Using response surface design for optimizing operating conditions in recovering heavy oil process, Peace River oil sands

In order to maximize oil recovery with minimal environmental damages and lower production costs for producing heavy oil and bitumen resources in Peace River oil sands, optimal operating conditions were conducted by using design of experiment and response surface methodology. This study was aimed to mitigate the risks of incomprehensive economic assessment and engineering in the process operation. Simulation responses for 26 design points were estimated based on amount of oil recovery and net present value for each case. Response surface methodology was applied to search for promising designs in contour plots and the response surface map. The best operating conditions of the Fast-SAGD1 process were an injector–producer spacing of 9 m, injection pressure of 6409 kPa, steam injection rate of 610 m3/d, subcool 6 °C for the SAGD system; while for the CSS well, injection pressure of 8333 kPa and a steam injection rate of 1007 m3/d. In this study, the amount of oil recovery produced through the Fast-SAGD1 process increased significantly and appeared to be more effective than the conventional SAGD process. In addition, it was observed that using lower injection pressures will not yield economical results in either SAGD or FastSAGD processes due to insufficient heat transfer from the steam into the solid bitumen in the reservoir, consequentially causing low NPV and oil recovery. The results presented can be widely applied and are practical for the effective recovery of unconventional resources in Alberta׳s oil sands.