From Vision to Reality: Development and Deployment of Continuous Low-Rate CO2 Injection System for Extended Pilot Well
Authors: Kurniadi Stevanus Dwi , Aliss Joseph , Al Baik Abdullah , Al Balushi Sameer 
Published: November 2024

The paper aims to present a novel development of modular low-rate CO2 injection equipment tailored for use in extended CO2 pilot operations. The objectives include demonstrating the equipment's efficacy in de-risking sustainable long-term field development plans via execution of extended injection pilots for Enhanced Oil Recovery (EOR) or storage purposes. The scope encompasses technical specifications and a case study illustrating the first field deployment of the technology, diving into the planning, engineering, implementation, and performance evaluation.

Our approach to developing the continuous low-rate CO2 injection equipment involved a multi-faceted process integrating innovative design, rigorous testing, and iterative refinement. Initially, a portfolio gap analysis was conducted to identify key process requirements that were currently not accommodated for including low flow rates, controlled temperature output and maintenance of the injected CO2 in the super dense phase.

Multidisciplinary engineering principles were applied to design a modular surface equipment spread, capable of 24 hour low-rate CO2 injection for extended periods. Furthermore, a flow assurance transient phase simulator was utilized to verify the equipment's process design to ensure safety and flexibility.

The results of the development and first deployment underscore the successful performance of the newly developed CO2 injection equipment, affirming its robustness and reliability. Over a continuous five-month period, the equipment demonstrated consistent and controlled CO2 injection, functioning semi-autonomously with minimal intervention in a remote desert environment. This prolonged injection facilitated a comprehensive examination of CO2 impact on a microporous, oil-bearing formation. Understanding efficiency of the overall system was also crucial, especially in relation to transportation, transferring, cool-down, priming, and pressure management. The implementation of the heater design and P&ID control system provided valuable data on the heating requirements necessary to raise cold CO2 to the designed temperature, thereby preventing thermal cracking of reservoir and cap rock. By providing continuous CO2 injection, the equipment aided in understanding the feasibility of implementing permanent surface infrastructure, such as CO2 pipelines and pumping technologies, crucial for the sustainable development objectives. Overall, the study's findings emphasize the pivotal role of the modular injection equipment in de-risking Carbon Capture, Utilization and Storage (CCUS) ventures and advancing knowledge in CO2 utilization for enhanced oil recovery and storage applications.

This paper offers novel insights by showcasing the successful deployment of newly developed continuous low-rate CO2 injection equipment in remote field settings. It provides valuable real-world data on equipment performance, reliability, and its ability to de-risk long-term field development plans for practitioners. Such practical information is essential for engineers involved in CCUS initiatives, aiding in informed decision-making and optimizing the implementation of sustainable CO2 utilization technologies.