Coaxing Oil from Shale Oil shale is plentiful, but producing its petroleum can be complicated. Since the 1800s, these rocks have been mined and fed into surface facilities where liquid hydrocarbons were extracted. Now, operators are developing methods to heat the rock in situ and pipe the liberated oil to the surface. They are also adapting oilfield technology to evaluate these deposits and estimate their fluid yields. Pierre Allix Total Pau, France Alan Burnham American Shale Oil LLC Rifle, Colorado, USA Tom Fowler Shell International Exploration and Production Houston, Texas, USA Oil shale is the term given to very fine-grained sedimentary rock containing relatively large amounts of immature organic material, or kerogen. It is essentially potential source rock that would have generated hydrocarbons if it had been subjected to geologic burial at the requisite temperatures and pressures for a sufficient time. In nature, it can take millions of years at burial temperatures between 100°C and 150°C [210°F and 300°F] for most source rocks to generate oil. But the process can be accelerated by heating the kerogen-rich rock more quickly and to higher temperatures, generating liquid hydrocarbons in much shorter time: from a matter of minutes to a few years. Michael Herron Robert Kleinberg Cambridge, Massachusetts, USA Bill Symington ExxonMobil Upstream Research Company Houston, Texas Oilfield Review Winter 2010/2011: 22, no. 4. Copyright © 2011 Schlumberger. For help in preparation of this article, thanks to Neil Bostrom, Jim Grau, Josephine Mawutor Ndinyah, Drew Pomerantz and Stacy Lynn Reeder, Cambridge, Massachusetts; John R. Dyni, US Geological Survey, Denver; Martin Kennedy, University of Adelaide, South Australia, Australia; Patrick McGinn, ExxonMobil Corporation, Houston; Eric Oudenot, London; Kenneth Peters, Mill Valley, California, USA; and Carolyn Tucker, Shell Oil, Denver. ECS and RST are marks of Schlumberger. CCR is a mark of American Shale Oil LLC. Electrofrac is a mark of ExxonMobil. Rock-Eval is a mark of the Institut Français du Pétrole. 1. Dyni JR: “Geology and Resources of Some World Oil-Shale Deposits,” Reston, Virginia, USA: US Geological Survey Scientific Investigations, Report 2005-5294, 2006. Smith MA: “Lacustrine Oil Shales in the Geologic Record,” in Katz BJ (ed): Lacustrine Basin Exploration: Case Studies and Modern Analogs. Tulsa: The American Association of Petroleum Geologists, AAPG Memoir 50 (1990): 43–60. 4 Oilfield Review Forcing petroleum products from immature formations is one of the more difficult ways to extract energy from the Earth, but that has not kept people from trying. From prehistoric times to the present, oil shale, like coal, has been burned as fuel. Methods for coaxing oil from the rock to produce liquid fuels have existed for hundreds of years. The earliest such ventures mined oil shale and heated it in processing facilities on the surface to obtain liquid shale oil and other petroleum products. More recently, methods have been tested to heat the rock in situ and extract the resulting oil in a more conventional way: through boreholes. These approaches are being developed, but the world’s oil shale resources remain largely untapped. Current estimates of the volumes recoverable from oil shale deposits are in the trillions of barrels, but recovery methods are complicated and expensive. However, with today’s sustained high prices and predictions of future oil shortages in the coming decades, producing oil from shale may soon become economically viable. Therefore, several companies and countries are working to find practical ways to exploit these unconventional resources. This article explains how oil shales form, how they have been exploited in various parts of the world and which techniques are currently being developed for tapping the energy they contain. Examples from the western US illustrate innovative applications of oilfield technology for evaluating oil shale deposits and assessing their richness. Oil Shale Formation Oil shales form in a variety of depositional environments, including freshwater and saline lakes and swamps, near-shore marine basins and subtidal shelves.1 They may occur as minor sedimentary layers or as giant accumulations hundreds of meters thick, covering thousands of square kilometers (above right). As with other sedimentary rocks, compositions of shales containing organic material range from mostly silicates to mostly carbonates, with varying amounts of clay minerals (right). Mineral composition has little effect on oil yield, but it can impact the heating process. Clay minerals contain water, which may affect the amount of heat required to convert the organic material to petroleum. Carbonate shales, upon heating, generate additional CO2 that must be considered in any oil shale development program. Many deposits also contain valuable minerals and metals such as alum, nahcolite, sulfur, vanadium, zinc, copper and uranium, which may themselves be targets of mining operations. Winter 2010/2011 > Outcropping oil shales. The oil shale of the Green River Formation in the Piceance Creek basin in Colorado covers about 3,100 km2 [1,200 mi2]. The inset (top) shows a hand specimen from that region, with dark layers of rich oil shale interbedded with pale layers of lean shale. The white scale bar is 7.2 cm [2.8 in.] long. (Outcrop photograph courtesy of Martin Kennedy, University of Adelaide. Inset photograph courtesy of John R. Dyni, US Geological Survey, Denver.) Calcite and Dolomite Calcareous or dolomitic mudstone Siliceous dolomite Gas shales from Poland Parachute Creek Member Garden Gulch Member Various other locations Eagle Ford Siliceous marlstone Niobrara Argillaceous marlstone Monterey Montney Haynesville Argillaceous mudstone (traditional shale) Clay Minerals Average shale Lower Marcellus Barnett Bakken Bazhenov Muskwa Siliceous mudstone Siliceous shale Monterey porcellanite Quartz and Feldspar > Shale mineralogy. Worldwide average shale composition regardless of organic content (black diamond) is high in clay minerals and contains some quartz and feldspar with little or no calcite or dolomite. Organic-rich shales (other diamonds and dots) tend to have a wider variety of compositions. Oil shales from the Green River Formation are highlighted in dotted blue ovals. Those from the Parachute Creek Member (green squares) have low clay-mineral content, while oil shales from the Garden Gulch Member (red dots) are richer in clay minerals. Gray lines subdivide the triangle into compositional regions. (Adapted from Grau et al, reference 32.) 5 Interspersed between the grains of these rocks is kerogen—insoluble, partially degraded organic material that has not yet matured enough to generate hydrocarbons. The kerogen in oil shale has its origins predominantly in the Products Given off from Kerogen Maturation CO2, H2O Oil Wet gas Dry gas Type I Type II Hydrogen/carbon ratio 1.5 No hydrocarbon potential Increasing maturation Type III 1.0 Type IV 0.5 0 0.1 0.2 Oxygen/carbon ratio > Kerogen maturation. The Type I and Type II kerogens in most oil shales are not yet mature enough to generate hydrocarbons. As these kerogens mature—usually through geologic burial and the increased heat associated with it—they transform into oil, and then with more heat, to gas. Methods that accelerate the maturation process attempt to control heat input, thereby producing only the desired type of hydrocarbon. remains of lacustrine and marine algae, and contains minor amounts of spores, pollen, fragments of herbaceous and woody plants and remnants of other lacustrine, marine and land flora and fauna. The type of kerogen has a bearing on what kind of hydrocarbon it will produce as it matures thermally.2 The kerogens in oil shale fall into the Type I and Type II classifications used by geochemists (left). The thermally immature kerogens in oil shales have undergone low-temperature diagenesis but no further modifications.3 Some other organic-rich shales may have reached thermal maturity but not yet expelled all of their liquid petroleum products. To distinguish them from oil shales, for the purposes of this article, mature, organic-rich shales that have not expelled all of their oil are called oil-bearing shales. Examples of these are the Bakken, Monterey and Eagle Ford shales, which currently produce oil in the US. Other organic-rich shales are more thermally mature or of different kerogen type and contain gas instead of oil, such as the Barnett, Fayetteville and Marcellus shales, also in the US.4 Many shales attain source-rock status, achieving full maturity and expelling their oil and natural gas, which then migrate, and under the proper conditions, accumulate and become trapped until discovered and produced. Some such shales can manifest in several ways. For example, the Kimmeridge Clay Formation is the main source rock for the oil fields of the North Sea, but where it outcrops in England it is an oil shale. Similarly, the Green River shale, which is presumed to be 50 Mined shale, million metric tons 40 Germany Scotland China Russia Brazil Estonia 30 20 10 0 1880 1890 1900 1910 1920 1930 1940 1950 1960 1970 1980 1990 2000 2010 Year > More than a century of commercial oil shale mining. Tonnage of mined shale rose dramatically in the 1970s when oil prices were also rising; it peaked in 1980, but declined as oil prices made shale oil noncompetitive. Several countries continue to mine oil shale as a source of heat, electricity, liquid fuel and chemical feedstock. Since 1999, mined shale tonnage has started to increase again. (Data from 1880 to 1998 from Dyni, reference 1.) 6 the source rock for the oil produced from the Red Wash field in Utah, USA, outcrops in the same region. It also contains the world’s largest reserves of shale oil. Oil Shales in Time and Space The earliest use of oil shale was as fuel for heat, but there is also evidence of weaponry applications, such as flaming, oil shale–tipped arrows shot by warriors in 13th-century Asia.5 The first known use of liquid petroleum derived from shale dates to the mid-1300s, when medical practitioners in what is now Austria touted its healing properties. By the late 1600s, several municipalities in Europe were distilling oil from shale for heating fuel and street lighting. In the 1830s, mining and distillation activities began in France, and reached commercial levels there and in Canada, Scotland and the US by the mid-1800s. The country with the longest history of commercial shale oil production is Scotland, where mines operated for more than 100 years, finally closing in 1962.6 Fuel shortages during the two World Wars encouraged other countries to exploit their oil shale resources. Tapping a kerogen-rich carbonate sequence, Estonia began mining oil shale from a deposit about 20 to 30 m [65 to 100 ft] thick that covers hundreds of square kilometers in the northern part of the country. The operation continues today. The shale, which occurs as 50 or so beds of organic-rich shallow marine sediments alternating with biomicritic limestone, is produced from open-pit mines at depths to 20 m. Where the shale is buried deeper than that, down to 70 m [230 ft], it is accessed by underground mines. Roughly three-quarters of the mined rock supplies fuel for electric power plants, providing 90% of the country’s electricity. The remainder is used for heating and as feedstock for petrochemicals. In the past 90 years, 1 × 109 metric tons [1 × 109 Mg, or 1.1 billion tonUS] of oil shale has been mined from the primary Estonia deposit (left).7 China has a significant history of oil shale mining as well, with shale oil production beginning in the 1920s. In the Fushun area, extensive shale layers 15 to 58 m [49 to 190 ft] thick are mined along with coal, both from Eocene lacustrine deposits. The total resource of oil shale at Fushun is estimated at 3.3 × 109 Mg [3.6 billion tonUS].8 As of 1995, Fushun’s petroleum production capacity from shale was 66,000 m3/yr [415,000 bbl/yr]. Brazil began developing an oil shale mining and processing industry in the 1960s. The national oil company, Petróleo Brasileiro SA (Petrobras), Oilfield Review Russia (2) 247 United States (1) 2,085 Canada (11) 15 France (12) 7 Morocco (6) 53 Brazil (4) 82 Shale oil resource, billion bbl (global ranking) Estonia (9) 16 Italy (5) 73 Israel (14) 4 Egypt (13) Jordan (7) 5.7 34 China (10) 16 Democratic Republic of Congo (3) 100 Australia (8) 31 > Significant oil shale deposits. Most of the known high-quality shale oil resources are in these 14 countries. (Data from Knaus et al, reference 11.) established the Shale Industrialization Business Unit (SIX) to exploit the country’s several large oil shale deposits. The Irati Formation, which outcrops extensively in southern Brazil, contains reserves of more than 1.1 × 108 m3 [700 million bbl] of oil and 2.5 × 1010 m3 [880 Bcf] of gas.9 Surface facilities at São Mateus do Sul, in the state of Paraná, are capable of processing 7,100 Mg [7,800 tonUS] of shale per day to produce fuel oil, naphtha, liquefied petroleum gas (LPG), shale gas, sulfur and asphalt additives. To date, almost all the oil extracted from the world’s oil shale has been from rock that was mined and then processed at surface facilities. Mining is typically performed either through surface mining or through underground mining using the room-and-pillar method associated with coal mining. After mining, oil shale is transported to a facility—a retort—where a heating process converts kerogen to oil and gas and separates the hydrocarbon fractions from the mineral fraction. This mineral waste, which contains substantial amounts of residual kerogen, is called spent shale. After retorting, the oil must be upgraded by further processing before being sent to a refinery. Mining operations require handling massive volumes of rock, disposing of spent shale and upgrading the heavy oil. The environmental impact can be significant, causing disruption of the surface and requiring substantial volumes of water. Water is needed for controlling dust, cooling spent shale and upgrading raw shale oil. Estimates of water requirements range from 2 to 5 barrels of water per barrel of oil produced.10 2. Tissot BP: “Recent Advances in Petroleum Geochemistry Applied to Hydrocarbon Exploration,” AAPG Bulletin 68, no. 5 (May 1984): 545–563. 3. For more on diagenesis: Ali SA, Clark WJ, Moore WR and Dribus JR: “Diagenesis and Reservoir Quality,” Oilfield Review 22, no. 2 (Summer 2010): 14–27. 4. Boyer C, Kieschnick J, Suarez-Rivera R, Lewis RL and Waters G: “Producing Gas from Its Source,” Oilfield Review 18, no. 3 (Autumn 2006): 36–49. 5. Moody R: “Oil & Gas Shales, Definitions and Distributions in Time & Space,” presented at the Geological Society’s History of Geology Group Meeting, Weymouth, England, April 20–22, 2007, http://www.geolsoc.org.uk/gsl/cache/ offonce/groups/specialist/hogg/pid/3175;jsessionid= 4CC09ACD6572AE54454755DE4A9077DC (accessed September 14, 2010). 6. Shale Villages: “A Very Brief History of the Scottish Shale Oil Industry,” http://www.almondvalley.co.uk/V_ background_history.htm (accessed September 24, 2010). 7. Sabanov S, Pastarus J-R and Nikitin O: “Environmental Impact Assessment for Estonian Oil Shale Mining Systems,” paper rtos-A107, presented at the International Oil Shale Conference, Amman, Jordan, November 7–9, 2006. 8. Dyni, reference 1. 9. Petrobras SIX Shale Industrialization Business Unit: “Shale in Brazil and in the World,” http://www2. petrobras.com.br/minisite/refinarias/petrosix/ingles/oxisto/ oxisto_reservas.asp (accessed November 10, 2010). 10. Bartis JT, LaTourrette T, Dixon L, Peterson DJ and Cecchine G: Oil Shale Development in the United States: Prospects and Policy Issues. Santa Monica, California, USA: The RAND Corporation, Monograph MG-414, 2005. 11. Knaus E, Killen J, Biglarbigi K and Crawford P: “An Overview of Oil Shale Resources,” in Ogunsola OI, Hartstein AM and Ogunsola O (eds): Oil Shale: A Solution to the Liquid Fuel Dilemma. Washington, DC: American Chemical Society, ACS Symposium Series 1032 (2010): 3–20. 12. Dyni, reference 1. 13. Screen mesh of –8 means the particles can pass through a wire screen with 8 openings per linear inch. Winter 2010/2011 The world’s oil shale deposits are widely distributed; hundreds of deposits occur in more than 30 countries (above). Many formations are at depths beyond mining capabilities or in environmentally fragile settings. In these areas, heating the rocks in place may offer the best method to hasten kerogen maturation. If ways can be found to do this safely, efficiently and cost effectively, the potential prize is immense. By conservative estimate—because oil shales have not been the target of modern exploration efforts—resources of the world’s shale oil total about 5.1 × 1011 m3 [3.2 trillion bbl].11 It is estimated that more than 60% of this amount—roughly 3 × 1011 m3 [2 trillion bbl]—is located in the US. Converting Oil Shale to Shale Oil Translating volume of rock to volume of recoverable oil requires information on oil shale properties, such as organic content and grade, which can vary widely within a deposit. Traditionally, for the purposes of surface retorting, oil shale grade is determined by the modified Fischer assay method, which measures the oil yield of a shale sample in a laboratory retort.12 A 100-g [0.22-lbm] sample is crushed and sieved through a 2.38-mm [–8] mesh screen, heated in an aluminum retort to 500°C [930°F] at a rate of 12°C/min [22°F/min] and then held at that temperature for 40 min.13 The resulting distilled vapors of oil, gas and water are condensed and then separated by centrifuge. The quantities delivered are weight percentages of oil, water and shale residue and the specific gravity of the oil. The difference between the weight of the products and that of the starting material is 7 Shale oil, degree API gravity 40 Project Name Dates Heater Holes Total Holes Depth, ft Red Pinnacle thermal conduction test ICP field demonstration 1981 to 1982 3 14 20 32 28 Mahogany field experiment ICP field demonstration 1996 to 1998 6 26 130 Mahogany demonstration project ICP field demonstration, recovery 1998 to 2005 38 101 600 Mahogany demonstration project, South ICP field demonstration, recovery 2003 to 2005 16 27 400 Deep heater test Heaters 2001 to present 21 45 700 Mahogany isolation test Freeze wall 2002 to 2004 2 53 1,400 Freeze wall test Freeze wall 2005 to present 0 233 1,700 ICP LLNL 24 20 100,000 10,000 1,000 100 10 1 Heating rate, °C/d > Improved oil quality with slow heating. Data from the Shell in situ conversion process (ICP) and Lawrence Livermore National Laboratory (LLNL), in California, show a clear increase in oil API gravity as heating rate decreases. The red endpoint represents the results of typical laboratory pyrolysis. recorded as “gas plus loss.” The oil yield is reported in liters per metric ton (L/Mg) or gallons per short ton (galUS/tonUS) of raw shale. Commercially attractive oil shale deposits yield at least 100 L/Mg [24 galUS/tonUS], and some reach 300 L/Mg [72 galUS/tonUS].14 The Fischer assay method does not measure the total energy content of an oil shale because the gases, which include methane, ethane, propane, butane, hydrogen, H2S and CO2, can have significant energy content, but are not individually specified. Also, some retort methods, especially those that heat at a different rate or for different times, or that crush the rock more finely, may produce more oil than that produced by the Fischer assay method. Therefore, the method only approximates the energy potential of an oil shale deposit.15 Another method for characterizing organic richness of oil shale is a pyrolysis test developed by the Institut Français du Pétrole, in ReuilMalmaison, France, for analyzing source rock.16 The Rock-Eval test heats a 50- to 100-mg [0.00011- to 0.00022-lbm] sample through several temperature stages to determine the amounts of hydrocarbon and CO2 generated. The results can be interpreted for kerogen type and potential for oil and gas generation. The method is faster than the Fischer assay and requires less sample material. The reactions that convert kerogen to oil and gas are understood generally, but not in precise molecular detail.17 The amount and composition of generated hydrocarbons depend on the heating conditions: the rate of temperature increase, the duration of exposure to heat and the composition of gases present as the kerogen breaks down. 8 Primary Purpose 36 > Shell’s thermal conduction pilot projects. Shell has performed seven field pilots using the in situ conversion process (ICP) to heat oil shale to conversion temperature. (Adapted from Fowler and Vinegar, reference 24.) Generally, surface-based retorts heat the shale rapidly. The time scale for retorting is directly related to the particle size of the shale, which is why the rock is crushed before being heated in surface retorts. Pyrolysis of particles on the millimeter scale can be accomplished in minutes at 500°C; pyrolysis of particles tens of centimeters in size takes hours. In situ processes heat the shale more slowly. It takes a few years to heat a block tens of meters wide. However, slow heating has advantages. Retorting occurs at a lower temperature so less heat is needed. Also, the quality of the oil increases substantially (above left). Coking and cracking reactions in the subsurface tend to leave the heavy, undesirable components in the ground. As a result, compared with surface processing, in situ heating can produce lighter liquid hydrocarbons with fewer contaminants. During in situ conversion, the subsurface acts as a large reactor vessel in which pressure and heating rate may be designed to maximize product quality and quantity while minimizing production cost. In addition to generating a superior product relative to surface processing, in situ methods have a reduced environmental impact in terms of surface disturbance, water requirements and waste management. Several companies have developed methods for heating oil shale in situ to generate shale oil. They are testing these techniques in the rich subsurface deposits of the western US. The Epitome of Oil Shales The Green River Formation at the intersection of the states of Colorado, Utah and Wyoming, USA, contains the most bountiful oil shale beds in the world. Estimates of the recoverable shale oil in this area range from 1.2 to 1.8 trillion bbl [1.9 to 2.9 × 1011 m3]. Nearly 75% of the resources lie under land managed by the US Department of the Interior. The fine-grained sediments of this formation were deposited over the course of 10 million years in Early and Middle Eocene time, in several large lakes covering up to 25,000 mi2 [65,000 km2]. The warm alkaline waters provided conditions for abundant growth of blue-green algae, which are believed to be the main component of the organic matter in the oil shale.18 The formation is now about 1,600 ft [500 m] thick and in places has shale layers that contain more than 60 galUS/tonUS [250 L/Mg] of oil (next page).19 A particularly rich and widespread layer, called the Mahogany zone, reaches a thickness of 50 ft [15 m]. It contains an estimated 173 billion bbl [2.8 × 1010 m3] of shale oil. The Green River area has been well studied, with more than 750,000 assay tests performed on samples from outcrops, mines, boreholes and core holes.20 Settlers and miners began retorting oil from the shale in the 1800s. The region experienced mining and exploration booms from 1915 to 1920 and again from 1974 to 1982, each period followed by busts.21 In 1980, Unocal built a major plant for mining, retorting and upgrading oil shale in the Piceance Creek basin in Colorado; it operated until 1991. During that time, the company produced 4.4 million bbl [700,000 m3] of shale oil.22 Recently, oil price volatility and growing energy needs have combined to again focus interest on the region. In 2003, the US Bureau of Land Management initiated an oil shale development program and solicited applications for research, development and demonstration (RD&D) leases. Several companies applied for and received lease awards to develop in situ heating techniques on public lands, and some are testing methods Oilfield Review Generalized Lithology Depth, ft Sandstone, siltstone and some marlstone and lean oil shale Oil shale 500 Marlstone and low-grade oil shale Leached oil shale; contains open solution cavities and marlstone solution breccias Nahcolite-bearing oil shale; contains nodules, scattered crystals and beds of nahcolite 1,000 Clay-bearing oil shale Interbedded halite, nahcolite and oil shale Total 147.17 bbl No data 172.94 159.09 52.42 178.72 60.85 107.78 18.72 58.38 20.08 53.07 10.70 115.35 No data No data 1,008.10 2,000 Parachute Creek Member No data 25.25 23.23 7.65 26.09 8.88 15.74 2.73 8.52 2.93 7.75 1.56 16.84 No data No data 109 Lean oil shale zones, clay rich B-groove R-6 zone L-5 zone R-5 zone L-4 zone R-4 zone L-3 zone R-3 zone 2,500 L-2 zone R-2 zone L-1 zone 3,000 Garden Gulch Member R-8 Mahogany R-6 L-5 R-5 L-4 R-4 L-3 R-3 L-2 R-2 L-1 R-1 L-0 R-0 tonUS Lean oil shale zones, carbonate rich Mahogany zone Shale Oil Resources Zone Rich oil shale zones, clay rich A-groove 1,500 109 Rich oil shale zones, carbonate rich R-8 zone Nahcolite and oil shale Green River Formation . Lithology (center) and grade (right) of the Green River Formation. Oil shales in the Parachute Creek Member are carbonate rich, and the underlying shales of the Garden Gulch Member are clay rich. High-grade (blue) oil shales are interspersed with lean layers (pink). Oil yield from Fischer assay measurement is plotted in red. Total shale oil resources contained in the various layers are shown in the chart (bottom left). (Lithology and shale oil resources from Dyni, reference 1; shale grade from Johnson et al, reference 19.) Uinta Formation (with tongues of Green River Formation) 0 Anvil Points Member R-1 zone L-0 zone R-0 zone 0 20 40 60 80 100 Shale oil yield, galUS/tonUS on privately held land. Examples from three companies—Shell, ExxonMobil and American Shale Oil LLC (AMSO)—show the range of concepts being applied to the challenges of in situ retorting in the Green River oil shale. Shell has done extensive laboratory and field work in efforts to demonstrate commercial viability of in situ retorting using downhole electric heaters.23 The process follows a method developed in Sweden during World War II—a technique used until 1960, when cheaper supplies of imported oil became available. Shell participated in early mining and surface retort attempts in the Green River area, but chose to withdraw from those in the mid-1990s to focus on an in situ method.24 Years of laboratory testing, thermal simulations and field pilots contributed to the development of Shell’s in situ conversion process (ICP). Through seven field pilot tests, Shell has investigated a variety of heating methods— including injected steam and downhole heaters— and well configurations with patterns of wells of varying depths for heating, producing and dewatering (previous page, top right). 14. Knaus et al, reference 11. 15. Dyni JR, Mercier TJ and Brownfield ME: “Chapter 1— Analyses of Oil Shale Samples from Core Holes and Rotary-Drilled Wells from the Green River Formation, Southwestern Wyoming,” in US Geological Survey Oil Shale Assessment Team (ed): “Fischer Assays of Oil-Shale Drill Cores and Rotary Cutting from the Greater Green River Basin, Southwestern Wyoming,” US Geological Survey, Open-File Report 2008-1152, http://pubs.usgs.gov/of/2008/1152/downloads/Chapter1/ Chapter1.pdf (accessed October 8, 2010). 16. Pyrolysis is the controlled heating of organic matter in the absence of oxygen to yield organic compounds such as hydrocarbons. Peters KE: “Guidelines for Evaluating Petroleum Source Rock Using Programmed Pyrolysis,” AAPG Bulletin 70, no. 3 (March 1986): 318–329. Espitalie J, Madec M, Tissot B, Mennig JJ and Leplat P: “Source Rock Characterization Method for Petroleum Exploration,” paper OTC 2935, presented at the Offshore Technology Conference, Houston, May 2–5, 1977. 17. Burnham AK: “Chemistry and Kinetics of Oil Shale Retorting,” in Ogunsola OI, Hartstein AM and Ogunsola O (eds): Oil Shale: A Solution to the Liquid Fuel Dilemma. Washington, DC: American Chemical Society, ACS Symposium Series 1032 (2010): 115–134. 18. Dyni, reference 1. 19. Johnson RC, Mercier TJ, Brownfield ME, Pantea MP and Self JG: “Assessment of In-Place Oil Shale Resources of the Green River Formation, Piceance Basin, Western Colorado,” Reston, Virginia, USA: US Geological Survey, Fact Sheet 2009-3012, March 2009. 20. US Department of Energy: “Secure Fuels from Domestic Resources,” http://www.unconventionalfuels.org/ publications/reports/SecureFuelsReport2009FINAL.pdf (accessed November 12, 2010). 21. Hanson JL and Limerick P: “What Every Westerner Should Know About Oil Shale: A Guide to Shale Country,” Center of the American West, Report no. 10, June 17, 2009, http://oilshale.centerwest.org (accessed August 4, 2010). 22. Dyni, reference 1. 23. Ryan RC, Fowler TD, Beer GL and Nair V: “Shell’s In Situ Conversion Process—From Laboratory to Field Pilots,” in Ogunsola OI, Hartstein AM and Ogunsola O (eds): Oil Shale: A Solution to the Liquid Fuel Dilemma. Washington, DC: American Chemical Society, ACS Symposium Series 1032 (2010): 161–183. 24. Fowler TD and Vinegar HJ: “Oil Shale ICP—Colorado Field Pilots,” paper SPE 121164, presented at the SPE Western Regional Meeting, San Jose, California, March 24–26, 2009. Winter 2010/2011 9 Plan View Wells Heater (2) Producer (1) Freeze (18) Inside monitor (8) 8 ft 22 ft 50 ft Side View 1,400-ft freeze interval 430-ft heated interval > Shell freeze wall isolation test. Using a technique dating to the 1880s, Shell constructed a circular freeze wall 1,400 ft [430 m] deep by circulating coolant in 18 freeze wells for 5 months. A 430-ft [130-m] interval of the enclosed formation was then heated to generate shale oil. The test verified that the freeze wall could confine produced fluids. The ICP method uses closely spaced downhole electric heaters to gradually and evenly heat the formation to the conversion temperature of about 650°F [340°C]. Depending on heater spacing and the rate of heating, the time projected to reach conversion temperature in a commercial project ranges from three to six years. Tests have demonstrated liquid-recovery efficiencies greater than 60% of Fischer assay value, with the lowvalue kerogen components left in the ground. The resulting oil is of 25 to 40 degree API gravity. The gas contains methane [CH4], H2S, CO2 and H2. Taking into account the oil equivalence of the gas generated, the recovery efficiency approaches 90% to 100% of Fischer assay value. From results of the pilot testing, a commercialscale project is expected to have an energy gain close to 3, meaning the energy value of the 10 products is three times the energy input to obtain them. Commercialization of the ICP process requires a method that prevents water influx to the heated volume and contains the fluid products, thereby maximizing recovery and protecting local aquifers.25 The Shell ICP process makes use of a freeze wall, created by circulating coolants, to isolate the heated formation from groundwater. Use of a freeze wall is a relatively common practice in some underground mining operations. Inside the freeze wall, water is pumped from the formation. The formation is heated, the oil is produced and the residual shale is cleaned of contaminants by flushing with clean water. The recovered oil in one test had 40 degree API gravity, similar to modeling results for oil produced at heating rates of 1°C/h [0.5°F/h] and 27 MPa. Pilot testing of the freeze wall began in 2002 with 18 freeze wells arranged in a circle 50 ft across. One producer, two heating wells and eight monitor wells were located within the freeze circle (left). After five months of cooling, the freeze wall was complete. This pilot showed that a freeze wall could be established and could isolate fluids inside the circle from those outside. Shell tested the freeze wall concept on a larger scale starting in 2005, with an ambitious project involving 157 freeze wells at 8-ft [2.4-m] intervals to create a containment volume 224 ft [68 m] across (next page, top). The operator began chilling in 2007 by circulating an ammonia-water solution—initially at shallow depth and gradually deepening. As of July 2009, the freeze wall was continuing to form in the deeper zones, down to 1,700 ft [520 m]. The test is designed to evaluate the integrity of the freeze wall, and will not involve heating, or production of hydrocarbons. ExxonMobil is also pursuing research and development of a process for in situ oil shale conversion. The company’s Electrofrac process hydraulically fractures the oil shale and fills the fractures with an electrically conductive material, creating a resistive heating element.26 Heat is thermally conducted into the oil shale, converting the kerogen into oil and gas, which are then produced by conventional methods. Calcined petroleum coke, a granular form of relatively pure carbon, is being tested as the Electrofrac conductant. By pumping this material into vertical hydraulic fractures, ExxonMobil hopes to create a series of parallel planar electric heaters (next page, bottom). As in the Shell ICP method, the resistive heat reaches the shale by thermal diffusion. A potential advantage of the Electrofrac process is that, compared with line sources, the greater surface area of planar fracture heaters will permit fewer heaters to be used to deliver heat to the subsurface volume. The use of planar heaters should also reduce surface disturbance when compared with line sources or wellbore heaters. 25. Ryan et al, reference 23. 26. Symington WA, Kaminsky RD, Meurer WP, Otten GA, Thomas MM and Yeakel JD: “ExxonMobil’s Electrofrac™ Process for In Situ Oil Shale Conversion,” in Ogunsola OI, Hartstein AM and Ogunsola O (eds): Oil Shale: A Solution to the Liquid Fuel Dilemma. Washington, DC: American Chemical Society, ACS Symposium Series 1032 (2010): 185–216. Symington WA, Olgaard DL, Otten GA, Phillips TC, Thomas MM and Yeakel JD: “ExxonMobil’s Electrofrac Process for In Situ Oil Shale Conversion,” presented at the AAPG Annual Convention, San Antonio, Texas, USA, April 20–23, 2008. Oilfield Review Plan View C C Freeze well 8 ft B A A B 224 ft Side View Test Section B 1,700-ft freeze interval Test Sections A and C 1,500-ft freeze interval > Large-scale freeze wall test. In a step toward supporting commercial viability of the ICP, Shell is testing a large-scale freeze wall for isolation and containment. In addition to the freeze wells shown in the plan view (left) there are 27 observation holes for geomechanical, pressure, fluid level and temperature measurements; 30 special-use holes for venting, squeezing, water reinjection, water production and hydraulic fracturing; and 40 groundwater monitoring holes. An artist’s rendering (right) depicts the freeze wall in 3D. 20/40 Mesh Proppant Toe connector well Production wells Electrofrac process heater wells Calcined Coke Hydraulic fracture with electrically conductive material Conductive heating and oil shale conversion > The ExxonMobil Electrofrac process. Horizontal wells penetrate the oil shale. The horizontal sections are hydraulically fractured (left) and filled with electrically conductive proppant made of calcined coke (bottom right). A 20/40 mesh proppant (top right) is displayed for scale. Field testing has shown it is possible to create an electrically conductive fracture and heat it for several months. The plus and minus signs indicate electric charge applied to heat the fractures. (Illustration and photographs courtesy of ExxonMobil.) Winter 2010/2011 11 0 Heating well Low-salinity water Nahcolitic oil shale caprock 2,000 Vapor High-salinity water 1,500 Condensate Mahogany zone 1,000 Condensate Depth, ft Production well Production well 500 Rubblefilled retort Illitic oil shale Boiling oil Heating well 2,000 ft > The AMSO CCR conduction, convection and reflux process. Two horizontal wells target the illitic oil shale beneath a nahcolitic caprock. The heating well is at the base and the production well is at the top of the shale (left). As heat causes the kerogen to decompose, the lighter products rise and condense (right), efficiently heating a large volume of rock. Hydrocarbon fluids are produced via the production well. s4HATACOMPLETIONSTRATEGYCANBEDESIGNEDTO create fractures that deliver heat effectively. Based on these results, ExxonMobil advanced to field research to test the Electrofrac method in situ.27 The test site is at the company-owned Colony oil shale mine in northwest Colorado. The Colony mine provides a large, highly accessible volume of rock for testing. ExxonMobil has created two Electrofrac fractures at Colony by drilling horizontally into the oil shale and pumping a 2,0 00 ft Panel being retorted 20 0f t Prior to embarking on field research, ExxonMobil conducted modeling and laboratory studies addressing several important technical issues for the Electrofrac process. These included establishing the following: s4HATTHECONDUCTANTINTHEFRACTURECANMAINtain its electrical continuity while the surrounding rock is heated to conversion temperatures. s4HATOILANDGASGENERATEDBYTHEPROCESSARE expelled from oil shale, not only at surface conditions, but also under in situ stress conditions. Panel being drilled 2,0 2,000 ft 00 ft > The AMSO concept for commercial-scale production. By using long horizontal wells concentrated in a 200-ft corridor, drilling should impact less than 10% of the surface area. While one 2,000-ft square panel is being heated and converted in situ, wells will be drilled in an adjacent panel. The operation is projected to produce about 1 billion bbl of shale oil over a 25-year period. 12 slurry of calcined petroleum coke, water and portland cement at pressures sufficient to break the rock. The larger of the two Electrofrac fractures has been heavily instrumented to measure temperature, voltage, electrical current and rock movement. As a preliminary test of the Electrofrac process, the fracture was heated to relatively low temperatures. This lowtemperature experiment was not intended to generate oil or gas. To date, the results of this field program have been encouraging. They demonstrate that it is possible to create an electrically conductive hydraulic fracture, to make power connections to the fracture and to operate it, at least at low temperature, for several months. AMSO, 50% owned by Total, proposes to use the CCR conduction, convection and reflux process to recover shale oil. By focusing the heating effort on shales beneath an impermeable shale caprock, this method isolates production zones from protected sources of groundwater.28 The company plans to drill two horizontal wells—a heater below a producer—in the bottom of the illite shale at the base of the Green River Formation (above left). Heat is delivered by a downhole burner that eventually runs on produced gas. As the kerogen decomposes, the lighter products—hot vapors—rise and reflux. Heat is distributed through the formation by the refluxing oil; thermomechanical fracturing, or spalling, creates permeability for the convective heat transfer. The concept for commercial-scale production uses an array of horizontal wells about 2,000 ft [600 m] long at 100-ft [30-m] intervals (left). The formation is heated slowly, yielding oil with lower concentrations of heteroatoms and metals than that generated by surface processing methods.29 Meanwhile, the aromatic portions of kerogen tend to stay in the rock matrix as coke. More than enough gas is coproduced to provide the energy required to operate a self-sustaining commercial retorting process, and it is likely that most of the propane and butane produced can be exported to market. Computational studies show that heat delivery by convection and conduction is much more effective than by conduction alone. The CCR process is estimated to give a total energy gain between 4 and 5, counting all the surface facility requirements, including an oxygen plant for producing pure CO2 from the downhole burner. The method is projected to use less than one barrel of water per barrel of oil produced. No water is needed to clean spent retorts because they remain isolated from usable groundwater. Oilfield Review AMSO’s initial RD&D pilot test is currently under construction and will begin in mid-2011. Heating will take up to 200 days. The operation will retort a formation volume equivalent to 4,000 tonUS [3,600 Mg] of oil shale and produce up to 2,000 bbl [320 m3] of shale oil. Development of a commercial operation will proceed in steps up to 100,000 bbl/d [16,000 m3/d], with plans to sustain that production for 25 years. That translates into about 1 billion bbl [1.6 × 108 m3] of oil to be produced from an 8-mi2 [20.8-km2] lease. Resistivity 90-in. Array 0.2 ohm.m 2,000 60-in. Array Gamma Ray 0.2 0 gAPI 200 0.2 PEF 0 ohm.m 20-in. Array 10 0.2 Caliper 6 ohm.m 2,000 Porosity 30-in. Array Depth, ft in. 16 0.2 ohm.m Density Porosity 2,000 45 10-in. Array ohm.m Total Organic Matter Kerogen 2,000 2,000 45 % –15 0 Core Fischer Assay % NMR Porosity TOM Log % % –15 0 50 50 Illite Montmorillonite Orthoclase Pyrite Dawsonite Nahcolite Albite Quartz Calcite Dolomite Bound water Kerogen Water X,000 Evaluating Oil Shales Companies are looking at ways to assess oil shale richness and other formation properties without having to take core samples and perform Fischer assay analysis. Methods that show promise include integration of several conventional logging measurements, such as formation density, magnetic resonance, electrical resistivity and nuclear spectroscopy. One way of quantifying kerogen content is by combining density porosity and magnetic resonance responses. In a formation with porosity that is filled with both kerogen and water, the density porosity measurement does not distinguish between kerogen- and water-filled porosity. However, the magnetic resonance measurement sees the kerogen as a solid, similar to the grains of the rock, and so senses a lower porosity. The difference between the magnetic resonance and density readings gives kerogen volume.30 The volume of kerogen can be related empirically to Fischer assay values for oil shales in the region. The method was tested in an AMSO oil shale well in the Green River basin. Kerogen content was calculated from density porosity and magnetic resonance logs (right). Using a correlation between kerogen content and Fischer assay 27. Symington WA, Burns JS, El-Rabaa AM, Otten GA, Pokutylowicz N, Spiecker PM, Williamson RW and Yeakel JD: “Field Testing of Electrofrac™ Process Elements at ExxonMobil’s Colony Mine,” presented at the 29th Oil Shale Symposium, Colorado School of Mines, Golden, Colorado, USA, October 19–21, 2009. 28. Burnham AK, Day RL, Hardy MP and Wallman PH: “AMSO’s Novel Approach to In-Situ Oil Shale Recovery,” in Ogunsola OI, Hartstein AM and Ogunsola O (eds): Oil Shale: A Solution to the Liquid Fuel Dilemma. Washington, DC: American Chemical Society, ACS Symposium Series 1032 (2010): 149–160. 29. Heteroatoms are atoms of elements other than hydrogen and carbon—the components of pure hydrocarbons. They commonly consist of nitrogen, oxygen, sulfur, iron and other metals. 30. Kleinberg R, Leu G, Seleznev N, Machlus M, Grau J, Herron M, Day R, Burnham A and Allix P: “Oil Shale Formation Evaluation by Well Log and Core Measurements,” presented at the 30th Oil Shale Symposium, Colorado School of Mines, Golden, Colorado, October 18–22, 2010. Winter 2010/2011 X,050 X,100 X,150 X,200 > Kerogen content from porosity measurements in Green River oil shales. Neither gamma ray (Track 1, dashed green) nor resistivity measurements (Track 2) show much correlation with kerogen content, but porosity measurements are more useful. The difference between density porosity (Track 3, red) and nuclear magnetic resonance (NMR) porosity (green) represents kerogen-filled porosity (gray). The kerogen values can also be depicted as a log (Track 4) of total organic matter (TOM, red), which compares favorably with laboratory Fischer assay results on core samples (black dots). Mineralogical analysis incorporating ECS elemental capture spectroscopy measurements (Track 5) indicates the high levels of calcite and dolomite in these shales, as well as the presence of rare minerals such as dawsonite (light gray) and nahcolite (solid pink) in some intervals. 13 40 TOC converted to Fischer assay yield Core Fischer assay 30 X,200 20 X,400 Total Totalorganic organicmatter matter as asfraction fractionofofore oreweight weight ρρk TOM ) TOM== ρρbk (φ( φDD––φφMR MR ) 10 X,600 Depth, ft Total organic matter (TOM), % X,000 b X,800 0 0 20 40 60 Modified Fischer assay, galUS/tonUS Y,000 Fischer assay, galUS/tonUS 80 Well log Fischer assay estimate Core-measured Fischer assay values 60 Y,200 40 20 Y,400 0 X,000 X,050 X,100 X,150 X,200 Depth, ft > Fischer assay estimates from wireline logs. Core measurements on Green River shales show a strong correlation between total organic matter (TOM), or kerogen, and Fischer assay values (top). Total organic matter is calculated using the density lk of the kerogen, bulk density of the formation lb and the difference between density porosity qD and magnetic resonance porosity qMR. Researchers computed a kerogen log from the difference between density and NMR porosity, then used this linear correlation to convert the kerogen log to a Fischer assay log (bottom). The log-based Fischer assay estimates (black) show excellent agreement with values from laboratory Fischer assay measurements on cores (red). results on Green River shales, researchers computed an estimated Fischer assay log based on the wireline logging measurements (above). The estimated Fischer assay values show excellent agreement with those from laboratory measurements on cores from the same interval. Another approach distinguishes mineral from organic content using spectroscopy data. The ECS elemental capture spectroscopy sonde measures concentrations of silicon [Si], aluminum [Al], calcium [Ca], iron [Fe], sulfur [S], potassium [K], sodium [Na], magnesium [Mg], titanium [Ti] and gadolinium [Gd].31 Grain mineralogy is computed from these element concentrations. The total carbon concentration comes from the RST reservoir saturation tool. Of this concentration, some carbon is inorganic and some organic. The inorganic carbon combines with calcium and other elements to form calcite and dolomite, along with lesser-known minerals, 14 20 40 60 Shale oil yield, galUS/tonUS 0 such as nahcolite [NaH(CO3)] and dawsonite [NaAl(CO3)(OH2)], which are common in Green River shales. The ECS concentrations of Ca, Mg and Na are used to compute the inorganic carbon. The remainder, called total organic carbon (TOC), makes up the kerogen. Using this spectroscopy method, researchers computed a TOC log for an AMSO well in the Green River basin, showing a good match between log-based results and core measurements (next page).32 The TOC log was converted to a Fischer assay yield log using a correlation derived independently by AMSO scientists. The Fischer assay log exhibited excellent agreement with Fischer assay tests performed on cores (above right). This technique employing geochemical logs, along with the complementary method using nuclear magnetic resonance logs, provides reliable, efficient means to characterize shale oil yield without having to resort to core measurements. > Fischer yield from TOC. Fischer assay estimates (black) from the TOC log exhibit an excellent correlation with core Fischer assay results (red). Heating Elements One of the most fundamental issues for oil shale retorting is how to get the heat into the oil shale. After early testing, steam injection was abandoned as other, more efficient techniques were discovered. In situ combustion has also been tried, but is difficult to control. Electric heaters, electrically conductive proppant and downhole gas burners have all been evaluated and reported to be effective with varying degrees of efficiency. Another concept, heating by downhole radiofrequency (RF) transmitters, has also been modeled and has undergone laboratory testing.33 Advantages of the RF method are that it heats the interior of the formation instead of the borehole, and it can be controlled to customize heating rate. But like all electrical methods, it sacrifices efficiency, losing about half the heating value of the fuel originally burned to produce the electricity. It is important to note that all the current projects to produce shale oil by in situ heating methods are in test and pilot stages; none have demonstrated large-scale commercial production. Operators are still working to optimize their heating technologies. For a given oil shale, the Oilfield Review X,000 X,200 X,400 Depth, ft X,600 X,800 150-ft interval Y,000 Y,200 Y,400 0 20 40 Total carbon, weight percent 0 10 20 Inorganic carbon, weight percent 0 20 40 Organic carbon, weight percent 0 10 20 30 40 TOC, weight percent > Organic and inorganic carbon from logs and cores. Total carbon (left) is made up of inorganic and organic carbon, the latter of which resides in kerogen. The inorganic carbon is present in mineral form, such as in carbonates and some exotic minerals sometimes found in oil shales. Estimates of inorganic (middle left) and organic carbon (middle right) based on nuclear measurements (black) correlate extremely well with laboratory measurements on cores (red). An expanded section (right) shows the quality of the match across the bottom 150-ft interval. heating history—how much heat and for how long—determines the amount and content of the resulting fluids. By controlling the heat input, companies can fine-tune the output, essentially designing a shale oil of desired composition. Beyond heating methods, there are other aspects of oil shale operations that have yet to be fully addressed. Mechanical stability of the heated formation is not well understood. All the in situ heating techniques rely on some thermomechanical fracturing within the shale to release matured organic material and create additional permeability for the generated fluids to escape the formation. With many oil shales containing 30% or more kerogen, most of which leaves the rock after in situ retorting, treated formations may not be able to support their newfound porosity. Overburden weight can help drive production, but may also cause compaction and subsidence, which in turn can affect wellbore stability and surface structures. It is also unclear how to deal with the CO2 generated along with other gases. Companies retorting oil shale in situ may need to investigate ways to capture and use the CO2 for enhanced oil recovery or sequester it in deep storage zones. An alternative, being explored by AMSO, is mineralization of CO2 in the spent shale formation.34 This option exploits the chemical properties of the heat-treated shale. AMSO scientists expect the depleted formation to have sufficient porosity to accommodate all the generated and reinjected CO2 as carbonate minerals. 31. Barson D, Christensen R, Decoster E, Grau J, Herron M, Herron S, Guru UK, Jordán M, Maher TM, Rylander E and White J: “Spectroscopy: The Key to Rapid, Reliable Petrophysical Answers,” Oilfield Review 17, no. 2 (Summer 2005): 14–33. 32. Grau J, Herron M, Herron S, Kleinberg R, Machlus M, Burnham A and Allix P: “Organic Carbon Content of the Green River Oil Shale from Nuclear Spectroscopy Logs,” presented at the 30th Oil Shale Symposium, Colorado School of Mines, Golden, Colorado, October 18–22, 2010. 33. Burnham AK: “Slow Radio-Frequency Processing of Large Oil Shale Volumes to Produce Petroleum-Like Shale Oil,” Livermore, California: Lawrence Livermore National Laboratory, Report UCRL-ID-155045, August 20, 2003. Raytheon: “Radio Frequency/Critical Fluid Oil Extraction Technology,” http://www.raytheon.com/businesses/ rtnwcm/groups/public/documents/datasheet/rtn_bus_ ids_prod_rfcf_pdf.pdf (accessed November 16, 2010). 34. Burnham et al, reference 28. 35. Bostrom N, Leu G, Pomerantz D, Machlus M, Herron M and Kleinberg R: “Realistic Oil Shale Pyrolysis Programs: Kinetics and Quantitative Analysis,” presented at the 29th Oil Shale Symposium, Colorado School of Mines, Golden, Colorado, October 19–21, 2009. Winter 2010/2011 Work also remains to understand the kerogenmaturation process. To optimize heating programs, operators would like to know when the shale has been heated enough and if the subsurface volume has been heated uniformly. To this end, scientists are conducting laboratory experiments to monitor the products of kerogen pyrolysis.35 To understand when the process should be modified or stopped, researchers plan to analyze the composition of an oil shale and its hydrocarbons as they evolve with time. In the future, it may be possible to control and monitor oil shale heating and production to obtain oil and gas of desired compositions. —LS 15
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