Development of the Surfactant-Based Chemical EOR Formula for Low Permeability Reservoirs

Abstract

Based on the results of the foam flooding for our low permeability reservoirs, we have explored the possibility of using low interfacial tension (IFT) surfactants to improve oil recovery. The objective of this work is to develop a robust low-tension surfactant formula through lab experiments to investigate several key factors for surfactant-based chemical flooding. Microemulsion phase behavior and aqueous solubility experiments at reservoir temperature were performed to develop the surfactant formula. After reviewing surfactant processes in literature and evaluating over 200 formulas using commercially available surfactants, we found that we may have long ignored the challenges of achieving aqueous stability and optimal microemulsion phase behavior for surfactant formulations in low salinity environments. A surfactant formula with a low IFT does not always result in a good microemulsion phase behavior. Therefore, a novel synergistic blend with two surfactants in the formulation was developed with a cost-effective nonionic surfactant. The formula exhibits an increased aqueous solubility, a lower optimum salinity, and an ultra-low IFT in the range of 10-4 mN/m. There were challenges of using a spinning drop tensiometer to measure the IFT of the black crude oil and the injection water at reservoir conditions. We managed the process and studied the IFTs of formulas with good Winsor type III phase behavior results. Several microemulsion phase behavior test methods were investigated, and a practical and rapid test method is proposed to be used in the field under operational conditions. Reservoir core flooding experiments including SP (surfactant-polymer) and LTG (low-tension-gas) were conducted to evaluate the oil recovery. SP flooding with a selected polymer for mobility control and a co-solvent recovered 76% of the waterflood residual oil. Furthermore, 98% residual crude oil recovery was achieved by LTG flooding through using an additional foaming agent and nitrogen. These results demonstrate a favorable mobilization and displacement of the residual oil for low permeability reservoirs. In summary, microemulsion phase behavior and aqueous solubility tests were used to develop coreflood formulations for low salinity, low temperature conditions. The formulation achieved significant oil recovery for both SP flooding and LTG flooding. Key factors for the low-tension surfactant-based chemical flooding are good microemulsion phase behavior, a reasonably aqueous stability, and a decent low IFT.