Vapex: An Efficient Process for the Recovery of Heavy Oil and Bitumen

Abstract

Summary The Vapex (vapor extraction) process may be a viable technique for the recovery of highly viscous heavy oil and bitumen. The size of the estimated heavy oil and tar sand resources in the United States amounts to 100 billion bbl and 62 billion bbl of oil in place (OIP), respectively. Although this represents a small fraction of the total world reserves, it is about one-third of the total estimated crude oil discovered in the United States. The world estimate of this resource is about 6 trillion bbl, six times the conventional oil reserves, and may be the future source of energy. Efficient extraction of these highly viscous crude oils poses a serious challenge to petroleum engineers. In some of the heavy oil reservoirs steam flooding and in-situ combustion processes were partially successful. For thick tar sand reservoirs, the steam-assisted gravity drainage (SAGD) process proved to be effective. However, thermal processes, in addition to other disadvantages, suffer from energy inefficiency caused by heat losses. The Vapex process involves injection of vaporized hydrocarbon solvents into heavy oil and bitumen reservoirs; the solvent-diluted oi1 drains by gravity to a horizontal production well. Recent research has shown that the process is highly energy efficient, environmentally friendly, causes in-situ upgrading, and requires low capital investment compared to its competitive process, SAGD. The applicability of the Vapex process may even surpass SAGD in thin reservoirs, reservoirs underlain by aquifer, offshore operations, etc. Some experimental results, a theoretical analysis, and the feasibility of this process for implementation in heavy oil and bitumen reservoirs will be presented.