Abstract
The technical and economic validities of the toe-to-heel air injection (THAI) process for heavy oils upgrading and production are yet to be fully realised even though it has been operated at laboratory, pilot, and semi-commercial levels. The findings from Canadian Kerrobert THAI project suggested that there is no proportionality between oil production and air injection rates. However, this conclusion was reached without having to dig deeper into the dynamics of the transport processes inside the reservoir especially that efficient combustion was clearly taking place as the mol% oxygen in the produced gas was negligible. As a result, this study is conducted with aims of identifying the similarities and differences of the dynamics of the transport processes in lab-scale and field-scale reservoirs. For the first time, this study has found oil drainage dynamics inside the reservoir to be both scale-dependent and operation-dependent. For the laboratory-scale numerical model E, what is clearest is that all of the head of the oil flux vectors are either totally vertically directed or slightly inclined and pointing upward towards the heel. None of them is pointing backward towards the toe of the HP well. Thus, it is apparent that oil drainage pattern in this laboratory-scale model E is efficient as all the mobilised upgraded oil, including from the base of the combustion cell, is produced as the combustion front advances in the toe-to-heel manner. However, the combustion front has a backward-leaning shape which is an indicator that it is propagating even inside the HP well. This implies that the process is operating in an unstable, inefficient, and unsafe mode. These two opposing patterns at laboratory-scale must be resolved to ensure healthy combustion front propagation with efficient oil drainage and production rates are achieved. At the field scale (i.e. model F), this study has shown for the first time that there are actually two mobile oil zones: the one ahead of the combustion front with lower oil flux magnitude (i.e. MOZ) and the one containing large pool of mobilised partially upgraded oil at the base of the reservoir just behind the toe of the HP well. The above findings in model F show that there is conflicting dynamics about the goal of achieving large oil production rates downstream of the combustion front with the propagation of forward-tilting stable, safe, and efficient combustion front. If the combustion is to be optimally sustained, then most of the mobilised upgraded oil might be lost going in the wrong direction towards the region behind the toe of the HP well. In actual reservoir in the field, shale with very low permeability and porosity must be present behind the toe in order for the large pool of mobilised upgraded oil that is continuously draining from the vertical adjacent planes to be forced into the toe of the HP well. As a result, to balance these two conflicting dynamics of upward-tilted combustion front going longitudinally towards the heel of the HP well and the mobilised oil draining down at an angle towards the region behind the toe of the HP well, future studies are essentially required. These are proposed and also listed under the conclusion section in order to ensure thorough design and operation procedures for the THAI process are established.