Incorporating Hybrid Technology of CSS + Foam in Heavy Oil Field Development Plans: Practical Experiences and Lessons Learned

Abstract

Abstract Using preformed foams to improve cyclic steam stimulation (CSS) has been under study by Ecopetrol since 2018. The research and development project included laboratory evaluations to select a foaming agent, a detailed well selection using reservoir engineering and simulation analysis, the development of a wellhead device to preform a stable foam at surface conditions, well treatment design, injection schedule, and technological monitoring tests. The field results showed benefits in incremental oil production, energy efficiency improvements, and carbon intensity reduction. Based on those outcomes and trying to extend the production life of mature assets, the hybrid technology of CSS + Foam improvements was incorporated into the heavy oil field development plans of the Middle Magdalena Valley basin (MMV), Colombia. In the last year, more than thirty (30) wells have been injected with preformed foam improvement before the steam cycle. The methodology includes preinjection laboratory evaluations to mitigate emulsion formation or compatibility problems, well selection and performance forecast, a wellhead device to control fluids (foaming agent and nitrogen) to generate the foam, and the chemical and geochemical surveillance process. Based on the field experiences, a description of the results in terms of incremental oil, energy efficiency, carbon intensity, and protocols of QAQC of injected foam and produced fluid are presented. Systematic monitoring of oil production response showed that most wells reported 50% incremental oil production (2,000 – 4,000 stbo/cycle) from baseline, more than 60% improvement in energy efficiency (MMBTU/stbo), and a 50% reduction in carbon intensity (CO2/stbo) by extending steam cycles (> 6-12 months). Additionally, the chemical analysis indicated that no residual foaming agent was detected in production, which avoids emulsions and problems in production facilities that represent the costs of additional chemical additives. The methodology developed to control foaming generation (water injection rate and foaming agent concentration) led to a high-quality and stable foam. This study shows a novel and representative insight into the best practices and recommendations to implement and monitor CSS + foam plans as a strategy to improve oil recovery in mature wells and avoid stranded assets in agreement with the energy transition plans.