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Technology

As a result of the upgrade, production increased and performance was optimised. (Image source: CS Combustion)

CS Combustion Solutions recently enhanced the capacity and efficiency of a sulfuric acid production plant located in Africa’s Copperbelt region, where demand for sulfuric acid is crucial in mining applications such as leaching copper and cobalt

Faced with growing demand, the plant needed to increase production while reducing operational costs and improving reliability. Through targeted improvements, CS increased daily production from 2,200 to 3,000 tons and optimised the plant’s overall performance.

Challenges before optimisation

Prior to the upgrade, the plant faced several challenges, including incomplete combustion, which led to sulfur droplets fouling downstream equipment like the waste heat boiler (WHB) and catalyst beds, increasing system pressure and requiring frequent shutdowns for maintenance. Clogging issues with conventional pressure atomisers resulted in frequent, costly nozzle replacements, while poor droplet atomisation caused hotspots in the refractory lining, increasing wear and reducing reliability.

Key measures implemented

CS Combustion Solutions tackled these issues with the following measures:
1. Ultrasonic atomisation: Replacing pressure atomisers with ultrasonic nozzles reduced droplet size from 400 to 110 µm, which minimised fouling, improved combustion, and protected the refractory lining from localised heat.
2. Swirl bodies: Introducing swirl bodies created rotational motion in the combustion air, enhancing flame formation and leading to more efficient sulfur combustion.
3. VectorWall installation: Replacing the plant’s original baffle walls with a VectorWall improved mixing within the combustion chamber, reduced hotspots, and prevented unreacted sulfur carryover to downstream components.
4. CFD analysis: A Computational Fluid Dynamics (CFD) study simulated and optimized the modifications prior to implementation, ensuring targeted performance improvements.

Results and benefits

With these enhancements, the plant boosted production capacity by 30%, enabling 40 tons of sulfur incineration per hour. The new configuration allows maintenance of sulfur guns without stopping operations, reducing downtime and saving US$160,000 annually by decreasing pressure drop. Additionally, precise ultrasonic atomisation prevented sulfur buildup on the refractory, extending its lifespan.

This case study highlights the importance of innovative combustion technologies and detailed pre-implementation analysis, offering valuable insights for facilities facing similar challenges in optimising sulfuric acid production.

SandTrapXL mitigates solids production. (Image source: Halliburton)

Halliburton has launched SandTrap XL consolidation service for sand control, a chemical resin consolidation technology to stop the production of formation sand

SandTrap XL sand control service employs an externally activated, low-viscosity resin system that provides consolidation strength to the formation grains without compromising rock permeability. Unlike internally activated resin systems, there are no restrictions on pumping or activation time to allow treatment of longer intervals.

The SandTrap XL system excels in the treatment of high-clay content minerology up to 25% and adapts to various formation mineralogies. It provides thermal stability above 550°F (287°C). This allows it to control sand in heavy oil reservoirs under enhanced oil recovery methods, such as steam flooding. As part of Halliburton’s portfolio of remedial solutions, SandTrap XL mitigates solids production, including formation sand and fines migration. This approach helps ensure the long-term stability and productivity of oil wells to address the needs of operators in diverse geological environments.

“Excessive sand production remains an issue in our industry,” said Luke Holderman, vice president, Production Solutions and Pipeline & Process Services. “SandTrap XL empowers our customers to maximise asset value through enhanced well performance and extended asset life. Through customised chemical consolidation, SandTrap XL provides a reliable solution for mature fields and unconsolidated reservoirs to ensure long-term productivity and efficiency.”

Effective well placement with real-time rock data analysis. (Image source: Viridien)

With gas and carbon storage activities expanding across the Middle East as operators pursue carbon reduction and energy efficiency goals, Viridien offers specialised geological analysis solutions for effective well placement in UBCTD

Underbalanced coil tubing drilling (UBCTD) technology is being utilised to re-enter existing vertical wells in depleted fields, allowing for the drilling of multiple horizontal legs, which significantly improves direct access to the reservoir. UBCTD lowers drilling costs and reduces formation damage, preserving permeability.

Specialised geological analysis is key for effective well placement in UBCTD. Advanced rock analysis of drill cuttings at the wellsite involves biosteering (microscopic fossil analysis), rock-typing, and visual porosity assessment (see figure). This approach is primarily used in limestone reservoirs, such as the Khuff, Arab, Habshan, Lekhwair, Kharaib, Shu’iaba, Natih and Misrif formations, where the integration of these techniques helps to accurately determine a borehole's position within the reservoir. Continuous analysis during drilling provides real-time data, enabling informed decision-making that can lead to successful well delivery with improved production rates or increased storage capacity.

Advantages of using Viridien’s real-time rock data analysis for well placement

These analytical techniques provide critical insights for maintaining or repositioning the borehole within the reservoir, offering several advantages:

• Accurate wellbore placement using biosteering, which, when combined with lithofacies and porosity data, is crucial for optimal reservoir targeting, especially when Logging While Drilling (LWD) is unavailable.
• Cost-effective solution for gas and carbon storage drilling.
• Real-time updates of the field’s static reservoir model while drilling.
• Fault identification with biosteering, including vertical displacements, allowing precise steering back to the target horizon.

Viridien's legacy in the Middle East

Viridien, formerly CGG, operating from its Abu Dhabi Geoscience hub, has undertaken biosteering, rock-typing and porosity evaluation in the region since 1994. These techniques have been applied to develop fields including the Shu’aiba, Kharaib, Lekhwair and Habshan and Khuff reservoirs. In 2003, Viridien participated in the first UBCTD project in the UAE and biosteering was key to successful well delivery. Viridien has undertaken UBCTD projects in Saudi Arabia since 2009, supported by its state-of-the-art laboratories in the UK. The adoption of these specialist geological techniques has become more widespread in the UAE recently, where Viridien is providing expert well placement services for several clients. The future of wellsite geological services for field development is bright, and the Middle East is leading the way.

Learn more about Viridien integrated solutions for exploration and reservoir development drilling including wellsite biostratigraphy and other advanced techniques at:

Viridien: Wellsite Services (https://www.viridiengroup.com/expertise/geological-services/wellsite-services)



Halliburton's iCruise Force. (Image source: Halliburton)

Halliburton has introduced its iCruise Force intelligent, high-performance motorised rotary steerable system

iCruise Force, when coupled with Halliburton's LOGIX automation and remote operations platform, is designed to expand drilling capabilities to optimise performance and maximise asset value for customers. Powered by high-performance mud motors, the system enhances efficiency with expanded rig capabilities and extended drilling depths in complex formations. This helps customers achieve faster penetration rates, lower drilling costs, and more precise wellbore placement.

"Our priority is to customise solutions to overcome diverse challenges in harsh environments to maximise asset value for our customer base," said Jim Collins, vice president of Halliburton Sperry Drilling. "We will continue to expand our intelligent portfolio, to drive efficiency, consistency and reliability."

When combined with the LOGIX platform, iCruise Force further enhances precision and operational efficiency. This combination facilitates more accurate steering and superior control, helping operators mitigate non-productive time and streamline the well construction process. 

The M4 Inflow Control System will be showcased at ADIPEC 2024. (Image source: TAQA)

TAQA, an international company offering leading well solutions for the energy industry, has revealed the next-generation inflow control system

The M4 Inflow Control System dictates the flow of undesired fluid (such as water and gas) and avoids any binary (open/close) effect that can result in instability or even stop production. Enabling operators to optimise their reservoir performance while sustainability managing fluid production, the new system excels in controlling water in ultra-light and light applications and enhances gas production control, providing stability and flexibility in diverse reservoir conditions.

Supercharging reservoir performance

“With the largest portfolio of inflow control systems more than 20 years of inflow control devices expertise, the M4 Inflow Control System represents the pinnacle of our innovation so far,” remarked Mojtaba Moradi, subsurface engineering manager of TAQA. “This new generation offers water control by gradually reducing inflow as water production increases, avoiding premature well shut in.
“Its main benefit is precision control based on reservoir production. The device allows operators to maximise output without risking shutting wells in, so they can manage production continuously and efficiently, which translates into obvious financial benefits.”

According to TAQA, the M4 Inflow Control System technology incorporates an advanced pilot control system that is super sensitive to density, making it suitable for a wide range of oil types, including ultra-light, light, medium, and heavy oils. It also features advanced multi-phase control, allowing the device to perform independently of its orientation in the wellbore.

TAQA also offers a ‘plug and play’ integration with its full portfolio of inflow systems and has been built to optimise performance in all types of wells in all reservoir types. Additional operational features such as last-minute capacity change, and the ability to circulate to the bottom have also been incorporated into the design.

Although not limited to any oil viscosity, so far, the system has demonstrated excellent performance with oil viscosities as low as 0.5cP tested together with water to define the operating and control points at various water cuts. A full qualification matrix of debris, erosion and cycle testing has also been completed.

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