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Abstract
The purpose of this research is to determine an estimate for actual optimal oil recovery through
cyclic Gas-Assisted Gravity Drainage (GAGD) process in a heterogeneous sandstone reservoir under
geological uncertainties. A robust optimization approach was adopted to determine the optimal
durations of gas injection, soaking, and oil production under geological uncertainties. 100 stochas-
tic reservoir realizations of the 3D permeability and porosity distributions were created to honor
geological constraints. Ranking was applied through quantifying of reservoir oil response to select
P10, P50, and, P90 that represent the overall reservoir uncertainty. A compositional reservoir flow
simulation was used for the GAGD process performance evaluation. Approximately 200 simulation
jobs were created, including the aforementioned durations and geological uncertainty parameters,
through Design of Experiments (DoE). The Latin Hypercube Sampling was adopted to create these
200 simulation jobs that then evaluated by the compositional reservoir simulation to calculate the
cumulative oil production by the end of 10 prediction years. The robust optimization approach was
then applied to select the true optimal solution of the highest oil recovery by taking into account the
geological uncertainties in permeability, porosity, and anisotropy models. The nominal optimization
of one single realization was also adopted for the comparison. The robust optimization has shown its
feasibility to increase oil production through the cyclic GAGD process from 4.535 to 4.62547 billion
barrels. However, the nominal optimization case increased oil production to 5.9726 billion barrels.
The presented robust optimization workflow under geological uncertainties resulted in higher oil
recovery and net present value than nominal realization optimization, with providing degrees of
freedom for the decision-maker to significantly reduce the project risk. It was specifically concluded
that the robust optimal solution represents the most economically feasible solution to obtain the
highest NPV through the GAGD process for a range $(30-80) per barrel oil prices. However, the
base case and nominal solution (no geological uncertainties) were not economical when the oil price
declines to be less than 36and32, respectively.
Keywords: Cyclic CO2 Flooding, GAGD Process, Robust Optimization, Geological Uncertainties,
Enhanced Oil Recovery, South Rumaila Oil Field
∗ Corresponding author
Email address: wmoham4@lsu.edu, Tel:+1-225-715-2578, Fax:1-888-965-9518 (Watheq J. Al-Mudhafar)
1 Researcher, Louisiana State University
2 Professor, Louisiana State University
3 Professor, Penn State University
© 2018. This manuscript version is made available under the Elsevier user license
http://www.elsevier.com/open-access/userlicense/1.0/
1. Introduction
Optimization of carbon dioxide flooding performance is an essential step in the development of oil
1
2 reservoirs under EOR process implementation. However, the optimization procedure requires a high
3 number of reservoir simulation runs, each of which can take hours to run, especially in some large
4
5 5 compositional reservoir models. In the real oil field evaluation of CO2 flooding, the reservoir models
6
are usually quite large with respect to the number of grids and fine-grids in near-wellbore injection
7
8 wells. The overall running time requires searching for the best optimization approach to obtain
9
10 the optimal solution with the fewest number of simulations. Additionally, the EOR optimization
11 process should take into account the geological uncertainties to obtain the true optimal solution.
12
13 10 Most of the previous optimization techniques have considered only a single reservoir model (nom-
14
inal optimization) and have not incorporated geological uncertainty by finding the optimum field
15
16 development scenario (Brouwer and Jansen , 2004, Sarma et al. , 2008, Wang et al. , 2009, Zakirov
17
18 et al. , 1996). Therefore, the Design of Experiments-based robust optimization was adopted in this
19 study to optimize CO2 flooding using the Gas-Assisted Gravity Drainage (GAGD) process under
20
21 15 geological uncertainties through the field-scale application on a heterogeneous sandstone reservoir
22 in the South Rumaila oil field.
23
24 Since sometimes limited geological information is used to build efficient reservoir models, there
25
is the inability to precisely evaluate the reservoir performance. The limited knowledge comes from
26
27 lack of observations, distinct scales of petrophysical data, measurement error, limited understanding
28
29 20 of physical problems, and non-linear data behavior. This increases the uncertainty associated with
30 forecasting in the future reservoir performance and negatively impacts the economic returns (Zhang
31
32 , 2003). Therefore, an uncertainty assessment is necessary to construct a strong reservoir manage-
33
ment base for which development and optimization can improve the decision making (Cruz , 2000).
34
35 Geological uncertainty becomes an essential factor in heterogeneous reservoirs, in which risk in-
36
37 25 creases because heterogeneity affects the performance of EOR processes, especially with respect to
38 the sweep efficiency and hydrocarbon recovery. Several studies have reported the effect of hetero-
39
40 geneity on the reservoir performance. The combined effect of permeability variation and spatial
41 correlation of the reservoir continuity on the performance of miscible and immiscible flooding dis-
42
43 placements have been quantified through horizontal wells. Accordingly, the combination of high
44
30 permeability variation and high correlation length significantly reduces the displacement perfor-
45
46 mance of horizontal wells (Gharbi et al. , 1997). Additionally, high reservoir heterogeneity in CO2
47
48 miscible flooding performance helps make the flooding front more unstable with early breakthrough
49 (viscous fingering). However, dip angle assists gravity segregation of CO2 by forming a more sta-
50
51 ble flood front, which in turn slows down the breakthrough and allows more oil to be recovered
52
35 (Summapo et al. , 2013). The heterogeneity has been assessed by creation of a synthetic reservoir
53
54 with two depositional systems: fining-upwards, or coarsening-upwards. It has been concluded that
55
56 the fining-upwards reservoir had earlier breakthrough, higher water production, and lower oil re-
57 covery than in the coarsening-upwards reservoir. The oil recovery factor increased with an increase
58
59 in the ratio of vertical permeability to horizontal permeability in a coarsening-upwards sequence;
60 40 while an increase in the same ratio resulted in a decrease in oil recovery factor in a fining-upward
61
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63 2
64
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sequence (Nguyen et al. , 2015a). A similar study concluded shale distribution is an indicator for
heterogeneity quantification. The various percents of shale, which were randomly created through a
1 set of reservoir models, were quantified for their impact on oil production through the SAGD process
2
3 efficiency. It was concluded that the location of shale baffles represents the key for their effects, espe-
4 45 cially between the injectors and producers which highly impact the recovery process (Ravalec et al.
5
6 , 2009). The heterogeneity has been likewise quantified through CO2 EOR and storage processes by
7 random generation of permeability and porosity by including thin, discontinuous and intermittent
8
9 shale laminae. The results showed that the presence of shale layers could lead to lower oil recovery
10
than the model when shale laminae disappear (Li et al. , 2015).
11
12 50 Many studies have been recently implemented using robust optimization approaches to deter-
13
14 mine the true optimal solution in various IOR/EOR studies under geological uncertainty. Robust
15 approaches have been adopted in water flooding optimization (Ambia , 2012, Lorentzen et al. ,
16
17 2006, Van Essen et al. , 2009), closed-loop reservoir management (Chen et al. , 2009, 2012), SAGD
18 process (Fedutenko et al. , 2013, White and Royer , 2003), well placement (Aanonsen et al. ,
19
20 55 1995, Alpak et al. , 2015), assisted-history matching (Nguyen et al. , 2015b), and unconventional
21
22 reservoirs (Nguyen et al. , 2016). The most recent efficient optimization approaches considering ge-
23 ological uncertainties utilize design of experiments-based robust optimization procedures. Different
24
25 approaches have been chosen for robust optimization: DECE, Designed Exploration and Controlled
26 Evolution (Nguyen et al. , 2015b, Yang et al. , 2011), Genetic Algorithm and Particle-Swarm Op-
27
28 60 timization(Ambia , 2012, Nguyen et al. , 2016), Steepest-Ascent Algorithm (Alpak et al. , 2015),
29
and Ensemble-based optimization (EnOpt) for robust optimizations (Lorentzen et al. , 2006, Chen
30
31 et al. , 2009). In Design of Experiments (DoE), setting multiple levels for each of the operational
32
33 decision factors that govern the EOR process performance results in many experimental simulation
34 runs. In EOR optimization, it is essential to determine the optimal levels of operational decision
35
36 65 factors that most significantly impact the EOR process performance. These factors are mainly in
37 the form of operational constraints in production and injection wells. The optimization of these
38
39 factors will result in the optimal reservoir performance over time with respect to field cumulative oil
40
41 production and Net Present Value (NPV).
42 In this paper, CO2 flooding was implemented through the cyclic Gas-Assisted Gravity Drainage
43
44 70 (GAGD) process simulation in a heterogeneous sandstone reservoir in the South Rumaila oil field,
45 located in Iraq. Optimal oil recovery through the cyclic GAGD process was developed by integrating
46
47 multiple geological scenarios into the optimization of injection, soaking, and production durations
48
over 10 years of future reservoir forecasting. Two comparative optimization procedures for the
49
50 cyclic GAGD process optimization were considered: Nominal one single realization of vertical and
51
52 75 horizontal permeability, and robust optimization using multiple permeability and anisotropy ratio
53 realizations. The DoE approach selected for the optimization of CO2 flooding under geological un-
54
55 certainty is Latin Hypercube Sampling (LHS). LHS was adopted for its ability to efficiently sample
56 the uncertainty distributions of reservoir and operational parameters (Jin et al. , 2005, McKay ,
57
58 2000). LHS was considered to create many designed simulation runs evaluated by the composi-
59
60 80 tional reservoir simulation to obtain the optimal reservoir flow responses. More specifically, LHS
61
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63 3
64
65
approach creates the experimental simulation jobs by combining continuous levels of operational de-
cision factors and discrete levels for geological realizations that reflect the overall uncertainty space.
1 Incorporating geological uncertainties into the EOR optimization processes requires the generation
2
3 of many stochastic reservoir images (realizations) for permeability, porosity, and anisotropy ratio.
4 85 Since it is difficult to simulate all the realizations, it is essential to rank them to select the least-
5
6 likely (P10), median (P50), and most-likely (P90) models. These combined experiments are then
7 evaluated using compositional reservoir simulation to calculate the reservoir flow response or Net
8
9 Present Value after a period of future prediction (White and Royer , 2003). To the best of the
10
authors’ knowledge, the presented workflow of robust optimization has never been adopted in the
11
12 90 gas flooding literature, especially for GAGD process evaluation on a real heterogeneous sandstone
13
14 reservoir.
15
16
17 2. Gas-Assisted Gravity Drainage (GAGD) Process
18
19 Gravity drainage is a very effective mechanism to achieve high oil recovery in water-wet, con-
20
21 nate, and water-bearing reservoirs as gravity represents the dominating driving force that controls the
22 95 gas/oil displacements. Therefore, the gravity drainage mechanism reduces the residual oil saturation
23
24 to minimum levels conditioning to the gravitational/viscous forces, shape of oil relative permeability,
25
and reservoir geometry and heterogeneity (Hagoort , 1980). Since the principle of gravity drainage
26
27 mechanism states vertical gas-oil-water displacements, the Gas-Assisted Gravity Drainage (GAGD)
28
29 process has been suggested as a promising technique to improve/enhance the recovery of oil in sec-
30 100 ondary and tertiary modes for both immiscible and miscible gas flooding processes. In the GAGD
31
32 process concept, horizontal producers are placed at the bottom of the payzone. The gas is injected
33
either immisciblly or misciblly in a gravity-stable mode using vertical wells completed at the top
34
35 of a formation (Rao et al. , 2004). Due to gravity segregation resulting from the contrast in fluid
36
37 densities at reservoir conditions, the injected gas accumulates at the top of pay zone to formulate a
38 105 gas cap and to provide gravity stable displacement of bypassed oil, which drains downwards to the
39
40 horizontal producers. The formed gas cap and the resulting gravity segregation of fluids, as well as
41 the drainage of oil towards the bottom of the pay zone leads to better sweep efficiency and higher oil
42
43 recovery (Mahmoud and Rao , 2008). The schematic of the GAGD process was illustrated in Figure
44
1. In comparison to other gases, CO2 is the most favorite solvent for injection because it attains high
45
46 110 volumetric sweep efficiency with high microscopic displacement efficiency by reducing the surface
47
48 tension of oil and water. Additionally, the high volumetric sweep efficiency assures delaying CO2
49 breakthrough to the production wells. Delaying or eliminating gas breakthrough results in diminish-
50
51 ing concurrent gas-liquid flow, and leads to increased gas injectivity while maintaining the injection
52
pressure. Furthermore, CO2 can extract heavier crude oil components up to C30, especially in the
53
54 115 miscible injection mode, as its solubility promotes swelling of hydrocarbon oil. CO2 also reduces
55
56 oil viscosity and attains miscibility at relatively low-pressure ranges of 1500-4500 psi (Mathiassen ,
57 2003, Rao et al. , 2004). However, many factors impede CO2 performance in oil reservoirs, such as
58
59 reservoir description in terms of: areal and vertical permeability distribution, fractures and faults,
60 as well as barriers and continuity. Moreover, gravity forces, viscous fingering, and mobility ratio
61
62
63 4
64
65
120 further affect CO2 sweep efficiency (Mathiassen , 2003).
CO2 has other advantages that make it very effective in enhanced oil recovery projects as it can
1 be economically obtained either from thermal power plants or refineries, especially in the area of
2
3 Rumaila field.
4
5
6 3. Reservoir Flow Modeling
7
8 125 The main pay reservoir in the South Rumaila oil field was selected for full detailed compositional
9
10 reservoir simulation to enhance oil recovery through the GAGD process. For field-scale reservoir
11 modeling, there are some factors that should be taken into consideration to decide the property
12
13 upscaling and grid dimensions selection. These factors are cost, time available to conduct the study,
14
as well as the processing speed of the CPU. Simulator type is also a significant factor to be consid-
15
16 130 ered in upscaling because the compositional model (CMG-GEM), for instance, requires much more
17
18 running time than the black-oil models (CMG , 2011).
19 The main pay does not contain any complex geological features such as faults or fractures. It has
20
21 three-lithology types: sand, shaly sand, and shale distributed in a fluvial depositional environment
22 (Wells et al. , 2013), with distinct spatial permeability distributions. Therefore, Multiple-Point
23
24 135 Geostatistics (MPS) has been adopted for 3D lithofacies modeling and Sequential Gaussian Simu-
25
lation has been used for petrophysical property modeling given each of the three lithofacies in MPS
26
27 simulation (Al-Mudhafar , 2016).
28
29 The original geological model has 1,908,900 grid cells with 210, 202, and 45 grids in I, J, and
30 K directions, respectively. The regular dimensions of the fine grid blocks are constant: 50m x 50
31
32 140 m. The root mean square-upscaled reservoir model, of 69, 66, and 12 grid dimensions was exported
33
to build the compositional reservoir flow simulation.The coarse grid system has a 150m x 150m
34
35 regular dimension 54,648 total grid cells. Based on the cross-sectional well log, the 45 vertical layers
36
37 were upscaled to only 12 layers. In order to preserve the data variation and reservoir heterogeneity,
38 arithmetic and harmonic mean formula were considered for well porosity and permeability upscal-
39
40 145 ing, respectively. Since the oil relative permeability is a key factor in the gravity-drainage process
41 (Hagoort , 1980), Three different relative permeability and capillary curves were included in the
42
43 reservoir model given the three available lithofacies based on the ranges of permeability: sand, shaly
44
sand, and shale (Mohammed et al. , 2010), as shown in Figure 2:
45
46 Primary oil production started in the South Rumaila field in early 1954, but water injection was not
47
48 150 initiated until the 1980s. During that period, 40 vertical production wells, mainly located at the
49 crest of reservoir, were opened to flow. Since there is an infinite active edge-water aquifer, natural
50
51 depletion and water drive were the only production mechanisms until the late 1970s. Later, 20
52
injection wells were drilled at the east flank in order to maintain the huge aquifer support from the
53
54 west flank, which accumulates up to 20 times the influx than east one (Kabir et al. , 2007). The
55
56 155 location of the original production and injection wells were shown in Figure 3. The production
57 of some layers ceased because water cut values exceeded 98%. The 20 injectors were primarily ar-
58
59 ranged in two parallel downdip rows. Specifically, the inner row was completed only in the bottom
60 two layers, while the others were completed only in the second two layer intervals. By the year
61
62
63 5
64
65
2004, the cumulative water injection was approximately 1.1 billion barrels. The injection rates have
160 varied widely, with a maximum of nearly 426,000 BPD for two months in 1988. Artificial lift has
1 been recently installed in the main pay wells in order to assist the wells incapable of flowing to the
2
3 surface after water cut reaches approximately 80%. Furthermore, the estimated original oil in place
4 (OOIP) for the main pay is 6.123 billion barrels. Moreover, the approximate current recovery factor
5
6 is 55% by the end of history matching period. The peak oil production rate was 1.35 MMBPD in
7 165 May 1979. The oil production rate in July 2013 was approximately 1.25 MMBPD. Figure 4 shows
8
9 the production and injection history for the field.
10
11
12 3.1. PVT Fluid Behavior
13 To track the fluids interaction through porous media in terms of their compositions, a full PVT
14
15 model was constructed through the WinProp package within the CMG reservoir simulator (CMG ,
16
17 170 2011). WinProp is a compositional equation-of-state based phase behavior and properties calculation
18 package. In WinProp, the fluid are characterized in terms of their components in order to allow
19
20 compositional fluids interaction through porous media. The calculation steps implemented to build
21 the complete PVT model, for the main pay/South Rumaila oil field, include:
22
23 1. Fluid component properties.
24
25 175 2. Plus fraction characterization.
26
27 3. Multiple-contact miscibility calculations and ternary diagram generation.
28
4. Flash, saturation, and envelope calculations.
29
30 5. Recombination and constant composition expansion calculations.
31
32 6. Differential liberation and constant volume depletion.
33
34 180 7. Separator and swelling tests.
35
36 The compositions of the primary oil and secondary (injected gas) was depicted in Figure 5 and
37 the general PVT data of solution GOR, oil and gas fomation volume factor (FVF), and oil and gas
38
39 viscosity, all as a function of pressure were outlines in Table 1.
40
41
42 4. History Matching
43
44 Validation of the reservoir model as it relates to matching the observed response to the calculated
45
46 values is a crucial step in integrated reservoir studies (Kabir et al. , 2003). If the validated reservoir
47
model accurately represents the fluid flow behavior through the reservoir and better captures the
48
49 current pressure and saturation state, it can then be used to predict future reservoir performance
50
51 in response to reservoir management and optimization. Performing an acceptable history matching
52 is not an easy step as it requires many iterations of simulation runs to reduce the discrepancy
53
54 between observed and calculated values. The difficulty of the history matching process stems from
55
the uncertainties related to reservoir and production parameters (Kabir et al. , 2003).
56
57 The parameters considered for history matching are: production and pressure data, the average
58
59 reservoir pressure, well bottomhole pressure, water cut, initial time of breakthrough, and depth of oil-
60 water contact. The most common parameters changed to achieve history matching are: permeability
61
62
63 6
64
65
Table 1: General PVT Data of the used in the GAGD Compositional Reservoir Simulation
pressure, psia solution GOR oil FVF gas FVF oil vis,cp gas vis,cp
1
2 14.70 0.0000 1.0469 0.21852 1.3624 0.00855
3
4 100.00 36.9525 1.0748 0.03127 1.0614 0.01017
5 200.00 89.6405 1.1096 0.01540 0.9292 0.01075
6
7 300.00 128.3230 1.1333 0.01018 0.8457 0.01111
8
400.00 161.8011 1.1529 0.00758 0.7805 0.01136
9
10 500.00 193.0021 1.1705 0.00603 0.7252 0.01155
11
12 600.00 223.1102 1.1872 0.00499 0.6767 0.01170
13 700.00 252.7181 1.2033 0.00426 0.6333 0.01183
14
15 739.46 264.2473 1.2095 0.00402 0.6175 0.01188
16 1074.80 366.4098 1.2641 0.00272 0.5008 0.01227
17
18 1644.93 567.8513 1.3717 0.00175 0.3561 0.01298
19
2313.55 868.1831 1.5330 0.00123 0.2438 0.01415
20
21 4577.55 3889.9479 3.2476 0.00069 0.0646 0.02749
22
23
24
and porosity distributions, aquifer strength, relative permeability and capillary pressure, along with
25
26 vertical to horizontal permeability ratios (Kv/Kh). For a given number of observations nobs , the
27
28 mismatch error can be quantified as the weighted sums of squares of the difference between the
29 observed response Y obs and the calculated model results Y cal (Landa , 2001):
30
31 n
X obs