Novel THAI well arrangements for improving heavy oil recovery rate in comparison to that achievable in the conventional THAI in situ combustion technology

Abstract

The toe-to-heel air injection (THAI) method is an environmentally friendly process for in situ upgrading of heavy oils and bitumen via in situ combustion (ISC). Unlike the conventional ISC that uses a vertical producer, the THAI process uses a horizontal producer (HP) well to produce the upgraded oil to the surface. Recent field data has shown that the THAI process is a relatively low-oil-production-rate technology. These considerations call for innovative solutions so that the oil production rate is improved, whilst propagating a stable, efficient, and safe combustion front. Consequently, this work has provided those solutions. Through numerical reservoir simulations, using CMG STARS, five completely new THAI well configurations, which have been labeled A01, A02, A03, A04, and A05, have been developed and studied, and their performances are compared against that of the conventional THAI process which has wells arranged in a classic SLD pattern (i.e. the best-performing conventional THAI process) and against each other. The THAI arrangements A02-A04, however, assume a horizontal air injection well, which currently is not used in field practice but may be developed in the future. In field practice, THAI is applied in a line drive configuration starting up-dip and going down on the structure whilst taking advantage of the contribution provided by the drainage due to gravity; the expansion is made one way only (by drilling new patterns in one direction only). For this reason, the classic SLD pattern refers to the case where the dip of the reservoir is significant (>2–3°). However, when the dip of the reservoir is not significant (“flat” reservoirs) there is a possibility to expand the process in both opposing directions. This is the case dealt with in this work. All configurations A01-A05 assume expansion of the THAI commercial operation in both directions. Selection criteria have been developed and used to determine the two best performing processes. For example, in terms of long-term stability, safety, and efficiency of the combustion process, a process named model A01 is the best, as it achieved 99.8% oxygen utilisation when compared with any other model. It also achieves oil recovery, due to two years of combustion only, of 30.78% OOIP, which is greater than that in the base case model. Overall, based on the weighted selection criteria, which are developed from the deepest analyses of the quantitative 1-dimensional time-dependent parameters and from thorough analyses of the qualitative 2-dimensional profiles of temperature, the combustion zone in the form of oxygen mole fraction, and the oil-flow dynamics inside the reservoir in the form of oil saturation, then model A01 is the best and is followed by model A03. The overall performance of each of these two novel methods outweighs that of the conventional THAI process. However, model A03 uses a horizontal well for injection, which is not current field practice. Therefore, future developmental work should concentrate on the novel method A01 for upgrading and recovery of heavy oils and bitumen, especially since this is low-carbon, efficient, wastewater-free, and provides upgrading inside the reservoir and hence it has a low surface footprint.