PARSONS Eco-Tec Inc. Bakersfield, California Calgary, Alberta - - PowerPoint PPT Presentation
Stuart M. Heisler, P.E. Michael Dejak, P. Eng. Senior Technical Director VP Business Development PARSONS Eco-Tec Inc. Bakersfield, California Calgary, Alberta Presentation for Canadian Heavy Oil Association Conference, Calgary, November 3,
Stuart M. Heisler, P.E. Michael Dejak, P. Eng. Senior Technical Director VP Business Development PARSONS Eco-Tec Inc. Bakersfield, California Calgary, Alberta
Presentation for Canadian Heavy Oil Association Conference, Calgary, November 3, 2015
The Mommas and the Papas - 1965
Billions of barrels of heavy oil reserves (4.5 API – 13 API in
California
Steam Injection started in 1964 – Billions of barrels of
heavy oil have been produced in 50 years
Operators found that the least expensive method for
generating steam is by using OTSGs with softened water
Current Steam Injection is ~1.5 MM BBL/Day Current EOR production is ~400 M BBL/day Steam-flood SOR ~ 3 - 5 Cyclic Steam Frac SOR ~ 5 - 12
Produced water is almost exclusively used for steam
generator feed-water since the typical production water cut is 90%
Typical Produced Water Quality
5000 – 15,000 ppm TDS 250 – 1500 ppm Hardness as CaCO3 100 – 250 ppm Silica
Usually, all of the vapor and liquid is injected downhole In some cases, only vapor is injected, the liquid is used to
preheat feed-water and then disposed
All of the water used for steam generation is being
softened with SAC/SAC or SAC/WAC softeners – no Lime Softening, no Evaporators
Older Steam Generators are 62.5 MMBTU/HR single pass
running at 65% to 80% Quality
Newer Steam Generators are 85 MMBTU/HR dual pass
running at 65% to 80% Quality
ANSI 900 Generators run 68 BAR, ANSI 1500 run 100 BAR,
ANSI 2500 run at 135 BAR
Steam Gen Emulsion Treating SAC/WAC Filters
IGF
Reservoir Oil 65-80% Steam and water
60,000 BPD
5,000 BPD 69,900 BPD 75,000 BPD Water: 135,000 BPD (21460 M3/D) Oil: 15,000BPD (2385 M3/D)
Reservoir Water
100 BPD
Disposal Wells
(9540M3/D)
(11,924M3/D) (16 M3/D) (795 M3/D) (11,112 M3/D)
Horizontal Nutshell Filters SAC/WAC Softeners
We see very little steam generator fouling – only after
water softening upsets
Steam generators are pigged every 1 – 3 years California Resources Corporation (OXY) reported only 2
steam generators with boiler tube failures in 8 years with a total of 44 Steam Generators
There are no Lime Softeners operating to make soft water
for steam generation in California
Trend is for increased production
from zones with high TDS (6000- 15000 mg/l) and high hardness (500-1200 mg/l as CaCO3)
An advanced filter and softener
design has been introduced and used at 10 sites over the past 5 years
Key benefits realized are:
Salt consumption reduced by 50% compared with traditional systems and elimination of HCl and NaOH for WAC regeneration.
Integrated construction for minimal site work, elimination of chemicals handling
Spectrum Filters Dual Media (Nutshell and Ultra Fine Media) (2 X 30,000 BPD / 4770 M3/D)skids) Integrated packed bed SAC/WAC softeners using brine-only counter-current regeneration (30,000 BPD / 4770 M3/D net skid shown)
Requirement: 60,000 BPD (9540 M3/D) treated produced
water for steam generator feed to replace existing system (traditional SAC and chemically regenerated WAC) for OPEX reduction.
Feed Water:
TDS: 9000-11,000 TDS Hardness: 1100 – 1300 mg/l as CaCO3 Silica: 180 mg/l
Results:
System commissioned 20 months after order placement. Achieved full rated capacity. Treated Water Quality: Hardness < 0.1 mg/l as CaCO3 OPEX:
30% reduction in salt consumption (8,500 MTPY) 100% elimination of HCl and NaOH consumption Reduced operator attention required
CAPEX – OPEX savings justified the system CAPEX to
replace an existing 5 yr old system with a 15% IRR.
Steam Gen Emulsion Treating SAC/ WAC Filters (ORF)
IGF
Reservoir Oil 80% Steam
52,500 BPD 1000 BPD 7350 BPD Water: 45,150 BPD (7178 M3/D) Oil: 15,000 BPD (2385 M3/D)
Reservoir Retention
100 BPD
Hot Lime Softener Filters 20% Blowdown 50% BD Recycle Makeup Water
6865 BPD 15,215 BPD (8347 M3/D) (159 M3/D) (2419 M3/D) (16M3/D) (1090M3/D) (1170 M3/D)
Steam Gen Emulsion Treating SAC Filters (ORF)
IGF
Reservoir Oil 100 % Steam
52,500 BPD 2760 BPD 7350 BPD
Reservoir Retention
100 BPD
Evaporator 5% Blowdown Makeup Water
11,000 BPD 1000 BPD Water: 45,150 BPD (7178 M3/D) Oil: 15,000 BPD (2385 M3/D) (16 M3/D) (1749 M3/D) (159 M3/D) (1168 M3/D) (8347 M3/D) (439 M3/D)
Steam Gen Emulsion Treating SAC/ WAC Filters (ORF)
IGF
Reservoir Oil 80% Steam
52,500 BPD 1000 BPD 7350 BPD Water: 45,150 BPD Oil: 15,000 BPD
Reservoir Retention
100 BPD
Hot Lime Softener Filters 20% Blowdown 50% BD Recycle Makeup Water
6865 BPD 15,215 BPD
Steam Gen Emulsion Treating SAC/ WAC Filters (ORF)
IGF
Reservoir Oil 80% Steam
52,500 BPD 1000 BPD 7350 BPD Water: 45,150 BPD Oil: 15,000 BPD
Reservoir Retention
100 BPD
20% Blowdown 50% BD Recycle Makeup Water
6865 BPD 15,215 BPD
Flash distillate
Steam Gen Emulsion Treating SAC/ WAC Filters (ORF)
IGF
Reservoir Oil 80% Steam
52,500 BPD 1000 BPD 7350 BPD Water: 45,150 BPD Oil: 15,000 BPD
Reservoir Retention
100 BPD
20% Blowdown 50% BD Recycle Makeup Water
6865 BPD 15,215 BPD
Flash distillate
Steam Gen Emulsion Treating SAC/ WAC Filters (ORF)
IGF
Reservoir Oil 90% Steam
52,500 BPD 1000 BPD 7350 BPD Water: 45,150 BPD (7178 M3/D) Oil: 15,000 BPD (2385 M3/D)
Reservoir Retention
100 BPD
10% Blowdown 75% BD Recycle Makeup Water
1460 BPD 9910 BPD
Blowdown Treatment
(1168 M3/D) (8347 M3/D) (232 M3/D) (1576 M3/D) (16 M3/D) (159M3/D)
Use SAC/WAC softeners and OTSGS to make 80-90%
Quality Steam for the least expensive Capex and Opex
Dispose of the SAC/WAC Regen (1-5% of total water) Separate the steam blowdown, preheat the generator
feed-water, then treat the High TDS, High Silica, Low Hardness water in an evaporator.
Dispose of the evaporator blowdown (25% of evaporator
inlet, 5% of total water)
Minimizing evaporator use minimizes total GHG
emissions
CAPEX reduction
TIC CAPEX estimate* for 60,000 BPD (9540 M3/day) boiler feed water capacity systems (CDN $ millions)
Evaporator HLS/SAC/WAC SAC/WAC 50-70 26-30 14-16
* All systems include skim tank, DGF, ORF
CAPEX reduction OPEX reduction
Compared with HLS/IX expected to be in the range of $500K to
$3000K/yr for 60,000 BPD (9540 M3/day) depending on water chemistry, balance, waste considerations
Operability
less equipment = simpler system =easier to operate
Directive 81 compliance – can be achieved Waste disposal – various configurations possible to optimize
depending on disposal options
GHG emissions – to be determined but less than evaporation
and expected to be less than HLS/IX
Silica = SiO2
Calcium Silicate = Ca2SiO4 Magnesium Silicate = Mg2SiO4 Iron Silicate = Fe2SiO4
Keep treated water hardness consistently low to eliminate formation of
silicates (ideally < 0.1 mg/l as CaCO3)
This is supported in theory – scale prediction simulations (e.g. OLI)
consistently predict very little scale formation even with high (i.e. 300 mg/l Si) when multivalent cations (i.e. hardness) are low
Without a lime softener, there is never any “release” of fine silicate particles
that can pass through to the OTSG or that can foul and impede ion exchange softener performance
Application of lessons learned from the California experience
ZLS “zero lime softening” Advanced water treatment systems
Stuart M. Heisler, P.E. Michael Dejak, P.Eng. PARSONS Eco-Tec Inc. Stuart.Heisler@Parsons.com mdejak@eco-tec.com