Screening High-Temperature Foams with Microfluidics for Thermal Recovery Processes

Abstract

Thermal recovery processes, and in particular, Steam-assisted gravity drainage (SAGD), are the most common and practical in situ technology for bitumen extraction. While SAGD is effective, steam injection results in poor steam chamber growth and distribution with poor conformance specifically in areas with poor formation geology and bedding properties. These factors result in economic and environmental costs. Co-injecting foaming surfactants with noncondensable gases along with steam is an alternative solution to control the steam chamber behavior and its advancement throughout the formation. Selecting appropriate foaming surfactants is essential for successful implementation of a foam-steam processes. Conventional laboratory methods provide some indication of foaming surfactant performance but fail to reflect reservoir conditions and time scales. Microfluidics is well suited to assess the relevant pore-scale performance of foaming surfactants, at relevant conditions, with tight control over experimental parameters. Here, we develop a microfluidic approach to generate nitrogen-foam and assess stability and mobility control performance at relevant temperature (>150 °C) with results compared to those of traditional bulk foam analysis. The microconfinement associated with porous media creates more stable foam at reservoir-relevant temperatures and pressures. Direct visualization of the foaming dynamics, subsequent stability, and mobility testing in porous media provide a rapid assessment of foam performance as well as a diagnostic of surfactant product failures such as precipitation and phase decomposition, findings that directly informed pilot operations here. This screening also enables down-selection of the most promising agents for subsequent testing with candidate reservoir oil, in conventional cores or micromodels.