SPE 100346

Suplacu de Barcau Field—A Case History of a Successfull In-Situ Combustion

Exploitation
A. Panait-Patică, D. Şerban, and N. Ilie, Petrom S.A.

Copyright 2006, Society of Petroleum Engineers

viscous oil originally indicated that under primary depletion
This paper was prepared for presentation at the SPE Europec/EAGE Annual Conference and expected recovery would be only 9 %, requiring more than 80
Exhibition held in Vienna, Austria, 12–15 June 2006.
years.
This paper was selected for presentation by an SPE Program Committee following review of
information contained in an abstract submitted by the author(s). Contents of the paper, as
Theoretical and laboratory studies accomplished between
presented, have not been reviewed by the Society of Petroleum Engineers and are subject to 1961 and 1964 led to the conclusion that thermal recovery
correction by the author(s). The material, as presented, does not necessarily reflect any
position of the Society of Petroleum Engineers, its officers, or members. Papers presented at methods (ISC and SD) could increase oil production and cause
SPE meetings are subject to publication review by Editorial Committees of the Society of
Petroleum Engineers. Electronic reproduction, distribution, or storage of any part of this paper
a very significant increase in the recovery factor, accompanied
for commercial purposes without the written consent of the Society of Petroleum Engineers is by a dramatic decrease in the exploitation period.
prohibited. Permission to reproduce in print is restricted to an abstract of not more than
300 words; illustrations may not be copied. The abstract must contain conspicuous Field pilot tests performed during 1964 – 1970 led to the
acknowledgment of where and by whom the paper was presented. Write Librarian, SPE, P.O.
Box 833836, Richardson, TX 75083-3836 U.S.A., fax 01-972-952-9435.
conclusion that both tested methods are commercial.
The first pilot (Fig.1) test was done for both metods:
Abstract • ISC Pilot - 04.1964 / 03.1967 – Injector I1 (left)
This paper describes the thermal recovery implementation • SD Pilot - 11.1963 / 11.1965 – Injector I2 (right)
used on the Suplacu de Barcău field, from the beginning of the
production life until 2005. The field is a heavy oil, near
surface Pliocene clastic reservoir, situated in the north-western
part of Romania, in the Pannonian Depression.
Drilling operations, beginning in 1956, revealed a heavy
and viscous oil reservoir. In 1961 a few wells were put into
production, as part of an in-situ combustion (ISC) test.
Between 1960 and 1970, an important number of wells
established the structure and reservoir parameters, from which
an original oil in place volume was calculated.
In order to confirm the theoretical model of high
efficiency, related to thermal recovery methods, steam drive
(SD) and in-situ combustion (ISC) were concurrently tested
during the period 1963-1970. The better performance of ISC Fig.1 First field pilot tests
during this semi-commercial stage led to the decision in 1970 A new stage of field experiments followed immediately,
to design the entire reservoir exploitation using this method. through infill drilling around the original panels (Fig.2).
The ISC exploitation has been successfully developed and
improved in time, becoming the largest of this type in the
world and is one of the most important fields exploited by
Petrom.
There are now nearly 800 wells with a total production of
about 1200 tones/day of crude oil (2005). The cumulative
extracted crude in 35 years is about 17,8 million tones, which
corresponds to a current recovery factor of 44,6%.
This paper presents the most significant highlights of this
field exploitation, including the challenges encountered, the
surveillance methods, as well as the important lessons which
have been drawn from the exploitation of this field.
Fig. 2 Extended field pilots and their performance

Introduction Based on the results, indicating 10 to15 % of additional

Although the Suplac reservoir has very good production recovery, a final decision was made to go forward with In-Situ
parameters, production forecasts for the high density and Combustion.
2 SPE 100346

Subsequent results have largely confirmed this forecast marly sands, gritty marls, marly sandstones, sandstones and
even if some factors were less known or ignored in the initial microconglomerates. The unconsolidated sands are present
development plans. throughout the entire reservoir and in most cases they are not
In spite of excellent performance in terms of recovery, recovered by means of mechanical coring. The value of the
close to 60 %, the ISC process offers potential for further average effective porosity, statistically from 97 samples, is
improvement, including: water injection behind the front, air 32.0%.
rate optimization and better control on the combustion front .
Production history
Major conclusions of the pilot tests The reservoir was put into production in 1960, the solution
• It is necessary for well stimulation in both ISC and SD gas drive being the main mechanism. Based on this
cases, to use cyclic steam injection mechanism, an ultimate oil recovery of 9% was predicted, due
• In situ combustion can improve recovery to over 40% to very small GOR values. Initial oil rates were in the range of
• Better performance of ISC conducts on the decision to go 2 to 5m3/day/well but they decreased very quickly to 0.3 to
at the industrial stage with exploitation 0.1m3/day/well. As a result thermal methods were considered
• A continuous combustion front has better results than a in order to increase oil recovery and the oil production rate.
“pattern” system Both ISC and SD method were tested at the upper part of
• The proper strategy for exploitation is to gradually sweep the structure, in the period 1963-1970. Initially ISC and SD
the reservoir from the upper part to the lower part of the was tested in two 0.5 ha panells (Fig. 1).
structure (approximately parallel to the isobaths) A semi-commercial stage, consisting of 6 contiguous
panells of 2 – 4 ha, were then developed for both methods
Reservoir geology (Fig. 2). Based on the semi-commercial performance, both for
The Suplacu de Barcau structure is situated in the ISC and SD, the decision to use the ISC for the commercial
north-east margin of the Panonian Depression. The structure exploitation was taken by 1970. At the same time, it was
forms a monocline treding east-west, with a fault-depedent agreed that steam injection would be used in a cyclic steam
closure to the south (fig. 3). stimulation (CSS) mode, in order to start the production wells
located close to the ISC front. At this time, the decision to
Type of trap Fault-dependant closure convert the “panel” exploitation to a line-drive exploitation
Depth, m 35 – 220 was made.
Dip, degree 5-8 The decision to sweep the reservoir starting from the
Net pay thickness, m 4 – 24 uppermost part of reservoir was also supported by two
Initial reservoir pressure, bar 4 – 22 experimental ISC patterns located at the middle and at the
Initial reservoir temperature, °C 18 lowest part (close to the water-oil contact) of the structure,
Porosity, % 32 respectively. These pilots showed that the control and the
Initial oil saturation, % 85 efficiency of the process are lower when not located up-
Absolute permeability, mD 2,000 structure. The performance of the commercial ISC project is
Oil dynamic viscosity, cP 2,000 shown in Fig. 4.
Oil density, kg/m3 960
Oil type asphalt-base-oil
Surface, ha 1,700
Oil, t/ month

RF = 45,3%

Time, months

Injected air
Injected air, 103 Sm3/ m3

Air/ oil ratio, Sm3/ m3

Air/oil ratio

Time, months

Fig. 4

Fig. 3 Schematic geological model
The reservoir rock is made up of poorly sorted,
unconsolidated sands, grainsize ranging from fine to gravel,
mainly medium and coarse grains. There are intercalations of
Since 1979, the “linear” ISC front was propagated down-
structure, parallel to isobaths. In the same time the process
was expanded in new areas towards the Western extent of the
field. The current position of the ISC front is shown in Fig. 2;
the air injection wells are included in an East-West line of
more than 10 km; the distance between two adjacent injection
SPE 100346
(or production) wells is 100m. Based on real performance of
the wells, for the zone already processed by ISC an ultimate
oil recovery of 55% was calculated and based on that, it was
estimated that the expected ultimate oil recovery for the entire
pool would be higher than 50%.
In 1983 a second linear ISC front, parallel to the main one,
but located slightly downstructure, was started in the middle
of the structure, in the wider, Eastern part of the reservoir.
The operation of two parallel ISC fronts was challenging
(mainly due to the reduction of the main, updip ISC front
propagation velocity), and due to the downgrading of the
whole performance. In 1996, the second ISC front was
abandoned; at the same time, with limited success. Since
1998, generally, both air injection rates and the capacity of
steam used for CSS have been reduced. Following this, total
oil production remained constant for the first six months, but
afterwards a decline of oil production was noticed.
It can be seen that maximum oil production was seen in
the period 1985-1991, when the total air injection rate was
maximum.
This project has generated a lot of ISC data, including
hundreds of bottom hole temperature (BHT) profiles in the
observation and production wells. Very high peak
temperatures (around 600 0C) have been observed in the upper
part of the layer, clearly indicating the segregated nature of the
ISC process. High temperature damage of some of the
producing wells have been experienced, as approx. 15% of the
producers have been replaced with new wells. Also, a large
number of cores from wells in the swept area showed some 5
– 7 m burned rock at the top, with 7 – 10 m, unburned rock
underneath heated by the ISC front .
For reasons related to the safety of workover operations at
the hot producers a special drilling mud was developed to kill
these “hot wells”, with temperatures in the range of 80 to
250 °C. This fluid ensured equilibrium in the well, avoidsing
blockage of the formation and maintained rheologic-colloidal
characteristics for the specified temperature. After the
completion of the workover this killing fluid was recovered
and re-used.
The ISC application has led to the increase of
concentration in natural emulgators in the produced oil, such
as asphaltene, resins, naphtenic acids and finely dispersed
solid particles, leading to the formation of the very tough,
problematic emulsions. Special fluidizers have been
administered at the bottom hole or even into the formation, to
break those emulsions. As far as the dehydration and
desalting of the crude oil is concerned, a patented, special
technology for the thermal-chemical treatment, with a final
step of stripping, was developed.
As of 01.01.2006 there were in production ~800 wells with
a medium daily production of 1200 tons of oil. Injection rates
were ~2000 thousand Sm3 air/day through 90 wells and ~1300
t/day steam through 24 wells.
The cumulative a recovery factor was 45.3%.
3
Combustion Laboratory
In 1972, at the time when the development of the in situ
combustion process started in Romania, the Combustion
Laboratory was set up. At that time, the laboratory was
supplied with a temperature ramped oxidation cell, a
Conradson coke device and an electric oven for sample
calcinations. In 1989, the combustion tube (combustion linear
model – fig. 5) was put into operation.
A collaboration was initiated between the IFP and the
ICPT-Câmpina, during the 70’s. IFP sent to ICPT-Câmpina
gas analyzers in order to analyze combustion gases from the
site. They also undertook Suplacu crude-oil oxidation and
burning studies on the oxidation-cell and combustion tube,
collaborating on data monitoring. The possibility of Suplacu
sand consolidation using short-time in-situ combustion
process.was also analyzed.
Oxidation cell uses:
• To study the phenomena that take place in an
infinitesimal volume as the combustion front draws near;
• A determination of the parameters necessary to
design the combustion process:
• Measurement of air consumption per m3 of rock;
deposited fuel per m3 of rock; ignition temperature; H/C
ratio.
Combustion tube tests:
• determination of the basic data for designing the
exploitation of a reservoir by in situ combustion;
• testing the possibility to initiate and maintain a
combustion front in a porous medium saturated with
oil;
• establishing the advancement speed of the
combustion front;
• estimation of the spatial conformance of the burnt
zone;
• establishing the influence of some operating
parameters over the process (air flow, ignition
temperature, concentrations in O2, etc.).
4 SPE 100346
Fig. 5 Combustion tube
Studies carried out in the combustion laboratory
• research works on the formation and burning of coke
deposits of in situ combustion processes;
• study of combustion in the case of horizontal wells;
• study of wet combustion;
• study of combustion with air enriched in oxygen;
• study of the changes induced by in situ combustion on the
physical &chemical properties of the produced oil;
• study of oxidation processes at low temperature, their
influence on the combustion process;
• monitoring the combustion processes; analysis of
produced fluids.
Some important aspects were observed in combustion with
oxygen enriched air test (42%):
• oil recovery is faster (after two hours in O2 combustion
comparing to four hours in air combustion) and the oil
production rate is higher (1,8 l/h comparing to 0,6 l/h for
air combustion);
• the average advancement rate of the combustion front is 5
cm/h comparing to 2,8 cm/h in air combustion;
• the concentration of carbon dioxide in combustion gases
is 23.5% comparing to 12% for air combustion.
The cumulative effects of the following factors: lower
injected gas volume, higher advancement rate of combustion
front and an increase in oil mobility due to CO2 solubilization,
lead to a shorter exploitation life and to low operation cost.
Wet combustion test had revealed some important aspects:
• the increase in burning, cracking and vaporization-
condensation zone from 10-20 cm in dry combustion test
to 30-40 cm in wet combustion test;
• the required amount of air/m3 reservoir and the deposited
fuel are smaller than in the case of dry combustion (11.2
Sm3/kg by 14.5 Sm3/kg and 13.0 kg/m3 by 13.7 kg/m3);
• the average advancement rate of the wet combustion front
is by 60% higher than in the case of dry combustion (3.6
cm/h as compared to 2.3 cm/h).
• the oxygen efficiency was 97.3%.
• In wet combustion an intensification of heat transfer from
behind to the front of to the combustion front was
observed, and the quantity of deposited coke and the
air/produced oil ratio are lower, so the air injected is
lower.
The presence of oxygen ahead of the combustion front and
the existence of a ‘burning’ front at low temperatures lead to
the alteration of the oil and to modifications in the chemical
composition of water. The characteristics of oxidized oils at
various temperatures are listed in the table below.
Produced fluid analysis
During the in situ combustion process oil characteristics
are changed because of phenomena which take place at high
temperature (400-6000C - cracking, vaporization -
condensation, distillation) or which take place at lower
temperature (t<2500C - low temperature oxidation).
Analysis of the oil samples from Suplacu field show
density between 920-965 kg/m3, viscosity between 200-14.000
cP, Conradson coke between 5-9%, asphaltene content
between 2-5,3%, resin content between 11-15%.
The lowest value for density, viscosity, asphaltene, and
resin content shows that the oil is from the vaporization-
condensation zone near the combustion front.
The highest value for density, viscosity, asphaltene, resin
content shows the presence of oxidation at low temperature.
Monitoring of the combustion processes using gas
analysis
Monitoring of the combustion processes was achieved by
the analysis of the composition of the produced gas and
produced oil, as well as by temperature measurements.
Every year at Suplacu de Barcău field there are 200-400
gas samples analysed. At the same time in Gas Laboratory
from ICPT there are 50-80 gas analyses made.
The hydrocarbon gas analysis showed the presence of
unsaturated hydrocarbons resulting from cracking at high
temperatures.
By taking into consideration the percentages of gas and the
atomic H/C ratio in the burnt residue, information is obtained
on the temperature in the combustion front, on the quality of
the burnt fuel, any channelling or excess air and quality of
ignition operation.
By taking into account the fact that the atomic H/C ratio of
the Suplacu oil is 1.7, a H/C ratio below this value will
indicate the burning of a carbon-rich fuel, while a higher H/C
ratio will indicate the presence of oxidation at low
temperature.
High values of CO2 (17 –19%) indicates high temperature
burning reactions of a fuel rich in carbon, while low CO2
percentages can indicate oxidation processes at low
temperatures or air channelling.
Operational challenges
• Well ignition
• Production and surface facilities
• Fluids processing
SPE 100346
Well ignition is a key element in ISC process as the
nucleus of the future combustion front. Ignition requirements:
• The saturation with O2 of the ignition zone and
generating a temperature higher than 400°C
• Once the ignition is achieved the well turns into a
combustion well through which the necessary air for the
the creation, stability and movement of the combustion
front is provided.
Well ignition methods used:
• With combustible gases
• Electrical
• Chemical
• Combined chemical + electrical
Surface facilities
Combustion gases collecting and transporting system
• Horizontal separator (3 Sm3)
• Combustion gas pipelines from steel OLT 45 (6-
20 in. diameter)
• Evacuating stack using steel (60 m height) or
PAFS (92 m height)
• Flow pipelines:
o From wells to gathering parks made
from steel insulated with CITOM (4 in
diameter)
o From gathering parks to main oil deposit
made from steel insulated with CITOM
(6-8 in diameter)
Air - compression and distribution:
• Total compressed air capacity 4.800.000 Sm3/day
• 2 pcs of air compressing stations (M1 FU – 10
pcs x 180.000 Sm3/day/pcs, and CCAE 21-300 – 10
pcs x 300.000 Sm3/day/pcs);
• Compressed air pipeline network (3-20 in
diameter);
• Air distributors
• Compressed air pressure - max. 17.5 bar
• Compressed cost 40.4 RON/1000 Sm3
• Total injectors – 90 wells with flow air injected
between 8000 and 40.000 Sm3/day
Steam producing and distribution system:
• Total producing capacity 6800 to/day
• 20 steam battery (68 steam boilers from which 58
pcs
• ABA 4S, 4 pcs ABA 10S, 4 pcs transportable
steam boilers
• 2 pcs ABA 2S) with steam pressure between 5
and 15 bar
• Insulated steam pipelines (3-6 in diameter)
• Average of producing steam/day/8 months 2005 –
1685 to/d
• Steam cost 8.76 RON/to
• Waste water treatment plant:
• Total capacity 4000 m3/day
5
• Treatments are based on chemical with Anionic
and Cationic Electrolits and Al2(S04)3
Cogeneration plant:
• Total energy supply capacity 3.6 MWh
• Total steam capacity supply 14 to/h
• Energy production cost per hour (including all
expenditures) is 62 USD/MWh
• Gases consumption 45.000 Sm3/day
Gathering parks:
• Total number – 29;
• Flow rates between 40 and 960 m3/day;
• Total number of wells 900;
Facilities:
• Pits;
• Hydrants;
• Tank with 200 m3 capacity;
• Plunger pumps (2PN 160 or 2PN 400);
• Combustion gases evacuation stack;
• Manifolds;
• Steam pipes (for liquid heating).
Fluid processing
C2+ components includ saturated and some unsaturated
and aromatic HC up to C 9. The polycyclic aromatic
hydrocarbons are present at total conc. below 1 mg/m3
Gas collection system started in 1985, formed from well
head gas separator, gas pipes to gathering park, blower and
steel stacks 55 m high, 0.8 m diam. and 8 mm wall thickness.
Due to water condensation, severe corrosion problems appears
in condensate drainage area, specifically In the lower part of
the stack and at the blower.
Corrosion was accelerated beside the O2 and CO2 present
in gases also by organic comp. entrained with steam. From
1991, the steel stacks were replaced with polyester/glass fiber
stacks which resist corrosion, and are higher (90-95 m)
Oil /water separation was done using a thermo chemical
process (demulsifier E 96) with acceptable results. For a short
period (in the 80’s) an installation for water removal from oil
by stripping with hot gases was in use. The nonionic
demulsifier is replaced now with a cationic polyacrilamide
Key technical challenges
• Optimize air rate
• Maximize oil rate
• Reduce operation cost
• Assess Steam drive potential
Acknowledgments
The authors would like to acknowledge the professional
assistance of Al. Condrachi. The authors would also like to
extend a special acknowledgement to the management of
Petrom S.A. for its support in writing this paper.
6 SPE 100346

References
1. Turta, A.: "In-Situ Combustion - From Pilot to
Commercial Application.” Proceedings of the Field
Applications of In-Situ Combustion - Past
Performance/Future Application Symposium, Tulsa, April
21-22, 1994.

2. Condrachi A., Panait-Patica A., et.al.: ”Review of the

Performance of the Suplacu de Barcau Field, Exploited
by Thermal Methods (In-situ Combustion and Cyclic
Steam Stimulation” Internal Report ICPT Campina,
Romania, 1995 - 2004

3. Machedon, V., Popescu T., and Paduraru R.:

"Application of In-Situ Combustion in Romania" Joint
Canada-Romania Heavy Oil Symposium, Sinaia,
Romania, March 7-13, 1993

4. Carcoana A. :”Results and Difficulties of the World’s

Largest in-Situ Combustion Process” Suplacu de Barcau
Field, Romania” APE/DOE 20248, 1990

5. Aldea Gh., Turta A. and Zamfir M.: “The In-Situ

Combustion Industrial Exploitation of Suplacu de Barcau
Field, Romania”, The Fourth International Conference on
Heavy Crude and Tar Sands, August 7-12, 1988,
Edmonton.

6. Ilie N., Serban D., et.al.: ”Review of the Performance of

the Suplacu de Barcau Field, Exploited by Thermal
Methods (In-situ Combustion and Cyclic Steam
Stimulation” Internal Report ICPT Campina, Romania,
2004 - 2006
SPE 100346 7

Fig. 6 Variation with depth of initial pressure

8 SPE 100346

Fig. 7 Variation with depth of reservoir temperature

 SPE 100346

Refinery
Chimney
for exhaust gas evacuation Barcau river
1,8M M Scm /day CONPET
Waist w ater
Oil 5.5 M cm /day
Liquid Central Deposit 1,2M to/ day
(STRIPPING)
- Decantation - Therm o chem ical treatm ent Waist Waist w ater
- Therm al treatm ent (E 96 and w arm ing at 110 0C) w ater treatment plant
(w arm ing at 800 C) - Decantation
- Treatm ent w ith Rom afluid

Oil

Steam Sludge
Gas Battery of
SM A Sludge
boilers Sludge Pits

Liquid
Production w ell
RESERVOIR stimulated w ith cyclic
Production w ell Air Injection w ell

Fig. 8 Flow chart

steam injection
1.5M to/ day

Exhaust
Gas Electrical energy Air Com pressor
Gas Battery of boilers
Cogeneration
SM A Station
plant 2 M M Scm /day
Water Electrical energy
Water cooling
Water treatm ent plant
9
10 SPE 100346

Fig. 9 Izoproductivity map