U.S. patent number 3,554,285 [Application Number 04/770,257] was granted by the patent office on 1971-01-12 for production and upgrading of heavy viscous oils.
This patent grant is currently assigned to Phillips Petroleum Company. Invention is credited to Robert F. Meldau.
United States Patent |
3,554,285 |
Meldau |
January 12, 1971 |
PRODUCTION AND UPGRADING OF HEAVY VISCOUS OILS
Abstract
Production and upgrading of viscous oils is effected by heating
an underground formation for a period of time sufficient to heat
said formation to a temperature of at least about 550.degree. F.
and form a substantial heat bank therein. A viscous oil is then
flowed into said heated formation and maintained therein for a
period of time sufficient to effect a significant reduction in
viscosity of the oil. Heating of said formation can be effected by
in situ combustion or injection of a heat-bearing fluid, e.g.,
steam.
Inventors: |
Meldau; Robert F.
(Bartlesville, OK) |
Assignee: |
Phillips Petroleum Company
(N/A)
|
Family
ID: |
25087955 |
Appl.
No.: |
04/770,257 |
Filed: |
October 24, 1968 |
Current U.S.
Class: |
166/258;
166/272.3 |
Current CPC
Class: |
E21B
43/243 (20130101) |
Current International
Class: |
E21B
43/243 (20060101); E21B 43/16 (20060101); E21b
043/14 (); E21b 043/24 () |
Field of
Search: |
;166/256,258,261,268,269,272,302,303 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Champion; Marvin A.
Assistant Examiner: Calvert; Ian A.
Claims
I claim:
1. A method of recovering hydrocarbons from a subsurface formation
containing same, said formation comprising at least two permeable
oil-bearing sands penetrated by at least one injection well and at
least one spaced apart production well which provide communication
between the surface of the earth and said formation, at least one
of said sands being open to said injection well, but only one of
said sands also being open to said production well, said method
comprising the steps of:
a. heating said sand which is open to both said injection well and
said production well for a period of time sufficient to heat a
substantial portion thereof to a temperature of at least
550.degree. F. and form a substantial heat bank therein;
b. terminating heating of said now heated sand;
c. flowing a viscous hydrocarbon oil from another sand of said
formation into said heated sand;
d. maintaining said hydrocarbon oil in said heated sand for a
period of time sufficient to significantly reduce the viscosity
thereof; and
e. resuming heating of said previously heated sand and displacing
said hydrocarbon oil therefrom into said production well and
recovering from said production well a hydrocarbon oil having a
reduced viscosity which is less than that of said oil of step
(c).
2. A process according to claim 1 wherein: said heating of said
formation in step (a) is accomplished by the injection of an
oxygen-containing gas to effect an in situ combustion in said
heated sand; and termination of said heating in step (b) is
effected by terminating injection of said oxygen-containing
gas.
3. A process according to claim 2 wherein: said formation comprises
a more permeable lower sand open to said injection well and said
production well and disposed below a less permeable upper sand not
open to said injection well and said production well; at least the
major portion of said oxygen-containing gas is injected into and at
least a major portion of said in situ combustion is effected in
said more permeable lower sand of said formation; after termination
of heating as per step (b), said hydrocarbon oil of step (c) flows
from said upper sand of said formation into said combusted lower
sand of said formation; and said oil of reduced viscosity in step
(e) is recovered by resuming injection of said oxygen-containing
gas to displace said reduced viscosity oil into said production
well.
4. A process according to claim 3 wherein said oil from said upper
sand of said formation is maintained in said combusted lower sand
of said formation for an average period of time of at least about
10 days.
5. A process according to claim 2 wherein: said formation comprises
a more permeable upper sand open to said injection well and said
production well and disposed above a less permeable lower sand not
open to said injection well and said production well; at least the
major portion of said oxygen-containing gas is injected into and at
least a major portion of said in situ combustion is effected in
said more permeable upper sand of said formation; after termination
of heating as per step (b), said hydrocarbon oil of step (c) is
flowed by fluid drive displacement from said lower sand of said
formation into said combusted upper sand of said formation; and
said oil of reduced viscosity in step (e) is recovered by resuming
injection of said oxygen-containing gas to displace said reduced
viscosity oil into said production well.
6. A process according to claim 5 wherein said oil from said lower
sand of said formation is maintained in said combusted upper sand
of said formation for an average period of time of at least about
10 days.
7. A process according to claim 2 wherein: said formation comprises
at least two permeable oil-bearing sands, separated from each other
by a stratum of shale or other impermeable barrier, open to said
injection well, but with only one of said sands being open to said
production well; the major portion of said oxygen-containing gas is
injected into and a major portion of said in situ combustion is
effected in said sand open to said production well; after
termination of said heating as per step (b), said viscous
hydrocarbon oil of step (c) flows from said sand which is not open
to said production well into said combusted sand; and said oil of
reduced viscosity in step (e) is recovered by resuming injection of
said oxygen-containing gas to displace said reduced viscosity oil
into said production well.
8. A process according to claim 7 wherein said oil of step (c) is
maintained in said combusted sand for an average period of time of
at least about 10 days.
9. A process according to claim 1 wherein: said formation comprises
at least two permeable oil-bearing sands, separated from each other
by a stratum of shale or other impermeable barrier, open to said
injection well, but with only one of said sands being open to said
production well; said heating of said formation in step (a) is
accomplished by injecting steam into said formation; the major
portion of said steam is injected into and a major portion of said
heating of said formation is effected in said sand open to said
production well; termination of said heating in step (b) is
effected by terminating said steam injection; after termination of
said heating as per step (b), said viscous hydrocarbon oil of step
(c) flows from said sand which is not open to said production well
into said combusted sand; and said oil of reduced viscosity in step
(e) is recovered by resuming injection of said steam to displace
said reduced viscosity oil into said production well.
10. A process according to claim 9 wherein said oil of step (c) is
maintained in said combusted sand for an average period of time of
at least about 10 days.
Description
This invention relates to the production of crude oils. In one
aspect this invention relates to the production of heavy viscous
crude oils.
Heavy crude oils, e.g. crude oils having a low API gravity and/or
high viscosity are very difficult to produce by ordinary methods of
primary and secondary production. In many fields containing such
oils only a few percent of the oil can be produced by ordinary
methods of production. Waterflooding and similar methods of
secondary production are not very effective in producing such oils
because of adverse mobility and fingering of the driving fluid.
Another problem associated with the production and use of such
heavy oils is that, after production, such oils frequently require
upgrading even before transferring same to a refinery or other
ultimate use. For example, such oils are difficult to pump in a
pipeline or load into tankers or other conveyance for
transportation. Thus, it is desirable that a permanent reduction in
viscosity be effected on such oils. These heavy crude oils
frequently have a high sulfur content. It is desirable to effect a
reduction in the sulfur content before processing such oils in
expensive refining equipment and subjecting said equipment to
corrosion by sulfur. Such oils can be rendered much more valuable
if, when produced, the viscosity and sulfur content thereof is
lowered.
The present invention provides an improved method of producing
heavy viscous crude oils which overcomes or at least mitigates the
above-described problems. Broadly speaking, the present invention
comprises heating an underground formation for a period of time
sufficient to heat same to a temperature of at least about
550.degree. F. and form a substantial heat bank therein. A heavy
viscous oil is then flowed into the heated formation and maintained
therein for a period of time sufficient to effect a significant
reduction in the viscosity of said oil. A reduction in sulfur
content usually occurs concomitantly with said reduction in
viscosity.
An object of this invention is to provide an improved method for
recovering hydrocarbons from subterranean formations containing
same. Another object of this invention is to provide an improved
method for producing heavy viscous crude oil from subterranean
formations containing the same. Another object of this invention is
to provide improved methods of producing heavy viscous crude oils
from subterranean formations whereby said crude oils are upgraded
in quality. Another object of this invention is to provide improved
methods for producing two or more spaced apart oil-bearing strata.
Another object of this invention is to provide an improved method
for producing underground oil-bearing formations of varying
permeability. Other aspects, objects, and advantages of the
invention will be apparent to those skilled in the art in view of
this disclosure.
Thus, according to the invention, there is provided a method of
recovering hydrocarbons from a subsurface formation containing
same, comprising the steps of: (a) providing communication between
the surface of the earth and said formation through at least one
well; (b) heating said formation for a period of time sufficient to
heat a substantial portion thereof to a temperature of at least
550.degree. F. and form a substantial heat bank within said
formation; (c) terminating heating of said now heated formation;
(d) flowing a viscous hydrocarbon oil into said heated formation;
(e) maintaining said hydrocarbon oil in said heated formation for a
period of time sufficient to significantly reduce the viscosity
thereof; and (f) recovering from said formation a hydrocarbon oil
having a reduced viscosity which is less than that of said oil of
step (d).
The methods of the invention are applicable to a wide variety of
formations containing a wide variety of crude oils. Said methods
are particularly applicable to formations containing heavy viscous
crude oils having an API gravity of not more than about 15 and/or a
Saybolt Furol viscosity at 122.degree. F. of at least 100 seconds.
However, the invention is also applicable to the production of
crude oils having an API gravity greater than 15 and a Saybolt
Furol viscosity of less than 100 seconds which, for one reason or
another, are difficult to produce by conventional methods. The
tabulation given below in Table I illustrates that the methods of
the invention are applicable to a wide variety of crude oils.
##SPC1##
In the above Table I the first four oils were heated for one day at
662.degree. F. in a manner similar to that described in the example
given hereinafter. The last two oils in said Table I were heated
for 14 days at 600.degree. F., similarly as described in said
example given hereinafter. The data show that in all cases there
was a significant reduction in viscosity, resulting in a definitely
upgraded oil.
The tabulation given in Table II below is based on a series of test
runs carried out on Morichal Gp. II crude oil in which said oil was
heated to various temperatures for varying periods of time.
##SPC2##
The date in the above Table II show that permanent viscosity
reduction by mild thermal cracking or visbreaking, as practiced in
the invention, is sensitive to both temperature and time. For
example, for a heating period of 10 days, at 500.degree. F. there
is only a 2 percent reduction in viscosity, at 550.degree. F. the
reduction in viscosity is 17 percent, and at 600.degree. F. the
reduction in viscosity is 72 percent. Thus, in the practice of the
invention it is desirable to heat the oil to a temperature of at
least about 550.degree. F., preferably at least about 600.degree.
F., for a period of time sufficient to obtain a significant
reduction in viscosity. Preferably, said period of time will be at
least about 10 days. As used herein and in the claims, unless
otherwise specified, a significant reduction in viscosity is
considered to be at least 10, preferably at least 25, percent of
the original viscosity of the oil.
FIG. 1 is a vertical cross section through a formation comprising
an upper less permeable oil-bearing sand and a lower more permeable
oil-bearing sand and illustrates an arrangement of wells for
carrying out one embodiment of the invention.
FIG. 2 is a vertical cross section through a formation comprising
an upper more permeable oil-bearing sand and a lower less permeable
oil-bearing sand and illustrates an arrangement of wells for
carrying out another embodiment of the invention.
FIGS. 3 and 4 are vertical cross sections through an oil-bearing
sand and illustrates an arrangement of wells for carrying out
another embodiment of the invention.
FIG. 5 is a vertical cross section through an oil-bearing formation
and shows a combination injection-production well for carrying out
another embodiment of the invention.
FIG. 6 is a vertical cross section through a plurality of permeable
oil-bearing sands separated by impermeable layers of shale or other
impermeable barrier and illustrates an arrangement of wells for
carrying out still another embodiment of the invention.
The drawings illustrate diagrammatically various methods of
producing and upgrading heavy viscous oils in accordance with the
invention. It will be understood that many valves, pumps,
compressors, and other items of apparatus not necessary for
explaining the invention to those skilled in the art have been
omitted for the sake of brevity. In one embodiment illustrated in
FIG. 1 the oil-bearing sand or formation is preferably at least 20
feet thick and comprises a more permeable lower portion 10 disposed
below a less permeable upper portion 12. Preferably, said more
permeable lower portion 10 is at least 5 feet thick and is at least
25, more preferably at least 50, percent more permeable than said
upper portion 12. In addition, said sand or formation will have
vertical permeability.
At least two wells, an injection well 14 and a production well 16,
are drilled into the formation to provide communication between the
surface of the earth and said formation. Said wells can be spaced
apart any suitable distance, depending upon the characteristics of
the formation and the oil contained therein. Usually, said wells
will be spaced apart a distance within the range of from about 10
to 1,000 feet. In some instances, the preferred well spacing will
be in the range of 50 to 300 feet. Air or other oxygen-containing
gas is injected into the formation at a high rate through said
injection well 14 for establishing and maintaining a combustion
front 18 and drive said front out into the formation a suitable
distance. Said formation is ignited at the injection well 14 in any
conventional manner known to the art. For example, a downhole
burner or a charcoal pack can be employed. Frequently, the
formation will ignite spontaneously upon injection of air. Also, if
desired, a spontaneously ignitable fuel can be injected into the
formation to accelerate ignition. Said distance the combustion
front is moved out into the formation can be any suitable distance
depending upon the characteristics of the formation and the oil
contained therein. However, for economic reasons it is usually
desirable to stop the injection of oxygen-containing gas before the
rate of heat loss by conduction reaches more than about 25 percent
of the heat generation rate. During said injection of
oxygen-containing gas and movement of the combustion front, the
formation is heated to a temperature of about 1,000.degree. F., or
greater, depending upon the gas injection rate and the oxygen
content of the injected gases. As illustrated in FIG. 1, only lower
section 10 is open to the injection of air. This is a presently
preferred method of operation. However, it is within the scope of
the invention for the upper section 12 of the formation to be open
to air injection. In such instances, the combustion front 18 will
advance farther into the formation in the more permeable lower
section 10 thereof with the establishment of a greater heat bank in
said lower section. The injection rate for the air or other
oxygen-containing gas should be high enough to substantially
overcome any tendency for gravity segregation of said gas into the
upper portion of the formation during the injection period. Upon
cessation of injection of oxygen-containing gases, oil from the
unburned upper portion of the formation will drain back into the
burned out lower portion of the formation as indicated by the arrow
20. The natural heating of the oil in the upper portion of the
formation by conduction and convection will lower the viscosity of
said oil and accelerate its flow from the upper portion to the
lower portion of the formation. The oil drained into the hot lower
portion of the formation is permitted to remain therein and "soak"
for a period of time which is at least sufficient to significantly
reduce the viscosity of said oil, or until the formation
temperature has decreased to about 550 to 600.degree. F. The
temperature of the heated formation can be calculated by methods
known to those skilled in the art. The formation temperature can
also be determined and/or monitored by temperature observation
wells drilled thereinto between the injection well and the
production well. Preferably, depending upon formation temperature
and oil characteristics, said oil drained into the heated lower
portion of the formation will be maintained therein for an average
period of time of about 10 days.
After said oil has soaked for the desired period of time, the
injection of oxygen-containing gases at injection well 14 is
resumed to displace the heated and visbroken oil into the
production well 16 from which it can be produced in any suitable
manner, as by pumping. The formation is again ignited and the
combustion front driven farther into the formation toward said
production well. Injection of oxygen-containing gases and movement
of the combustion front through the formation are again continued
until the rate of heat loss by conduction reaches about 25 percent
of the rate of heat generation. At this time, injection of
oxygen-containing gases is terminated, oil is again permitted to
flow by gravity from the upper section to the hot lower section of
the formation, is permitted to soak or remain therein for a period
of time sufficient to significantly reduce the viscosity of the
oil, and is then displaced by again resuming injection of
oxygen-containing gases. The described alternate injection of
oxygen-containing gases with burning, and oil draining and soaking
periods, will produce the maximum amount of visbroken and upgraded
oil. This method of production will also result in increased total
oil recovery due to heating of the portions of the formation
surrounding the portion of the formation which is actually
burned.
Another embodiment of the invention, illustrated in FIG. 2, is
particularly applicable to those formations wherein the
oil-containing formation or sand comprises a more permeable upper
section 10' disposed above a less permeable lower section 12'. In
this embodiment of the invention, one method for injection of
oxygen-containing gases is through annulus 15 of injection well 14
into more permeable section 10' of the formation, said formation is
ignited at well 14, and gas injection is continued until the
combustion front 18' has proceeded out into the formation a
suitable distance as described above. After terminating injection
of oxygen-containing gases, water is injected into the lower
portion 12' of said formation through tubing 17 to displace oil
therefrom up into the heated portion of the formation as indicated
by the arrow 22. Any suitable arrangement of tubing, casing, and
packers 19 can be employed for so injecting said water. The oil so
displaced into the heated portion of the formation is maintained
therein for a period of time sufficient to significantly reduce the
viscosity thereof. At the end of the soaking period injection of
oxygen-containing gases is resumed to displace the visbroken oil to
the production well from which it is produced in any suitable
manner, the formation is again ignited, and the combustion front
18' moved farther into the formation to reheat same, similarly as
described above. In this embodiment of the invention injection of
oxygen-containing gases with combustion can be alternated with the
water injection.
The above-described technique of alternate combustion and water
displacement is also applicable where the oil-bearing sand or
formation is homogenous. Field experience has shown that in such
formations the fire flood will proceed through the top portion,
e.g., 8 to 12 feet, of the sand only. With the burned out section
of the formation at the top or in the middle thereof, water
injection can be employed to displace oil from the lower to the
upper portion of the sand as described above.
In another embodiment of the invention illustrated in FIG. 3, a
direct drive in situ combustion is initiated at injection well 14
and carried out in conventional manner until the combustion front
18 has proceeded out into the formation 24 from the injection well
a suitable or desired distance. At this time injection of
oxygen-containing gases is terminated. Gas pressure on the
injection well 14 is then vented which causes heavy oil from the
heated but uncombusted portion of the formation to be sucked into
the heated portion of the formation, as indicated by the arrow 23.
Said formation 24 is preferably at least 10 feet thick. After a
suitable soaking period as described above, injection of
oxygen-containing gases is resumed through well 14 to displace the
visbroken oil to the production well 16 from which it is produced
in any suitable manner, the formation is ignited again, and the
front again driven farther out into the formation. These periods of
alternate gas injection with combustion and then pressure venting
can be repeated, similarly as described above, to move the front
farther into the formation until it reaches the production well
16.
In another embodiment of the invention illustrated in FIG. 4, two
or more wells, at least one injection well 14 and at least one
production well 16, are completed in an oil-bearing sand or
formation 26 which is preferably at least 10 feet thick.
Oxygen-containing gases are injected through the injection well 14,
the formation is ignited at well 14, and a combustion front 18
moved out into the formation a suitable or desired distance to form
a sizable heat bank in said formation. At this time injection of
oxygen-containing gases is terminated and a previously produced
dewatered crude oil is introduced through the injection well 14 and
pumped through said heat bank to the production well 16 from which
the oil is pumped in conventional manner. The rate of injection of
said produced crude oil and movement thereof through the heat bank
will be such as to maintain a residence time for said oil in said
heat bank which is sufficient to significantly reduce the viscosity
of said oil. Preferably, said residence time will be at least about
10 days. Pumping of said produced oil through the heat bank is
continued until the temperature of the heat bank drops below about
600.degree. F. At this time the injection of oxygen-containing
gases through well 14 is resumed, the formation is reignited and
the combustion front moved farther into said formation. Injection
of oxygen-containing gases is stopped after a suitable period of
time, determined as described above, and injection of produced
dewatered crude repeated. This alternate burning and injection of
produced dewatered crude not only will furnish a method for
upgrading previously produced crudes but will also markedly
increase oil production from the formation, particularly around the
production well when the heated oil from the heat bank reaches said
production well. Said previously produced crude oil can be any oil
which can be upgraded in accordance with the invention, e.g., an
oil previously produced from the formation being heated or an oil
from a different formation or field.
In another embodiment of the invention illustrated in FIG. 5, only
an injection well 14 is employed. One or more of said wells can be
employed. In this embodiment oxygen-containing gases are introduced
through the well 14, and the formation 28 ignited to form a
combustion front and move same out into the formation a suitable or
desired distance, determined as described above. Injection of
oxygen-containing gases is then terminated and a dry produced oil
introduced into the formation until the temperature of the heated
portion of the formation decreases to a temperature below about
600.degree. F. This can be computed from heat transfer calculations
by methods known to those skilled in the art, or can be observed in
a special temperature observation well drilled for that purpose.
When sufficient oil has been introduced to decrease the temperature
of the heated formation to less than about 600.degree. F., the well
is returned to production. Oil is produced from the well, as by
pumping or by formation pressure, until the production rate and/or
temperature of the produced oil indicates that the heating portion
of the cycle should be repeated. This process can be repeated,
employing alternate periods of heating, injection of dry produced
oil, and production of oil, as desired. This process will provide
considerable stimulation of production from the formation
surrounding the injection well in addition to the visbreaking of
the injected previously produced oil. The process is particularly
advantageous after a number of cycles have been run and the heat
from the heat bank has penetrated to adjacent sands. The process
avoids the production of hot air and hot combustion gases which can
damage a well when the well is returned to production immediately
after termination of injection oxygen-containing gases. The
injection of the previously produced oil will also "kill" the well
and facilitate the running of temperature surveys or other well
work which are sometimes performed prior to production.
It is not uncommon for a heavy oil reservoir to comprise a
plurality or series of permeable oil-bearing sands separated by
shale or other impermeable barrier. The Morichal field in Venezuela
is an example of such a field. FIG. 6 illustrates diagrammatically
such a field and one presently preferred method for producing same
in accordance with the present invention. In this embodiment of the
invention one or more injection wells 14 are completed open to all
of the penetrated sands 30, 32, 34, and 36. One or more production
wells 16 are completed, but said production well or wells are open
to only one sand, e.g., 32, hereinafter referred to as a
visbreaking sand. Said visbreaking sand will usually be the sand
having the highest permeability. However, in some cases it may be
desirable to choose the sand having the highest capacity
(permeability times thickness), or to choose a sand near the middle
of the reservoir (vertically speaking) if the permeabilities of the
adjacent sands are not greatly different.
In this embodiment of the invention a presently preferred procedure
is to initiate injection of oxygen-containing gases through
injection well 14, ignite the formations, and move a combustion
front out into the formations a desired or suitable distance,
determined as described above, so as to form a sizable heat bank.
Since the visbreaking sand 32 is usually the one of highest
permeability, and the fact that this sand is open to the production
well, the major portion of the introduced oxygen-containing gases
will go into this sand to produce the largest heat bank therein.
After the combustion front has moved out into the formation 32 a
suitable or desired distance, injection of oxygen-containing gases
is terminated, and the other sands 30, 34, and 36 in the reservoir
are produced by permitting oil therefrom to flow, as by formation
pressure, through the hot visbreaking sand 32 to the production
well. Flow of said oil through the visbreaking sand 32 is
controlled, by controlling the rate of production from said
production well, so as to maintain said oil in the hot visbreaking
sand for a period of time sufficient to significantly reduce the
viscosity thereof. Flow of said oil into and through the
visbreaking sand 32 is continued until the temperature of the sand
decreases to about 600.degree. F. At this time, injection of
oxygen-containing gases is resumed and the formation ignited to
again heat the formation. The process can be repeated in cycles, as
described, and the period or frequency of injection of
oxygen-containing gases can be adjusted, taking into consideration
heat transfer calculations and the desired time-temperature
relationship for visbreaking of the oil so as to maximize heat
utilization for maximum economic benefits. This embodiment of the
invention is particularly applicable when employing relatively
close well spacings, e.g., in the 50 to 200 foot range, more
preferably 50 to 100 foot range.
A number of advantages are obtained in this method of producing
plural sands in reservoirs. Included among these advantages is the
fact that the heat generated in the visbreaking sand by combustion
is used repeatedly to visbreak oil flowing through said sand.
Another advantage is that the heat conducted to adjacent sands from
the visbreaking sand is picked up by the counterflow of oil in said
adjacent sands. Thus, said conducted heat is not lost and serves to
improve productivity from the region around the injection well, as
well as the region around the production well, during the
production cycle of the process. Still another advantage is that
the upper part of the injection well is not used for oil
production. This reduces the explosion hazard and well work when
switching from the oxygen-containing gas injection step of the
process to the production step of the process. Another advantage is
that since the injection of oxygen-containing gases is
intermittent, most of the production at the production well will be
at a low gas-oil ratio, thus further increasing productivity.
It may be desirable in some instances to inject an inert gas or a
limited amount of water at the end of the oxygen-containing gas
injection period so as to displace the oxygen-containing gases to
the fire front. In a commercial application of this embodiment of
the invention, it is desirable to employ a plurality of air
injection wells so as to employ the air compressors continuously.
The number of injection wells per production well will depend upon
the characteristics of the formation and the oil contained therein
and the time-temperature relationship in the visbreaking step of
the invention. In many instances, a 1 to 1 ratio of injection wells
to production wells is desirable.
All of the above-described embodiments of the invention afford the
advantage of heat conservation. The heat stored in the heat bank is
used repeatedly in visbreaking the heavy oil flowed into said heat
bank, as the heat bank is moved farther and farther into the
formation. Even when the temperature of the heat bank decreases
below the visbreaking temperature, less heat is required to reheat
the formation than in other methods of thermal production. Another
advantage which is obtained in all of the methods of the invention
is that the heat arriving at the production well with the visbroken
oil side in the primary recovery of oil because said oil heats the
oil in the formation around the production well.
While the various embodiments of the invention have been described
with particular reference to employing in situ combustion as the
method of heating the heavy oil containing sands or formations, the
invention is not limited to employing in situ combustion as the
method of heat generation. In all the above-described embodiments
of the invention the injection of a heat-containing fluid such as
steam or superheated steam can be employed for heating the
formation if the formation pressure is high enough, or can be
increased sufficiently by steam injection, to heat the formation to
a temperature of at least 500.degree., preferably at least
600.degree. F.
The invention is not limited to any particular rate for the
injection of oxygen-containing gases in the in situ combustion
heating steps. In the practice of the various embodiments of the
invention, any suitable injection rate for the oxygen-containing
gases commonly employed in in situ combustion processes can be
employed. Usually, said rate will be within the range of from about
500,000 to 10,000,000 scf per day, depending upon the
characteristics of the formation being produced. However, it is
within the scope of the invention to employ injection rates of
oxygen-containing gases which are outside said ranges. Generally
speaking, low injection rates for the oxygen-containing gases are
undesirable because of excessive heat losses. As indicated above,
high rates are especially desirable for the embodiment of the
invention illustrated in FIG. 1. Lower gas injection rates can be
employed in the other embodiments of the invention. The injection
of oxygen-containing gases will be carried out for a sufficient
period of time to burn out or move the combustion front out into
the formation any suitable or desired distance. The time of
injection is frequently determined by heat losses. Generally
speaking, it is not desirable to continue heating of the formation
after the sum of the heat losses by conduction to adjacent sands is
more than 25 percent of the heat generation rate.
Air is the oxygen-containing gas most commonly used in the practice
of the invention. However, it is within the scope of the invention
to use air enriched with oxygen or air diluted with an inert gas,
e.g., CO.sub.2 or combustion gases. The oxygen content of the
oxygen-containing gases can range from about 5 to about 60 percent
oxygen, by volume, or higher. It is also within the scope of the
invention to vary the oxygen content of the injected oxygen
containing gases so as to control the temperature of the heat
bank.
Similarly, the invention is not limited to using any particular
rate for the injection of steam in those embodiments of the
invention where the heat bank is generated by the injection of
steam. Any suitable rate can be employed. Usually, said steam
injection rate will be within a range sufficient to supply from
5,000,000 to 100,000,000 BTU per hour, depending upon the
characteristics of the formation. In all instances it is preferred
that the steam injection rate be such that the heat input to the
formation is at least twice the heat losses in the well bore and
the formation. The times of heating when using steam injection can
be determined similarly as described above when injecting
oxygen-containing gases.
The following example will serve to further illustrate the
invention.
EXAMPLE
A sample of Morichal Group II crude oil was heated to 600.degree.
F. in a one-liter glass flask and maintained as said temperature
for 14 days at atmospheric pressure. Said flask was equipped with
suitable liquid traps for collection of oil and liquid products
boiling below 600.degree. F. and a gas collection bulb for
collection of gas. The results of this test are set forth in Table
III below. ##SPC3## There was also produced 6720 ml of gas
(nitrogen free) having a composition including H.sub.2, C.sub.1 to
C.sub.6 hydrocarbons, H.sub.2 S, COS, CO.sub.2, and O.sub.2.
The results of the above test show there was a reduction in
viscosity of more than 79 percent and a reduction in sulfur content
of almost 22 percent for the oil which remained in the flask. For
the aliquot blend of flask oil and distilled oil the reduction in
viscosity was more than 94 percent and the reduction in sulfur
content was more than 24 percent. These reductions in viscosity and
sulfur content represent marked upgrading in the oil treated.
While the invention has been described and illustrated in several
embodiments as employing one injection well and one production
well, it will be understood that in all embodiments of the
invention any number of injection wells and any number of
production wells, arranged in any suitable pattern, can be employed
in the practice of the invention. Similarly, the well spacings set
forth above in connection with the embodiment illustrated in FIG. 1
are applicable to the other embodiments of the invention.
While the invention has been described primarily with reference to
producing heavy viscous crude oils of lower gravity, the invention
is also applicable to the recovery of higher gravity crude oils.
The invention can also be employed to recover oil from reservoirs
which have already been subjected to primary and/or secondary
recovery methods. The invention can also be employed in recovering
high gravity oil from low energy reservoirs, e.g., reservoirs which
contain very little, if any, dissolved gas, and thus very little,
if any, reservoir pressure.
While certain embodiments of the invention have been described for
illustrative purposes, the invention is not limited thereto.
Various other modifications of the invention will be apparent to
those skilled in the art in view of this disclosure. Such
modifications are within the spirit and scope of the
disclosure.
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