Tatneft archives significant progress in energy and resource efficiency
(April 11, Tatar-Inform, Anvar Malikov). Tatarstan oil deposits are characterized by high depletion and water content, which increase oil extracting costs. Under these conditions, Tatneft has to apply well thought-out technology policy to preserve its competitiveness. Oil production conditions, becoming more complicated with each passing year, have forced the company to think about the energy and resource efficiency.
Tatneft has been implementing the Energy Efficient Economy comprehensive program since 2000. It is aimed at reducing consumption of fuel and energy resources (FER). The initial steps were made during the first five-year energy saving program. For example, the introduction of an automated system made it possible to establish optimum control on the power consumption.
By 2010, the company had ensured the long-term and significant energy-saving effect, but it required large investments. The most significant result was achieved in reduction of energy consumption per tonnes of oil.
In 2011, Tatneft has started up the implementation of a ten-year target program on resource saving, scheduled up to 2020, inclusively. It is more difficult and costly that its precursors, therefore investments will not be paid off immediately, as it is designed for a long-term period. Unlike previous programs focused only on energy efficiency, the new program involves savings of natural and material resources by oil services companies, oil refining, petrochemicals, distributors.
Tatneft has presented the intermediate results of this activity at an annual exhibition, Energy. Resource Saving, held recently at the Kazanskaya Yarmorka exhibition center. Tatarstan President Rustam Minnikhanov, Heads of Volgograd and Kaliningrad regions Andrey Bocharov and Nikolay Tsukanov, Russian Deputy Minister of Energy Anton Inyutsin spent much time viewing Tatneft’s stands, which presented the impressive outcomes of its activities and future projects.
What can be learned by taking a look at Tatneft’s stands? The most important thing is that the company exceeded its own targets of the program over five years: it reduced the consumption of energy resources by 28.7 percent instead of planned 7.4 percent. During 2011-2015, it saved more than 311 thousand tonnes of equivalent fuel. A total of 7.5 billion rubles are associated with material and natural resources saved.
During the exhibition, Rustam Minnikhanov chaired a thematic session of Tatarstan’s government. It reviewed the implementation of a state program, Energy Saving and Energy Efficiency in Tatarstan for 2014-2020. The meeting considered results of a republic contest for the best achievements in energy saving and energy efficiency in 2015. Tatneft has become the winner in the Fuel Industry category. The company has also been recognized as the best among the television media of the republic in promotion of the energy-saving program.
Let's make a brief overview of some of Tatneft’s projects in the context of the topic.
Entire stream – to reservoir
The development of natural bitumen is one of the most promising, but at the same time, the most energy- and resource-intensive projects of Tatneft. Given this fact, improvement of cost reducing is being constantly conducted there.
As an instance, the company achieved a significant reduction of heat loss through using a condensing economizer. Boiler efficiency, which produces steam for injection, was increased. An economizer is a part of a boiler, a heat exchanger, where water is heated by gases before being fed to the boiler.
An additional heat exchanger can cool gases from 150-200 to 60 degrees. Produced heat is used to generate steam.
One of the main resources used in this extraction method is water. Tatneft launched implementation of its circulation by stages. To do this, it built a unique facility for preparation of produced water with viscous oil. After purifying, it is used for steam production once again. Experts say it is actually becoming drinkable at the final stage of the production.
Chain drive and dual completion
Balancer-free chain drives in sucker rod pumping units have long proven themselves in the complicated wells. These vertical structures are an alternative to traditional reciprocating shaker. Due to the smooth operation, they are less energy-intensive and a half times less likely to break.
These devices, designed at TatNIPIneft institute, were started up for the production flow at Bugulma Mechanical Plant. Their actual number will soon be close to 2,000.
One of the strategic and rapidly developing technologies of Tatneft is a system of dual completion of two or more layers through one well. It gives the average increase in oil production of 3.7 tonnes per well daily. This eliminates the need to drill a separate well and build separate pipelines.
At the beginning of this year, Tatneft operated 2,370 such wells. The potential number for introduction of dual completion wells is estimated at several thousand objects.
A reservoir pressure maintenance system (RPM) has a great potential for saving energy and resources. The company is developing promising technologies to reduce costs and increase reliability in this field. For example, Tatneft keeps on protecting injection well equipment from high pressure and corrosion, as well as optimizing comprehensive RPM process.
Favourable import substitution
One another resource saving field appeals to the foreign policy situation. In terms of the Western sanctions, Tatneft has developed its own program of import substitution. As it turned out, considerable savings can be achieved with domestic developments.
The company conducts pilot projects on the use of lightweight backfill mixture with addition of foam glass produced by PD Tatneft-Alabuga Steklovolokno. This is an alternative to the material produced by a Norwegian company. Using the domestic material stabilized the cost of one meter of penetration.
The grouting mortars produced with granulated foamed glass is designed for cementing production casing in a productive and higher-lying zones. Its cost is three times less, compared to the imported analog.
Replacement of American units for repair of inclined wells while developing extra-viscous oil deposits was also found nearby, in Yelabuga. Tatneft purchased nine lifting units from PO ElAZ, each of which is 150 million rubles cheaper then the North American analogs.
The Elabuga machine builders took into account the international experience and Tatneft's repair practice . Along with the low cost, another benefit is reducing delivery terms from one and a half years to one month, as well as much simpler and cheaper repair.
Tatneft experts believe that the creation of national inclined drillingsystems could be the next step to take.