Project: Increased reservoir recovery rates by EXTRACTing oil using an innovative autonomous and reversible inflow control valve

We aim to show in this proposal that our consortium has identified an innovative solution to one of the major challenges facing oil companies globally. The solution is ambitious and demanding, addressing the needs of the market by providing a step change in the technology used to control outputs from oil wells. Specifically the aim is to increase the oil reservoir recovery rates and increase oil production by 25%._x000D__x000D_The EXTRACT project will enable our SME Pship to create a novel, highly differentiated, validated pre-production prototype that can be quickly commercialised, post project completion providing outstanding benefits for ourselves, oil company clients, national government exchequers and Europe as a whole. This area of the industry is one that SMEs are very well placed to contribute to and respond to the competitive threat we all face. It is vital for us and Europe that a solution is developed before other regions around the world do so._x000D__x000D_In 2010, the EU oil import bill was around €210 billion with 40% from OPEC. COtaining security of energy supply is one of Europe’s single biggest objectives. Recognising this Council Directive 2009/119/EC imposed an obligation on Member States to COtain minimum stocks of crude oil and/or petroleum products. Regardless of where oil is found the fundamental problem is maximising extraction. On average, 32% of available oil reserves globally are extracted from oilfields. On the Norwegian continental shelf the figure rises to 46% as there is a focus on improving technology in the North Sea. Annex 1- Fig 1 illustrates the oil recovery issue in the Norwegian sector of the North Sea and the potential that exist to prolong the productive life of oilfields. A 1% additional recovery rate from the Norwegian sector alone would generate €36.6 Billion. A key issue in oil extraction is water and gas breakthrough, where the unwanted water/gas displaces the required oil phase. Water is particularly problematic as it is contaminated and needs treating in an expensive cleaning process. Water production is a huge challenge and is getting worse as oil fields age. Typically for every 80m barrels of oil recovered daily 250m barrels of water are brought to the surface._x000D__x000D_The challenge of increasing recovery can be visualised (Annex 1- Fig 2) by considering a typical horizontal well of up to 2.5km length with around 200 inflow control zones mounted in the wall of the pipe well. Oil is drawn down into the well pipeline through small inlets every 12m. However, the heterogeneous character of reservoirs result in water and gas migrating within the strata as oil is extracted. This results in a breakthrough introducing a mixed flow of water and/or gas with the oil, reducing production rates and ultimately reduces recovery._x000D__x000D_The problem would be solved by stopping the flow of water and gas ‘locally’ within sections of the pipe. A conclusion supported by the Norwegian OG21 Task Force that called for research to improve existing solutions through development of Autonomous Inflow Control Valves (AICV) that can deliver an assured flow of oil. The EXTRACT project will achieve this._x000D__x000D_Our AICV is a patented new idea that will replace conventional inflow control devices and ensure a significant increase in oil production and recovery rates. As a vertical supply chain consortium we aim to develop a pre-production prototype that is capable of meeting all the needs of the industry that performs reliably under the harsh well conditions. The device may also find a secondary application in oil spillage situations; incorporated into booms to recover floating oil and reducing environmental damage._x000D__x000D_Our AICV utilises known fluid dynamic principles in a novel way to open the valve when oil is present and close it if water or gas are detected. The device is fully reversible, opening again when oil is detected. It is fully autonomous requiring no external power or control. The principle relies upon achieving laminar flow within a microfluidic channel in the valve which is strongly influenced by the oil properties: viscosity, density and flow rates. Our project therefore focuses on research to understand and optimising performance of the AICV in any oilfield, regardless of viscosity, density, flow rate, or harsh environmental conditions (temperatures, pressures, aggressive chemicals)._x000D__x000D_Our consortium comprises two leading, research capable SMEs: InflowControl AS and Advanced Chemical Etching Ltd. InflowControl is a Norwegian provider of inflow control devices with expertise in developing novel solutions to increase oil recovery inflow devices, including the current state of the art RCP device from Statoil. They have over 20 patents/applications in this area. Advanced Chemical Etching Ltd is a world leader in precision photoetched metallic components, constantly pushing the boundaries of etching technology and is the only company in the world to successfully etch exotic metals required by EXTRACT.

Acronym	EXTRACT (Reference Number: 8430)
Duration	01/09/2013 - 28/02/2015
Project Topic	EXTRACT will create an innovative, reversible, Autonomous Inflow Control Valve (AICV) to selectively block unwanted phases of water and gas and improve oil reservoir recovery rates by up to 25%. The research optimises performance of the AICV for a range of oil viscosities, densities and flow rates.
Project Results (after finalisation)	The laminar flow element in the Autonomous Inflow Control Valve (AICV) was the CO issue in EXTRACT. EXTRACT led to us successfully developing the laminar flow element (LFE) for a wide range of oil fields to broaden the market and applications.
Network	Eurostars
Call	Eurostars Cut-Off 10

Project partner

Number	Name	Role	Country
2	Advanced Chemical Etching Ltd	Partner	United Kingdom
2	InflowControl AS	Coordinator	Norway