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TRANSCRIPT
Problem Solving :Water Flood for Oil Production
GROUP 11
ALIF NUZULUL HIDAYAT (1206249832)DIDIK SUDARSONO (1206242555)ENI MULYATININGSIH (1206201971)RAHGANDA (1206261182)SYLVIA AMANDA S (1206241230)
OUTLINE
INTRODUCTION (Background, Project Objective, Plant Condition, Basic Theory)
PROCESS SYNTHESIS(Alternative Process, Process Selection, Process Description, BFD, PFD)
MASS AND ENERGY BALANCE (Mass Balance, Energy Balance, Simulation)
INTRODUCTION - BACKGROUND
• Reservoir pressure in Kerisi has started to decline Enhanced Oil Recovery (EOR) will be conducted to lift the remaining oil in the well.
• Based on studies by ConocoPhillips, EOR method chosen for Kerisi field is waterflood.
• Waterflood will be done by injecting seawater taken from well K-14 to K-13 well.
• Oil and gas reservoir that will be injected by seawater contains no H2S gas
• Waterflood by injecting seawater into the formation will lower the temperature of the reservoir to a temperature level that is conducive to the SRB activity
INTRODUCTION - BACKGROUND
• Two methods of seawater pre-treatment to be considered today are sulphate removal membrane and nitrate injection.
• The selection is not only based on its ability to reduce H2S in the product, but also considering the limited space available on the platform and also the cost required to install the pre-treatment facility.
INTRODUCTION – PROJECT OBJECTIVE
• To make a preliminary design of a seawater treatment plant to meet the specifications of seawater injected into the well K-13 in order to perform the waterflood to reservoir.
• To choose the most appropriate method to avoid the formation of H2S by SRB which are the main problem that can occur due to the waterflood
• To estimate the cost required to install the process facilities which are needed for seawater treatment
INTRODUCTION – PLANT CONDITION
INTRODUCTION – PLANT CONDITION
INTRODUCTION – PLANT CONDITIONComponent Concentration in raw seawater
K1+, mg/l 293
Na1+, mg/l 10493
Mg2+, mg/l 1150
Ca2+, mg/l 351.1
Cl1-, mg/l 18387
SO42-, mg/l 2671
HCO31-, mg/l 93
TDS, mg/l 33458
pH 8.3
TSS, mg/l 15-20
Temp., °C 20
Oxygen, mg/l 5-8
INTRODUCTION – BASIC THEORY
INTRODUCTION – BASIC THEORY
INTRODUCTION – BASIC THEORY
Mechanism of Sulfate Reducing Bacteria (SRB)
Dissimilatory sulfate reduction occurs in three steps:• Conversion (activation) of sulfate
to Adenosine 5’-phosphosulfate (APS)
• Reduction of APS to sulfite• Reduction of sulfite to sulfide
PROCESS SYNTHESIS
Basic Mechanism
Alternative Process : • Sulfate Removal Membrane • Nitrate Injection
PROCESS SYNTHESIS - SULFATE REMOVAL MEMBRANE
• Objective: reduce sulphate as main food supply for SRB
PROCESS SYNTHESIS - SULFATE REMOVAL MEMBRANE
• The process for removing sulfate ions from seawater is based on nano-filtration (NF) membrane separation.
• NF is a membrane process that selectively removes sulfate ions to produce seawater with low concentration sulphate (20-40 ppm).
PROCESS SYNTHESIS - SULFATE REMOVAL MEMBRANE
Advantages Disadvantages
• High quality injection ion sulphate from water
• Reduction in need for biocides
• Reduction of scaling
• More effective squeeze treatments
• Assists control of bacterial (sulphate reducing bacteria) well souring
• Lower operating costs and increases productivity
• Degrade very quickly upon exposure to free chlorine
• Use of DBNPA or equivalent biocide be considered to prevent biological fouling.
• Must add anti-scale to prevent calcium scaling. • Need high CAPEX to buy the sulphate
removal membrane. • < 40 mg/L ion sulphate CAPEX is
$20MM USD • < 30 mg/L ion sulphate incremental
CAPEX $103,000 USD; need higher spec membrane.
PROCESS SYNTHESIS – NITRATE INJECTION
Facilities Process
1. Added NaOCl in order
2. Passing through course filter (range 50 - 2000 μm.
3. Passing through Multimedia filter (<40 micron)
4. Oxygen Scavenger or de-aeration
5. Injection of chemical compounds:• Nitrate • Biocide • Corrosion inhibitor
• Objective : bio-competition, to reduce food supply for SRB
PROCESS SYNTHESIS – NITRATE INJECTION
Advantages Disadvantages
• Cheap nitrate price, around 30 US Dollar per ton to get 45% of Ca(NO3)2.
• Can clean soured reservoir with gradually injection up to 100 ppm nitrate ion to facilities.
• Simple usage,
• Safe to use, not caused damage to environment and potential for microbial EOR.
• Water treatment facilities need to be constructed with non-iron material.
• Reservoir performance can be lower as there is permeability reduction to bacterial colonies in critical flow passages.
• There are no significant dosage of nitrate for injection and also every well will has different dosage depend on condition
PROCESS SYNTHESIS – PROCESS SELECTION
Rating
Criteria Performance
to Prevent H2S Production
Space Required
Corrosion Effect to Sub-
Surface Facilities
Easy to Operate Investment Cost
Environment Effect
Weight
(%)30 25 15 10 15 5
1More than 600
ppm H2S concentration in
10 year
Require very large spacing ( > 4000 m2),
so must require expansion platform
Contain corrodent (O2, acid, bacteria) and electrolyte
with high concentration
Cannot operate automatic, always
change parameter of composition in
chemical injection and often
maintenance
More than $40 million
Very dangerous for environment,
chemical injection is
strongly hazardous
and explosive
2600 ppm-300
ppm H2S concentration in
10 year
Require large spacing (4000 -
3000 m2), so must require
expansion platform
Contain corrodent (O2, acid, bacteria)
with low concentration and electrolyte
with high concentration
Cannot operate automatic, sometime change parameter of
composition in chemical injection
and often maintenance
$40 million - $30
million
Dangerous for environment,
chemical injection is
strongly hazardous
3300 ppm -100
ppm H2S concentration in
10 year
Require middle spacing (3000-2000 m2), so must require
expansion platform
Contain corrodent (O2, acid, bacteria) and electrolyte
with low concentration
Cannot operate automatic, sometime change parameter of
composition in chemical injection
and seldom maintenance
$30 million - $20
million
Less dangerous for environment,
chemical injection is bit
hazardous
PROCESS SYNTHESIS – PROCESS SELECTION
Rating
Criteria Performance
to Prevent H2S Production
Space Required
Corrosion Effect to Sub-
Surface Facilities
Easy to Operate Investment Cost
Environment Effect
Weight
(%)30 25 15 10 15 5
4100 ppm -50 ppm H2S concentration
in 10 year
Require narrow spacing (2000-1000 m2), not
require expansion platform
Not contain corrodent (O2, acid, bacteria),
but contain electrolyte
Can operate automatic, sometime change parameter of
composition in chemical injection and seldom maintenance
$20 milion - $10 milion
No-negative environmental
. chemical injection is less
hazardous
5Less than 50 ppm H2S concentration
in 10 year
Require very narrow spacing (< 1000 m2), not
require expansion platform
Not contain corrodent (O2, acid, bacteria)
and electrolyte
Can operate automatic, seldom
change parameter of composition in
chemical injection and seldom maintenance
Less than $10 milion
No-negative environmental
. chemical injection is not
hazardous
PROCESS SYNTHESIS – PROCESS SELECTION
Parameter Weight (%)
Sulphate Removal
Membran
Weight Score
Nitrate Injection
Weight Score
Performance to prevent H2Sproduction
30 5 1.5 4 1.2
Space required 25 2 0.5 4 1Prevent corrosion on sub-surfaceFacilities 15 4 0.6 2 0.3
Investment Cost 15 2 0.3 4 0.6
Ease to Operate 10 2 0.2 4 0.4Environment Effect 5 4 0.2 5 0.25
Total 100 3.3 3.75
PROCESS SYNTHESIS - BLOCK FLOW DIAGRAM
Figure 2.17. Vacuum Stripping De-aeration
PROCESS SYNTHESIS - PROCESS DESCRIPTION
Capacity waterflood : 50.000 barrel or 339000 kg/h
Capacity seawater : 741000 kg/h
Waterflood Characteristic
PROCESS SYNTHESIS - PROCESS DESCRIPTION
1. Pre-Primary Filtration
• Basin is a reservoir of seawater to be pumped.
• Basin serves to prevent floating dirt is not carried into seawater lift pump.
• A deeper intake is aim to get sea-water that contain low TSS, low oxygen, low temperature and consistent water quality
• In basin, seawater is injected sodium hypochlorite () that is produced in hypochlorite generator.
Figure 2. 8. Basin Structure for Pre-Primary Filtration
PROCESS SYNTHESIS - PROCESS DESCRIPTION
1. Pre-Primary Filtration
• Raw material : Seawater
• Process : Electrolysis (In Situ)Anode : Cathode : Overall :
Figure 2. 9. Hypochlorite Generator
PROCESS SYNTHESIS - PROCESS DESCRIPTION
2. Primary Solid Removal
• Remove suspended solid (> 100 µm) with 98% efficiency.
• Type : Dead End Filtration • Flow capacity up to 2270 GPM (619 m3/h)• If pressure drop is high, flush process start
to clean the solid that is restrained.
• Flush process can operate automatic.
Raw Water Inlet Filtered Water Outlet
Sludge Outlet
Figure 2.10. Coarse Strainer Unit
PROCESS SYNTHESIS - PROCESS DESCRIPTION
3. Secondary Solid Removal
• Remove suspended solid (> 2 µm) with 98% efficiency. (high turbidity in seawater)
• Type : Granular Filtration • Flow capacity up to 425 m3/h• Backwash : Clean the bed, High pressure
drop• The ideal backwash rate is 250-450 m3/h.
Figure 2.11. Multi Media Unit
Raw Water Inlet
Filtered Water Outlet
Sludge Outlet
Backwash Inlet
AnthraciteFine Garnet
Coarse Garnet
PROCESS SYNTHESIS - PROCESS DESCRIPTION
4. De-aeration• Remove oxygen in seawater (< 50 ppb) • Type : Vacuum Stripping De-aeration • Equipment : De-oxygenation tower, Ejector,
Vacuum Pump, Separator. • Principle : o Partial pressure of oxygen in water is a
function of the total pressure of the system.o Vacuum the system can reduce the partial
pressure of oxygen and make driving force for mass transfer of oxygen from the liquid to the gas phase.
Figure 2.17. Vacuum Stripping De-aeration
PROCESS SYNTHESIS - PROCESS DESCRIPTION
6. Chemical Injection PackageChemical Dosage Treatment Application Injection Point
Scale Inhibitor 20 ppm First, 200.000 bbls of water injection
Inhibits CaCO3 scale Discharge seawater lift pump
Calcium Nitrate 100 ppm Continuous Microbial control by bio-competition
Suction of water injection pump
Biocide THPS 200 ppm Batch, Once a week for 4 hours
Microbial control Suction of water injection pump
Oxygen Scavenger 10 ppm Continuous, Reduce oxygen to low concentration
Exit of de-aerator
Corrosion Inhibitor 30 ppm Continuous, To prevent corrosion in subsurface facilities
Suction of water injection pump
PROCESS SYNTHESIS - PROCESS FLOW DIAGRAM
PROCESS SYNTHESIS - PROCESS FLOW DIAGRAMStreams
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17Mass Flow Rate (kg/h) 741,523 741,498 88,979 24.22 339,309 339,308 33,058 33,060 339,305 2.66 339,305 4.79 40.48 1.79 32.41 339,384 339,384
Pressure (bar) 7.10 7.01 7.01 7 7.01 7.01 1.01 1.01 7.10 7.10 17.01 1.01 1.01 1.01 1.01 1.01 125.01Temperature (C ) 25.06 25.06 25.06 25.10 25.06 25.06 25.00 25.00 25.06 25.06 25.10 25.00 25.00 25.00 25.00 25.10 25.63Alga (% mass) 0.0005 0.0005 0.0005 0.0003 0.0005 0.0000 - 0.0049 0.0000 - 0.0000 - - - - 0 0
Solid (% mass) 0.0015 0.0000 0.0000 10.9000 0.0000 0.0000 - 0.0003 0.0000 - 0.0000 - - - - 0 0
TDS (% mass) 3.25 3.25 3.25 0.43 3.25 3.25 3.25 3.25 3.25 - 3.25 - - - - 3.24 3.24
NaOCl (% mass) 0.00001 0.000001 0.000001 0.000001 0.000001 0.00000 - - 0.00000 - 0.00000 - - - - 0 0
Oxygen (% mass) 0.0008 0.0008 0.0008 0.0000 0.0008 0.0008 0.0008 0.0008 0.0000 100.00 0.0000 - - - - 0 0
Water (% mass) 96.74 96.74 96.74 53.21 96.74 96.74 96.74 96.74 96.74 - 96.74 - - - - 96.74 96.74
Na2SO3 (%mass) - - - - - - - - - - - 40 - - - 0.0006 0.0006Water (% mass) - - - - - - - - - - - 60 - - - - -Ca(NO3)2 (% mass) - - - - - - - - - - - - 45 - - 0.0054 0.0054
Water (% mass) - - - - - - - - - - - - 55 - - - -THPS (% mass) - - - - - - - - - - - - - 50 - 0.0003 0.0003Water (% massa) - - - - - - - - - - - - - 50 - - -Cyclo-hexylamine (% mass) - - - - - - - - - - - - - - 13 0.0012 0.0012
Morpholin (% mass) - - - - - - - - - - - - - - 7 0.0007 0.0007
Water (% mass) - - - - - - - - - - - - - - 80 - -
PROCESS SYNTHESIS - PROCESS FLOW DIAGRAM
MASS AND ENERGY BALANCE – MASS BALANCEMass Balance Inlet for Overall Processes
Inlet Stream Mass Flow (kg/hr) Inlet Component Mass Flow
(kg/hr)
Seawater (Feed) 741,522.87
H2O 717,402.61Oxygen 5.93
Dissolved Solid 24,099.49Suspended Solid 14.83
NaOCl 18 0.23 NaOCl 0.23
Chemical Injection Package
12
79.47
Oxygen Scavenging Chemical 4.79
Calcium Nitrate Solution 40.4813
Biocide Solution 1.791415 Corrosion Inhibitor 32.41
Total 741,602.57
(Source: Author’s personal data)
MASS AND ENERGY BALANCE – MASS BALANCEMass Balance Outlet for Overall Processes
(Source: Author’s personal data)
Outlet Stream Mass Flow (kg/hr) Outlet Components Mass Flow
(kg/hr)
Injected Seawater 16 339,384.98
H2O 328,329.49Oxygen 0.05
Dissolved Solid 11,055.34Suspended Solid 0.09
Oxygen 10 2.66 Oxygen 2.66
Utility Water 3 88,979.86
H2O 86,086.77Oxygen 0.71
Dissolved Solid 2,891.91Suspended Solid 0.47
Disposed Seawater
313,235.06
H2O 303,038.314 and 8 Oxygen 2.51
Dissolved Solid 10,179.97 Suspended Solid 14.27
Total 741,602.56
MASS AND ENERGY BALANCE – ENERGY BALANCE
(Source: Author’s personal data)
[Energy In] – [Energy Out] = [Accumulation of energy]
Inlet Stream Heat Flow (MJ/h) Outlet Stream Heat Flow
(MJ/h)
Seawater 77,423.15 Injected Seawater 17 36,322.63
NaOCl 18 0.01 Oxygen 10 0.06Pump 1 191.16 Backwash 8 32,783.85Pump 2 60.19 Utility Water 3 9,313.59Oxygen
Scavanging Chemical
12 0.36
Calcium Nitrate 13 2.63Biocide 14 0.38
Corrosion Inhibitor 15 2.99
Total 78,427.17 Total 78,421.69Pump 3 746.28 Sludge 4 1.56
MASS AND ENERGY BALANCE – ENERGY BALANCE
Mass Efficiency
Energy Efficiency
NEED FOR MASS AND ENERGY
To produce 50,000 BWPD for waterflood, it needs
108,667 barrels water per day in the feed, and
3 pumps with total power 1669 kW
MASS AND ENERGY BALANCE – SIMULATION
• Using SuperPro
CONCLUSION1. Process of Enhanced Oil Recovery (EOR) will be conducted to lift the remaining oil
from Kerisi well with water flood method.
2. Design for the process need to meet criteria such as reduce amount of content that may cause problem in well like TSS, sulphate ion, and oxygen from seawater, facilities can be placed on available area and should be as economical as possible.
3. Parameters that will be used in process selection are performance to prevent H2S production, space limited, corrosion effect, investment cost and environment.
4. Process selected for seawater for injection well is nitrate injection process which is used calcium nitrate with concentration 100 ppm to process water.
5. There are several main section of this plant as follow pre-primary filtration, primary solid removal with coarse strainer, secondary solid removal with multimedia filter, de-aeration and chemical injection package.
6. We simulate the overall process using SuperPro Software and processing the data to calculate mass and energy balance. It needs 108,667 barrels water per day or equivalent to 741,522 kg/h to produce 50,000 barrels water per day to fullfill demand of waterfloods in the oil well. For energy needs, we will have three pumps with total power 1669 kW.
Injection of 50,000 bpd of seawater will likely increase the H2S level in the production system to around 600 ppmv in 10 years. The increase of H2S is caused by several factors:
Decrease in Reservoir temperature
over time.
High (dissolved organic carbons)
DOC in produced water. High Sulphate in the Seawater. Bacteria availability from the seawater.
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