Revolutionizing Oil Recovery and Separation Efficiency in Zaafarana Field: A Nano-Technology Approach Validated by Lab-Simulated Experiments and Simulation Modeling

Abstract Zaafarana Field, managed by Cheiron Petroleum Corporation, emerges as one of the most important offshore assets, located 90 km south of Suez City within the Gulf of Suez. It comprises two reservoirs, Kareem and Rudeis, which have collectively sustained significant oil production over 26 years. However, the Rudeis reservoir presents distinct challenges with its high residual oil saturation and robust water drive mechanism, resulting in a stable 90% water cut across the majority of wells, limiting oil recovery potential. In response to these challenges, a groundbreaking nano-technology product was introduced to modify wettability via structural disjoining pressure mechanisms, showing immense promise in addressing recovery constraints. By incorporating non-toxic, non-hazardous, and cost-effective nano-particles into the reservoir matrix, remarkable advancements have been observed in lab-simulated experiments. Lab experiments with Zaafarana core plugs and reservoir fluids revealed that the introduction of nano-particles significantly altered wettability, reducing residual oil saturation (SOR) and enhancing interfacial tension between oil and water. Notably, the time required for oil-water separation plummeted from half an hour to a mere one minute, underscoring the technology's potential to revolutionize separation processes. To quantify the technology's impact and present tangible evidence to management, extensive reservoir simulation modeling efforts were undertaken. These simulations, rooted in operational excellence and company SOPs, elucidated the economic implications and potential production enhancements achievable through this innovative approach. By modifying the simulation model to reflect the introduction of nanoparticles and altering relative permeability curves to simulate invasion scenarios, remarkable gains were projected. This comprehensive approach, integrating lab-simulated experiments and validated simulation modeling, underscores Zaafarana Field's commitment to operational excellence and innovation. By leveraging the benefits of nanotechnology, the field stands poised to optimize oil recovery, minimize water cut, and enhance separation processes, all while adhering to stringent environmental standards and maximizing cost-efficiency.