downstream compressor 53 is directed into the separated gas 47 upstream from the cooler 48. Alternatively, gas from downstream the compressor 53 may be mixed with the liquid phase 43 upstream the gas/liquid separator 44.
(43) In other embodiments, more than two compressors may be necessary.
(44) The compressed gas 55 is mixed into separated gas stream 26, to form combined gas stream 56. This is then processed in the same way as in gas stream 26 in
(45)
(46) In this embodiment, the gas stream 47 is directed to ejector 48. Ejector 48 is powered by motive gas flow 49 from downstream the compressor 30. The ejector utilises this high pressure gas flow 49 to increase the pressure of stream 47. This significantly simplifies the system, and may also remove the need for any intermediate cooler. Since the ejector motive gas flow 49 is taken from downstream the compressor 30, this will be ultimately be recycled through the compressor 30, in addition to the compressor recycle flow 32. Thus, more gas might be recycled through the compressor 30 in the embodiment of
(47) In some embodiments, more than one ejector may be used.
(48) Whilst in the embodiments of