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exploration&production
SOUR GAS
A history of
expertise
//. Contents
soUr GAs
A history
of ExpErtisE
sss
page 3
foreword
page 4 Context
40% of the worlds untapped gas reserves
hold sour gas.
page 6 ChAllenGes
since the lacq discovery, total has
continuously improved its sour gas
development processes.
page 8 expertise
After mdEA, sprex opens a new road
to the monetization of ultra-sour gas reserves.
p. 10 lacq: a world first
p. 14 Continuous innovation
p. 18 sustainable management
of residual products
p. 20 production safety
page 22 GroUp
total worldwide in 2006.
middle East.
//. foreword
of hydrocArBon rEsourcEs
Totals Exploration & Production branch
continually pushes oil and gas production
to new limits. Drawing on the complete
integration of its multidisciplinary
expertise, the Group has honed a
capacity for innovation that has secured
its rank among the frontrunners in the
technologies strategic to the future
of the energy industry.
Totals Exploration & Production branch
is involved in all of the industrys key
technological challenges, namely,
extra-heavy crude oil, ultra-deepwater
offshore, sour gas, hydrocarbon
resources that are deeply buried (highpressure/high-temperature) or difficult to
produce because they are in tight sand
reservoirs. At the same time, the Group
04
//. Context
SOUR GAS
s
1. Doha, Qatar.
What is
sour gas?
Sour gas is natural gas that
contains not only methane and
some long-chain hydrocarbons,
but also H2S and/or CO2.
Mercaptans, organic sulfur
compounds in the form RSH,
are usually also present. The
tubing, pipes and pumps for
sour gas must be made of special
metal, since H2S, CO2, and
mercaptans are corrosive. These
compounds must be removed
before the gas can be sold.
of gas waiting
to be tapped
sss
SOUR GAS
06
//. Challenges
A history
of expertise
sss
Faced with the new challenges of the Lacq gas
field, Total invented many production and processing
techniques for sour gas that are now used around
the world.
In the 1950s, with the development of the vast Lacq gas field in France,
Total marked a world first by successfully upgrading a very sour gas
(16% H2S and 10% CO2) in high temperature and pressure conditions.
To cope with the corrosive fluids and sulfur deposits, the Group
developed techniques and materials to treat this aggressive gas
efficiently and safely. This strong base of know-how has continuously
evolved; Totals technology has made its way around the world to permit
the successful development of more than sixty sour gas fields. Flagship
projects include Elgin/Franklin (United Kingdom), South Pars and
Dorood (Iran), Bongkot (Thailand), Kharyaga (Russia), Sleipner (Norway),
and very sour gas reserves in Abu Dhabi. At present, Total is once again
pushing back frontiers with cost-effective production methods for
ultra-sour gas (over 20% of CO2 or H2S) and future-looking sweetening
processes in preparation for increasingly stringent specifications.
In the Groups hydrocarbon production, the share of gas should reach
35% by 2010.
While the cost-effectiveness of technological solutions is a crucial
factor for the future of sour gas development, safety for people and the
environment is an equally requisite dimension. The Groups commitment
to minimize the environmental impact of its operations is supported
by major research activities. For sour gas, the focus is on improving
the energy efficiency of sweetening processes, but the teams are also
working on breakthrough technologies like the Sprex (for Simple
PRe-Extraction) process. Currently in the pre-industrial phase, this
process leads to significant savings in both the energy requirements and
the cost of treating gas. In line with its comprehensive approach, Total
also studies solutions for the management as well as the marketing
of sulfur streams and other by-products of the process. For the longer
term, additional research programs are under way to explore options for
the reinjection and storage of the acid fractions from these gases. nnn
07
3
1. Bongkot South, Thailand.
2. Elgin/Franklin, United Kingdom.
3. Kharyaga, Russia.
//. expertise
A pioneer
in the field
of sour gas
sss
Total discovered the Lacq gas field in southwestern
France in 1951. Given the high H2S and CO2
concentrations of this gas, producing and processing
the reserves meant a totally new challenge. Less than
seven years later, the feat was accomplished Total had
found solutions for the aggressive properties of these
streams and could deliver a high-quality sales gas.
The momentum of innovation sustained constantly
since that time has driven the Groups technological
leadership for more than sixty years, with the
development of solutions that combine sound economics
with respect for the environment.
10
//. expertise
SOUR GAS
lAcQ:
A world first
sss
It took Total a mere few years to develop efficient
techniques, notably amine-based sweetening processes,
to address the challenges of a high-pressure,
high-temperature sour gas reservoir. The Companys
solutions are now used around the world.
Totals first experience with sour gas began in 1951. During an exploration
campaign for oil in southwestern France, the Lacq 3 well revealed a
significant oil reservoir. The major quantities of hydrocarbons were found at
a depth of 3,450 meters but in gaseous form. The pressure here was so
high that a great geyser of gas shot up through the borehole on
December 19, 1951: Totals historic introduction to the Lacq gas giant.
Reservoir
Depth: 3,500 m
on average
Pressure: about
650 bar on discovery, 24
today
Bottomhole temperature:
bar
140C
Gas composition
Hydrocarbons: 74.2%
Methane: 69%
Ethane: 3%
Propane: 0.9%
Butane: 0.5%
Pentane: 0.2%
Hexane and other: 0.6%
Acid gases: 24.8%
Hydrogen sulfide: 15.3%
Mercaptans: 0.2%
Carbon dioxide: 9.3%
Water: 1%
genuine decline
in well potential
Reservoir
650 bar
Reservoir
24 bar
Record recovery
Since 1957 and the start of Lacq gas
production, 246 billion cubic meters
of gas have been recovered here.
Pressure inside the reservoir has
dropped from 650 to 24 bar.
A great number of seismic surveys
and studies were carried out
to model the reservoir in 3D,
11
1
1. Aerial view of the Lacq complex,
France.
2
sweet
gas
raw gas
sulfur
thio
products
commercial gas
thiochemicals
Condensate
removal
lpg
ethane
steam cracker
(butane, propane)
Ethylene
light hydrocarbons
condensates
stabilization
petroleum products
the drilling assembly and plug the well. When the drill string was pulled
out, the engineers discovered an unusual phenomenon the gas had
altered the molecular composition of the steel and caused cracking in
all the welded parts.
//. expertise
SOUR GAS
12
s
pp
A GAs GiAnt
Ram River,
35% H2S
In 1961, capitalizing on the
experience gained at Lacq,
Total first exported its knowhow to the Pincher Creek field
in Alberta, Canada. In 1972,
the Company rose to a new
challenge by producing the
gas from Albertas Ram River
field. H2S content: 35%! By
successfully sweetening this gas
with an amine technology, Total
set yet another international
precedent, demonstrating that
its solutions can be effectively
applied to the development
of ultra-sour gas resources.
The first production phase began in April 1957, with a processing and
production capacity of 1 million cubic meters per day. It included
desulfurization, condensate removal, the recovery of sulfur from
the H2S, and the refining of the by-products. This phase yielded streams
of purified gas along with hydrocarbons that are used by the chemical
industry ethane, propane, butane and sulfur. Three additional
phases were commissioned in July 1958, May 1959, and 1960,
boosting processing capacity to more than 20 million cubic meters
of gas per day, with an unflinching emphasis on the highest standards
of industrial safety.
Through Totals determination and efforts, Lacq grew into a world-class
complex. The sulfur from Lacq accounted for 100% of French output,
and 8.5% of world supply. In 1960, the field produced 90% of the gas
consumed in France. The complex began to take shape as a hub
of industry, with a power plant, an aluminum plant, and various plants
manufacturing methanol, fertilizers and vinyl chloride, all of which
made use of residual gas from the Lacq operations. At its plateau
production level in the 1970s, the site was producing 33 million cubic
meters of gas a day.
Simplified process
flow diagram.
SOUR GAS
14
//. expertise
Continuous
innovation
sss
Taking advantage of steady progress in the field of
amines, Total has developed efficient and cost-effective
solutions for sour gas processing. The success story
of innovation is now continuing with the conquest
of ultra-sour gas fields, notably via optimized amines
and the new Sprex process.
Ever since the first studies for the Lacq gas field in the 1950s, Total
has steadily improved its amine-based sweetening processes to hone
their efficiency and expand their scope of application. These intensive
and sustained R&D efforts have produced a rich and diversified palette
of solutions for all types of sour gas streams, consolidating Totals
leadership through the years.
South Pars
The South Pars gas field in Iran
holds slightly sour gas: 2% CO2
and 0.54% H2S. Since
March2002, this field has been
delivering high-quality gas into
Irans sales network. To avoid
hydrate formation and control
corrosion in the multiphase
pipelines that transport the gas
105 km to shore, a solution of
mono-ethylene glycol with
MDEA-controlled pH is injected
at the production point. The
selective sweetening process is
carried out onshore, using
MDEA. From start-up until now,
the treated gas output has
exceeded the original project
objectives by 10 to 15%.
In 1957, Totals first sour gas sweetening unit went into operation.
It was designed to treat 1 million cubic meters of gas per day, using a
process based on diethanolamine (DEA). In contact with the raw gas, the
lean diethanolamine rapidly reacts with the H2S and CO2, stripping out
the acid compounds. The loaded amine is regenerated in a reboiler
and then used again. This process was improved over the years to
reduce costs and energy consumption, and boost sweetening efficiency.
In 1978, Total achieved another technological milestone that opened
the era of selective sweetening using methyl diethanolamine (MDEA).
This process was applied for the first time at the Chmery unit,
then integrated into several Lacq units in 1980. MDEA has slow CO2
absorption kinetics. It thus captures significant amounts of H2S only,
with practically no change in CO2 levels. This property makes MDEA
a very attractive candidate for some North Sea and Middle East fields.
In addition, its regeneration requires less energy than for DEA, adding up
to substantial savings in the gas treating cycle.
In 1990, the studies conducted by the Group paved the way for another
major step: Total extended its portfolio with a process for made-tomeasure sweetening. In this new-generation process, first used on
the Lacq gas field, the MDEA is activated using a secondary amine that
accelerates the reaction of the CO2 with the aqueous solvent. The speed
of reaction is modulated by using different types of activators, in different
concentrations. The process thus allows either complete or specifically
controlled removal of CO2 (see process flow diagram, page 15).
These technological achievements have met with commercial success
worldwide. Robust, reliable and efficient, the processes have found
numerous international applications: as early as 1961 for DEA, and since
1987 and 1996 for MDEA and activated MDEA respectively. Between
1957 and 2005, some 70 projects in Canada, India, Iran, Nigeria, Norway,
15
Qatar, Russia, the United Kingdom and elsewhere chose Totals amine
technologies to treat their raw sour gas, either entrusting the operations
to the Group or applying Totals technologies under license.
pp
//. expertise
SOUR GAS
16
s
pp
Extending
Sprex to CO2
The Sprex process was initially
developed to separate H2S. An
improved version is now ready
for the treating of gas with high
CO2 levels. In this process, named
Sprex CO2, a temperature of
about -60 to -70C must be
attained, depending on the target
specification. That requires
preliminary dehydration of the
gas, to avoid hydrate formation in
the Sprex column. Sprex CO2
is a cost-effective alternative to
conventional processes based on
solvents or semi-permeable
membranes for treating gas with
high CO2 concentrations.
10-12% H2S
sprex
Pretreated gas
Liquid H2S
Conventional
treating
(e.g., amine
scrubbing)
Re-injection
17
- 30C
Raw gas in
Lowtemperature
separation
Reflux
(H2O
rectif)
Distillation
Reboiler
(HC stripping)
Purified
gas out
Scrubber
60-70C
Liquid H2S
H2O
In the period from April 2005 to July 2006, the Sprex process was
validated at the Lacq plant in a unit with a treating capacity of
70,000 cubic meters of raw gas per day. The feed stream was a
water-saturated gas containing 18 to 40% H2S. The experience gained
by running this industrial pilot has allowed Total to demonstrate
the robust qualities of the Sprex process, which has now been fully
integrated into the Groups portfolio of sweetening solutions. nnn
License
co-management
with IFP
Total has entrusted the French
Petroleum Institute (IFP)
with the management and
marketing of its gas sweetening
processes. IFPs wholly-owned
subsidiary Prosernat designs
the sweetening units.
SOUR GAS
18
//. expertise
Sustainable
management
of residual products
sss
Total is developing specific techniques to make
the development of sour resources as safe as possible
for the environment. Injection is an option that avoids
sulfur production and reduces emissions of CO2.
Sour gas processes generate emissions that have strong concentrations
of H2S a lethal gas in even minimal doses and that may also contain
CO2, entailing harmful effects on the environment. The safe and reliable
management of these so-called residual gases is a priority focus of
the Groups Research & Development efforts.
19
The various types of geological storage
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a depleted gas field.
in a saline aquifer.
1
reservoirs, deep saline aquifers, and coalbeds, but also the use of CO2 for
enhanced oil recovery (EOR). In 2001, Total E&P teamed up with various
research institutes and partners in academia and industry to undertake an
R&D program dedicated to CO2 capture and storage. The program gives
the Group a role in a number of national and international initiatives that
draw on theoretical and experimental research, industrial pilot installations,
and lessons learned from ongoing projects. For example, Total is a
member of CO2 ReMoVe, a consortium uniting different industries and
research organizations to foster the development of projects for the
geological storage of CO2 in Europe and neighboring countries. The Group
is also a member of the ENCAP (ENhanced CAPture) working group,
coordinated by the Swedish energy concern and power producer,
Vattenfall. ENCAP focuses on the development of CO2 capture processes
for coal-, natural gas- and oil-fired power generation systems. The Group
also supports Picoref (Pigeage du CO2 dans les Rservoirs en France)
which is preparing industrial demonstrations of CO2 injection in France,
notably in hydrocarbon reservoirs and salt aquifers around Paris. More
concretely, Total is participating in the project on the Sleipner field,
where CO2 has been injected into an aquifer since 1996. The Group is
also a partner in the CO2 injection project in the Statoil-operated Snhvit
field (Berens Sea). In this project, the CO2 is extracted onshore in an
LNG plant, then piped back out to sea and injected via subsea wells into
the saline formations of the Tuben sandstone, at a depth of 2,600 m.
On Canadas Weyburn oil field, Total is a partner in yet another R&D
project centered on the first industrial-scale application of CO2 capture
combined with enhanced oil recovery.In 2005, the Group launched the
study phase in preparation for the construction of a pilot oxyfuel
combustion installation for CO2 capture and storage in the depleted
reservoir of the Lacq basin in France. nnn
Crystallizing sulfur
in the reservoir
An alternative to geological
storage of H2S is to produce
solid sulfur not in surface
facilities, but in depleted
hydrocarbon reservoirs that
contained H2S. This principle
involves burning the H2S or
sulfur to obtain SO2 that can be
reinjected into the reservoir. In
a Claus reaction, the contact of
this fluid with the native H2S
in the reservoir would yield
water and sulfur. If it proves
feasible, this method will offer
the advantage of a long-term
solution to the problem posed
by H2S, since solid sulfur is
perfectly stable. This option
could thus be applied in
appropriate depleted reservoirs
near producing sour gas fields.
SOUR GAS
20
//. expertise
Production
safety
sss
Toxic, corrosive and sometimes flammable, sour gas raises
critical production safety issues. Using purpose-designed
materials, dense arrays of sensors and leading-edge risk
modeling, Total can produce these challenging resources
without compromising on safety.
Ensuring the safety of facilities and operations is a core responsibility
for an industrial player like Total. This imperative requires specific
measures when producing and processing hazardous fluids such as
sour and acid gases.
Gas detectors.
3
1. and 2. The control room at Lacq,
France.
Corrosion control
Total has implemented alloys specifically adapted to sour gas flows
since the late 1950s, with the development of the Lacq field. The more
aggressive fluids in as-yet undeveloped fields pose new challenges
in terms of both tubing and pumps. For example, future development
schemes call for the re-injection of the residual acid gases fluids
with high concentrations of H2S or CO2 and at this point their behavior
under high pressure is less well known. A lab study by the Total R&D
group working on gases with high H2S levels has measured the
corrosiveness of these water-undersaturated gases in supercritical
conditions. Having worked on many sour gas fields for several decades,
Total has successfully expanded its expertise to include dense-phase
sour gas fluid dynamics.
//. group
SOUR GAS
22
total
worldwide
in 2006
sss
Present in more than 130 countries, Total is one of
the most dynamic players in the global oil and gas industry,
with a number of truly major technological and economic
achievements to its credit.
ACTIVITIES IN EVERY SEGMENT OF THE OIL
AND GAS SECTOR
Exploration
& Production
in figures 2006
Workforce: 13,624 employees
(31 December 2006).
Investments: e9 billion.
Oil and gas production:
2.36 Mboe/d.
Proven oil and gas reserves:
11.12 Bboe.
Operations in more
than 40 countries.
Leading oil and gas producer
in Africa.
Second-largest hydrocarbon
producer in the Middle East.
23
The 30 giant projects for sustained growth
Forecast growth
in production
n Africa
n North America
n Asia
n Europe
n Rest of the world
n Extra-heavy oils
n Deep/ultra-deep water
n Other liquids
n LNG
n Other gas projects
n Extra-heavy oils
n Deep/ultra-deep water
n Other liquids
n LNG
n Other gas projects
Photo credits: F. Guiziou/Hmisphres, Photodisc, DR/Total, Castano, M. Dufour and M. Roussel for Total Infographics: Id, Total
Design-production:
Printing: Comelli Total March 2007.
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