|
Producers
In The "Water Business"
Water
Management Options
Downhole
Separation and Disposal
Case
Studies
Table
1
DOWS
System Design Options
Figure
1
Table
2
Figure
2
DGWS
System Design Options
Figure
3
Figure
4
Costs
Current
Activity Related to DOWS
Regulatory
Issues
Downhole
Separation to Play Increasing Role
References
Sidebar
1
Joint Venture Provides Innovative Produced Water Management
Sidebar
Figure
Sidebar
2
Water Recycling and Modified Reverse Osmosis
Sidebar3
High-Water Saturation Dewatering Projects |
Managing Produced Water
by
Karl Lang, Hart Energy Publications Excerpts in PTTC Network News,
4th Quarter 2000
In the mature producing basins of the U.S.,
managing water production is an important part of the oil and gas
business. In the words of one producer, When you realize youre
spending several thousand dollars a week on water, you start thinking
carefully about alternatives. Some of these alternatives have included
new technologies for handling produced water or for reducing the amount
produced. As with any new technology, the challenge for the smaller
producer is to take advantage of cost-saving benefits as early as
possible, without becoming a major contributor to the learning curve
investment. This is particularly true in the case of water management,
because one of the most promising new technologies, downhole separation,
can require a significant capital investment on the strength of what to
date has been mixed performance results. This article looks at the current
state of a number of new technologies for produced water management, and
focuses on downhole separation in particular.
In
1995, US domestic hydrocarbon production totaled 2.4 billion barrels of
oil and 19.5 Tcf of gas. In order to reach that total however, it was
necessary to simultaneously produce nearly 18 billion barrels of water (Petrusak,
2000). Thats enough water to cover the state of Wyoming with a little
less than ½ an inch (or, if you prefer, Washington DC to a depth of 53
feet). More than 92% of this water was re-injected, with 71% used for EOR
and 21% disposed of in Class II injection wells. Only about 3% of the
water volume produced in 1995 was discharged to the surface under NPDES
permits, and almost all of that was related to coalbed methane production.
Another 2% was put to beneficial use (irrigation, livestock, etc.).
Although the number of producing oil wells has declined over the past five
years, the general trend of increasing water production with increasing
field maturity practically guarantees that total annual water production
is comparably high today.
The
cost of lifting, separating, handling and disposing of this water is
substantial. While U.S. water hauling costs generally average about
$1/barrel, the fully burdened cost of water disposal, including capital
and operating expenses, has been estimated at between $1.30 and
$2.00/barrel, depending on volume (GTI, 1999). Adding in permitting and
other legal costs boosts the total industry burden to the tens of
billions. This burden is disproportionately borne by the independent
producer, who is more likely to be the operator of older, higher water cut
wells.
Approaches
to this problem vary. Some companies are very reactive, some are more
proactive and some see the problem as an opportunity, says Jon Rudolph,
Manager of Produced Water Management for Gas Technology Institutes
E&P Services. GTI interviewed 35 operators in Texas, Louisiana and
Colorado to learn how they managed produced water and came up with some
interesting insights. Many companies dont recognize or account for
the full cost of water management, says Rudolph. Companies are
organized functionally in ways that tend to compartmentalize the
permitting costs from, say, the chemical costs or the hauling costs.
Waters role and impact can be significantly underestimated. If you look
at water management in a holistic way and recognize its importance from
the initial estimate of a prospects recoverable reserves right through
to the valuation of an asset for divestiture, you can make decisions that
will improve your overall economics.
This
approach can result in something as simple as recognizing the need to
drill a well a hundred feet deeper to allow for future injection into a
water zone via a downhole separation and disposal system. A truly
integrated approach to water management matches the best technology value
to life-cycle needs, adds Rudolph. Some independent operators see
this as their strength. They are water management experts and sell that
expertise to larger companies that are focused more on exploration than
reducing the costs of production.
The primary technologies available for dealing with
produced water generally fall into one of three categories, any
combination of which may be employed in a given field:
1.
Conformance
control measures.
These are modifications to well completions or production patterns
designed to reduce the volume of water produced from the formation.
2.
Conventional
disposal methods.
Surface handling and disposal of separated, produced water, either into
injectors for enhanced recovery, into disposal wells, through surface
discharge, or through beneficial uses (e.g., irrigation).
3.
Downhole
oil/water or gas/water separation and disposal methods. Subsurface equipment that separates the
hydrocarbon and water phases, disposes of the water into a non-productive
zone, and produces the relatively water-free hydrocarbon to the surface.
Most operators rely on a combination of technologies
from categories one and two. A number of new options have been proposed
for reducing the costs or increasing the efficiency of surface water
treatment and disposal processes (e.g., see sidebar on Crystal Solutions,
LLC). Some researchers are looking at ways to utilize produced water as a
replacement for fresh water in remote, dry areas (e.g., see sidebar on
recycling modules and modified reverse osmosis). For the most part,
operators continue to rely on conventional disposal solutions and focus on
finding ways to reduce the cost of those operations as much as possible.
However, over the past several years the third category, downhole
separation and disposal, has seen an increased number of installations and
attention.
Downhole oil/water separators (DOWS) and downhole
gas/water separators (DGWS) are devices that separate hydrocarbons from
water at the bottom of a well. A significant portion of the separated
water is reinjected into a non-productive interval, while the oil, gas and
remaining water are produced to the surface.
Reducing the volume of water that must be produced,
handled at the surface, and reinjected, has a number of benefits:
1.
Reduced facility investment costs If water volumes do not
increase over the life of the field, facility and piping expansions to
avoid constraining oil production will not be necessary. Expensive
disposal systems will not be needed.
2.
Reduced chemical costs Increased water production results in
increased treating chemical consumption (scale inhibitors, corrosion
inhibitors, emulsion breakers, etc.).
3.
Reduced power consumption Depending on the type of lifting
system in place in a field and the type of DOWS or DGWS selected, the
power requirement to separate and reinject downhole can be significantly
less than that required to lift the fluids to the surface and reinject the
water.
4.
Increased oil or gas production This can result if surface
facilities are constrained by water volume and wells are not producing at
their optimum drawdown, or if producible wells are lost to water
injection. Also, by reducing the operating costs, the economic limit of a
field can be extended, increasing the ultimate recovery.
5.
Reduced environmental risk Reduced risk of surface spills and
reduced risks of potable water formation contamination during reinjection.
Offsetting these benefits are two important
issues: the equipment is expensive to purchase and install, and its
performance appears to be dependent on a number of key well and fluid
characteristics. In other words, downhole separation and disposal may not
be cost-effective for all high-water cut wells.
Two
independent studies published in 1999 looked at the performance of DOWS
and DGWS installations. The first, undertaken by Argonne National
Laboratory, CH2M-Hill and the Nebraska Oil & Gas Commission and funded
by the U.S. Department of Energy, looked at data from 37 DOWS
installations by 17 operators in the U.S. and Canada (Veil, 1999). The
second, undertaken by Radian International for Gas Research Institute (now
Gas Technology Institute), looked at 53 DGWS installations by 34 operators
in the U.S. and Canada (GTI, 1999). The results of these two analyses
revealed that performance has been mixed (Table 1). Depending on the
definition of success, somewhere between 45% and 65% of the
installations could be considered successful. However, as operators and
equipment vendors gain experience in selecting candidate wells and as
equipment design improvements are made, indications were that the overall
performance of this technology should improve.
Table 1: Results
of Downhole Separation and Disposal Studies
| |
DOWS
(Argonne/DOE) |
DGWS
(Radian/GTI) | |
Cases Reviewed |
37 |
53 | |
Operators Involved |
17 |
34 | |
Location |
10
US
27 Canada |
35 US
18 Canada | |
Type of Installation |
21
Hydrocyclone
16 Gravity |
32
Modified Plunger
17 Bypass Toll
4 ESP | |
Performance |
19
Oil increase
12 Oil decrease
6 No change or undefined
27 Decrease in water to surface |
29
Gas increase
13 Gas decrease
11 No change or undefined | |
Reasons for Failure |
·
Low injectivity in disposal zone
·
Insufficient zone
isolation (recycling)
·
Plugging due to sand or fines
·
Corrosion or scaling
|
·
Low injectivity in disposal zone
·
Insufficient zone
isolation (recycling)
·
Poor wellbore integrity (includes sand production)
|
Two
basic types of DOWS systems have been developed: hydrocyclone separation
powered by a downhole electric motor or a rod pump, and gravity separation
with production via rod pump (Veil, et
al., 1999). The hydrocyclone DOWS systems can handle up to ten times
the volume of water that can be produced with gravity systems, which have
a limit of about 1000 barrels per day (bpd). A hydrocyclone system (Figure
1), separates oil from water and then uses a pump to inject the water to
disposal and lift the oil to surface. One system offered by Centrilift has
two modes of operation: the pump through system where reservoir
fluids are pumped into the separator, and the pull through system
where the reservoir provides the pressure to enable flow through the
separator and the separated fluid volumes are pumped in their respective
directions. With the push through system, the flow to surface can be more
readily controlled. Production fluid homogeneity is maximized and free gas
is dispersed, compressed and put back into solution. With pull through
systems, emulsions are minimized since there is less shearing of the
produced fluid.
Figure
1: DOWS Hydrocyclone System

Gravity separation systems are manufactured by a
number of rod pump suppliers (Table 2). Separation of oil and water takes
place in the annulus and water is removed from a point below the oil/water
contact. A dual action pumping system (DAPS) employs a rod pump with two
pump assemblies and an injection valve. On the upstroke, water is pulled
into the tubing through the lower inlet valve and oil/water is lifted up
the tubing via the upper pump assembly. On the downstroke, oil/water is
pulled into the upper pump assembly while water is pumped into the
injection zone. A new modification of this system (Figure 2), the
triple-action pumping system (TAPS), adds an additional pump assembly with
a smaller plunger (Wacker, et al, 1999). TAPS permits injection at higher pressure and is a
relatively simple and inexpensive system that relies on only one specialty
piece of equipment.
Table
2: DOWS and DGWS Vendor Information
|
Vendor
|
URL
|
Products
|
Details
|
|
Chriscor
Downhole Tools (Calgary, AB)
|
www.chriscortools.com
|
Downhole
Water Injection Tool (DWIT)
|
Rod
pump or PC pump DGWS systems
|
|
Down
Hole Injection, Inc.
(Tulsa, OK)
|
www.downholeinjectioninc.com
|
Below
Production Zone, Above Prod. Zone, and Dual Annulus Prod. Disposal
Systems
|
Rod
pump DGWS systems
|
|
Centrilift
(part of Baker Hughes)
(Claremore, OK)
|
www.bakerhughes.com
|
Variety
of ESP products (e.g., GasPro)
HydroSep downhole oil/water separator
|
ESPs
for DGWS
DOWS system with hydrocyclone
|
|
Harbison-Fisher
(Crowley, TX)
|
www.hfpumps.com
|
Variety
of pump products
BSN bypass tool
|
Bypass
tool for DGWS
|
|
Burleson
Pump Co.
(Oklahoma City, OK)
|
|
Variety
of pump products
|
|
|
Reda
Pumps (part of Schlumberger, Inc.)
(Houston, TX)
|
www.slb.com
|
Variety
of ESP products
|
|
|
Weatherford
(Houston, TX)
|
www.weatherford.com
|
Variety
of pump products of all types
|
|
|
Petrospec
Engineering, Ltd.
(Sherwood Park, AB)
|
|
Coiled
tubing deployed ESP pumps
|
|
Figure
2: DOWS Triple-Action Pumping System (after Wacker, et al., 1999)
The study carried out for DOE (Veil, et al., 1999) determined that DOWS systems have a higher chance of
success if they are installed in wells with:
·
High water oil ratio and relatively high gravity oil
·
A chemically compatible injection zone isolated from the
producing zone
·
Good mechanical integrity
All of the installations where pre- and
post-installation water production data were available, showed a decrease
in the volume of water brought to the surface. In 22 of 29 trials the
reduction exceeded 75%. The top three gravity separator installations
exhibited increases of between 100% and 235% in oil production. The top
three performing hydrocyclones exhibited increases between 450% and 1160%
in oil production (Veil, et al., 1999).
DGWS systems utilize rod pumps,
electric submersible pumps (ESPs) and progressive cavity pumps (PCPs). All
operate on the fundamental fact that gravity separation of gas and water
occurs in the annulus as formation fluids enter the wellbore. The simplest
DGWS device is a bypass tool in which the bottom end of an insert sucker
rod pump is seated (Figure 3). The pumping action acts to load the tubing
with water from the casing tubing annulus. When the the hydrostatic head
in the tubing is great enough, the water drains into the disposal zone
below the producing perforations and packer. Gas flows up the
tubing-casing annulus.
Figure
3: DGWS Bypass Tool (courtesy of Gas Technology Institute)

A
second type of rod pump operated DOWS system is termed the modified
plunger pump (Figure 4). This system consists of a short section of pipe
with one to five ball-and-seat intake valves and an optional back-pressure
valve, run below a tubing pump in which the traveling valve has been
removed from the plunger. On the upstroke the solid plunger creates a
lower pressure area in the barrel, allowing the ball-and-seat valves to
open and water to enter. On
the downstroke, the plunger moves the fluid down and out of the barrel and
into a disposal zone below the packer.
Figure
4: DGWS Modified Plunger Tool (courtesy Gas Technology Institute)

Electric
submersible pumps are another alternative, and in the case of DGWS they
would be configured as a bottom-discharge system with the pump below the
motor rather than in the conventional motor-on-bottom design. ESPs provide
for very high disposal rates and are generally more economic in deeper
wells. Another alternative is a rod string powered progressive cavity
pump.
An
economic comparison of various DGWS technologies with conventional water
separation facilities carried out by GTI, showed that the selection of an
appropriate DGWS tool is primarily a function of water flow rate and well
depth (GTI, 1999). For water production rates less than 50 bpd,
conventional surface disposal is most cost effective. Bypass tool systems
are more cost effective in the 25-250 bpd range, up to a maximum depth of
about 8000 feet. A modified plunger system was shown to be most cost
effective for 250-800 bpd over about the same depth range. For high water
rates (>800 bpd) and at depths below 6,000 feet, ESP systems are
typically more cost effective. Of course, these rules-of-thumb must be
considered approximate.
The
GTI study also determined that a DGWS system stands the best chance of
success when it is installed in a well with:
·
Well
cemented casing
·
Minimal
sand production
·
Soft water (little scaling)
·
Water
production of at least 25-50 bpd
·
Disposal
costs greater than $25-$50/day
·
A
low pressure, high injectivity disposal zone below the producing interval
While these criteria are somewhat restrictive, quite a few gas wells
could be considered viable candidates, particularly if the potential for
an eventual DGWS installation is considered prior to completion. (Note:
The GTI report (GRI-99/0218), which is available on CD and includes an
interactive economic model to facilitate evaluation of candidate wells, is
available from GTI at
www.gastechnology.org/).
A
hydrocyclone DOWS system can cost between $90,000 and $250,000, excluding
the cost of a workover to install the equipment, which can add another
$100,000 or more. Hydrocyclone DOWS systems are from two to three times
the cost of a comparable conventional ESP. Gravity separation DOWS systems
are considerably less expensive, and range between $15,000 and $25,000,
plus the cost of an installation workover. (Veil, et
al.,1999). Obviously, any work required to prepare an appropriate
disposal zone can add significantly to the cost.
The
cost of a DGWS system can be less, depending on the system. For example, a
bypass tool runs about $1,200 to $3000 and a modified plunger rod pump
about $4,400, excluding installation. An ESP for a DGWS system runs
between $10,000 and $30,000, excluding additional equipment and
installation (GTI, 1999). These numbers are rough approximations based on
typical operating specifications, but they give some idea of the relative
costs of these technologies.
A number of new DOWS installations have been
carried out since the Argonne/DOE study was completed. One new DOWS system
has been installed by Marathon in Wyoming, Phillips Petroleum has
completed the first offshore installation in the China Sea, and two new
installations have been completed by Astra in Argentina, according to
Bruce Langhus, one of the authors of the DOE report. The US DOE
feasibility project is continuing with three new field trials operated by
Texaco, UNOCAL, and Avalon Exploration. The Texaco and UNOCAL wells have
ceased operations while the DOWS equipment in the Avalon well is expected
to be installed during the first quarter of 2001.
The Texaco well employed the first TAPS system (Wacker,
et al, 1999), a beam-pump
powered gravity separation system designed to operate at high injection
pressures. The UNOCAL well project, the first hydrocyclone equipped DOWS
installation in the East Texas area, has finished the data-gathering phase
and the well has had its DOWS equipment removed. As has been the case
with many DOWS installations, the technical and economic success of this
installation was mixed, said Langhus. A report on the results of that
work is expected to be completed next year.
The Avalon well, located just north of Oklahoma
City, is expected to be the first DOWS test in an oil field dewatering
project. Recently, some operators have found that under certain
circumstances it can be profitable to pump large volumes of water from
watered out wells, if the reservoirs dual porosity system allows
unrecovered oil to drain into a fracture system that is drawn down by the
removal of water (see sidebar). This has only been feasible in fields
with an existing water disposal infrastructure, adds Langhus. The
possibility of economically dewatering wells in fields without that
infrastructure, using an electrical submersible pump DOWS system, is what
this test is designed to investigate.
Langhus conducted the first PTTC-sponsored DOWS workshop held in Lansing,
Michigan in July, 2000. More of these 8-hour workshops are planned as
industry interest picks up.
Prior to January 2000 the state regulatory
community had not yet come to a general agreement on how to classify DOWS
and DGWS installations that simultaneously inject and produce. Some states
had chosen to classify DGWS wells as Class II injection wells or regulate
them as such (Texas, California, Colorado, Oklahoma). Four states had
chosen to regulate DOWS wells with requirements similar to regular Class
II injection wells (Texas, Oklahoma, Louisiana, and Colorado). Other
states had not yet decided how to deal with the problem.
Responding to requests from UIC offices in several
regions, the U.S. Environmental Protection Agency issued guidance on the
issue of wells with downhole separators on January 5, 2000. The EPA
classified them as Class II enhanced recovery wells. This determination
was based on the fact that fluid was injected and production of
hydrocarbons was enhanced. Both DGWS and DOWS installations were included
in this definition. Under the UIC program, a permit must be obtained from
the appropriate state or federal agency prior to installation of equipment
that would cause a well to be classified as a Class II enhanced recovery
well. In most cases the states have primacy in establishing standards.
The convergence of two trends will most likely
ensure that downhole separation and disposal technology sees wider
application in the future: (1) increasing water cuts in older fields and
(2) greater economic risks associated with environmental damage. It will
be important, however, to select wells that stand the best chance of
benefiting from downhole separation and disposal technologies.
Petrusak,
R.L.; Freeman, B.D.; Smith, G.E.; 2000. Baseline Characterization of
U.S. Exploration and Production Wastes and Waste Management, SPE paper
63097 presented at the SPE Annual Technical Conference and Exhibition,
Dallas, TX, October 1-4, 2000.
Gas
Technology Information; 1999. Technology Assessment and Economic
Evaluation of Downhole Gas/Water Separation and Disposal Tools,
GRI-99/0218, report prepared for Gas Research Institute by Radian
International, November 1999.
Veil,
J.A., Langhus, B.G., and Belieu, S.; 1999. Feasibility Evaluation of
Downhole Oil/Water Separation (DOWS) Technology, prepared for U.S.
Dept. of Energy, Office of Fossil Energy, NPTO, by Argonne National Lab,
CH2M-Hill, and Nebraska Oil & Gas Conservation Commission, January
1999. (Available online at
http://www.ead.anl.gov/pub/dsp_detail.cfm?PubID=31
Wacker,
H.J.; R.M.Parker; L. Stuebinger, R. Harding; and B. Watson; 1999.
"Test Proves Out Triple-Action Pump in Downhole Separation", Oil
& Gas
Journal, Oct. 4, 1999., pp. 49 - 55.
Doran,
G.F.; Williams, K.L.; Drago, J.A.; Huang, S.S.; and Leong, Y.C.; 1999.
Pilot Study to Convert Field Produced Water to Drinking Water or Reuse
Quality, SPE paper 54110 presented at 1999 SPE International Thermal
Operations and Heavy Oil Symposium, Bakersfield, CA, March 17-19, 1999.
Sidebar 1
Joint Venture Provides Innovative Produced Water Management
After
nearly one year of operation,
Crystal Solutions, LLC, a joint venture of Gas Technology Institute
(formerly Gas Research Institute) and BC Technologies, has plans to expand
its operations in response to a high level of customer interest in the
Rocky Mountain region. The company began accepting water at its first
major commercial treatment facility near Wamsutter, Wyoming late last
year. Freeze-Thaw/Evaporation. FTE®, the companys innovative treatment
process, is a simple and economic solution to year-round treatment of
produced water in regions that experience seasonal sub-freezing
temperatures. The FTE process relies on naturally occurring temperature
swings to alternately freeze and thaw produced water, concentrating the
dissolved solids and creating relatively large volumes of clean water
suitable for various beneficial uses.
The Wamsutter facility, which began operating in December 1999, serves the
Red Desert/Great Divide Basin of Wyoming. Nine independent producers have
contracted with Crystal Solutions to handle their produced water, and the
facility is operating near design capacity. The joint venture also entered
into a contract to operate a McMurry Oil Company-owned facility (now owned
by AEC Oil & Gas USA Inc. following its acquisition of McMurry Oil).
"It's been an exciting first year, says John Harju, GTI Project
Manager and Vice President of Crystal Solutions, LLC. We hope to
continue to expand the operating sphere of Crystal Solutions, ideally
getting two or more new facilities designed and permitted within the next
year and potentially expanding the capacity of the current facility.
Three potential new facilities in Wyoming, one in Utah, and two more in
Colorado are currently at the negotiation stage.
Early evaluations of the process performed in conjunction with Amoco
Production Company (now BP Amoco) in the San Juan Basin in New Mexico, and
a commercial deployment evaluation with McMurry Oil Company in the Green
River Basin in Wyoming, demonstrated significant economic and
environmental benefits from the process. These pilot projects, conducted
by BC Technologies, the University of North Dakota's Energy &
Environmental Research Center, GTI and the Department of Energy (DOE),
showed that concentrating produced brine through FTE cut overall disposal
and/or treatment costs significantly. Such cost savings can help increase
production from marginally economic wells or spur development of new gas
resources.
The principle behind freeze-thaw is based on the fact that salts dissolved
in water lower the freezing point of the solution below 32 degrees F.
Partial freezing occurs when the solution is cooled below 32
degrees F, but held above the depressed freezing point of the solution. In
that range, relatively pure ice crystals form, and an unfrozen brine
solution containing elevated concentrations of the dissolved salts can be
drained away from the ice. When the ice melts, it is essentially pure
water. For example, during the 1999-2000 cycle, field data show that a
feed water with 14,000 mg/l of total dissolved solids (TDS) is converted
to a brine with 64,300 mg/l TDS and a melt water with only 924 mg/l TDS.
Roughly 55% of the feed is converted to melt water, about 30% is lost to
evaporation and/or sublimation, and only about 15% of the original feed
remains as concentrated brine which in this particular case, due to
the brine having a potassium chloride concentration in excess of 2%,
results in a usable product for drilling applications.
The produced water is frozen by spraying onto a lined pond (freezing pad)
when winter temperatures reach the appropriate level (see figure). The
concentrated brine is drained from the pad during the freezing cycle, and
the purified melt water is collected during the thaw cycle.
To learn more about this and other technologies being commercialized by
GTI and its partners, contact John Harju at
jharju@gastechnology.org/
or John Boysen at
john_boysen@hotmail.com/.
FTE
Water Treatment
Facility

Sidebar 2
Water Recycling
and Modified Reverse Osmosis
The
Texas Water Resources Institute (TWRI) is funding a Global Petroleum
Research Institute (GPRI) effort to develop projects directed at the
management of produced water. The first project will be to develop small,
modular units that can be used to produce fresh water from produced water
streams at lease sites. David Burnett, GPRI Director of Technology,
explains that this project is not necessarily trying to provide a new
produced water treatment solution, but to find a way to use produced water
to help solve other problems. There are a number of situations where
relatively small volumes of fresh water are needed at remote sites.
Restoration of overgrazed ranchland is one example. Just one or two
thousand gallons a day from a produced water facility, perhaps just 10% of
the total volume, could be used to restore a two-acre plot of range land
in one-half to one-quarter the time it would take without water, says
Burnett. Portable, remotely operated water treatment modules utilizing
membrane technology might be a way to provide on-site water treatment in
an economic fashion. Marathon Oil Company at the Yates Field in West Texas
has joined the project and will offer an area to be used for wildlife
habitat restoration. One benefit of the program will be to increase the
availability of water resources in regions where their absence currently
limits economic stability and diversity. Ultimately, the technology
developed could reduce the cost of wastewater disposal. Persons interested
in participating in this program may contact David Burnett at
burnett@gpri.org.
Another project being undertaken by the
Petroleum Recovery Research Center (PRRC), a research division of the New
Mexico Institute of Mining and Technology, relates to the use of a
modified reverse osmosis (RO) technology for producing fresh water from a
stream of produced brine. Earlier studies have shown that, while
expensive, RO might be an option for turning produced water into a
drinking water resource under certain circumstances (Doran, et
al., 1999). This work, just recently begun in September 2000, will be
funded in part by DOEs National Petroleum Technology office in Tulsa,
Oklahoma. The technology will employ natural clays to separate produced
water into a fresh water stream and a concentrated brine or solid salt for
disposal. The goal will be to develop a technology that is more economical
and operates at lower pressures than conventional reverse osmosis
desalination equipment.
Sidebar 3
High-Water Saturation Dewatering Projects
A
report in Petroleum Technology Digest in September 2000, described how New
Dominion, LLC of Tulsa, Oklahoma had used electric submersible pumps to
produce 50,000 bwpd from 28 wells in a 4800-acre Hunton limestone field in
Oklahoma. This drawdown resulted in a field-wide oil and gas production
rates that climbed from essentially zero to about 2000 bopd and 14 MMcfd
respectively. Recoverable reserves of 2.2 million barrels and 16.2 Bcf of
high-Btu gas have been developed in what was considered to be a
watered-out field. This required an infrastructure investment of $4
million, not including well costs. About 60% of per well average monthly
operating expense of $6,000 is required for electricity for the pumps.
According
to David Chernicky of New Dominion LLC, "We looked carefully at
downhole separation and found that the degree of separation possible with
existing technology was just not sufficient for our purposes." The
economics of oil reservoir dewatering relies on capturing essentially all
of the relatively small amount of oil produced along with an enormous
volume of water. "Getting close to 100% separation with downhole
equipment wasn't possible," said Chernicky, "So we plan to
continue to use surface separation in our new projects." New Dominion
has plans to duplicate their success in another Oklahoma field where they
have become a significant leaseholder, using the same approach.
Author:
Karl R. Lang is a Director of Hart Publication's Hart/IRI Fuels
Information Services, a part of Chemical Week Associates. He edits GasTIPS,
a technical journal produced by Hart for Gas Technology Institute (GTI),
and contributes to a number of Hart publications. E-mail:
klang@phillips.com.
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