Production of high viscous oil from reservoirs is associated with high level of geological and technological risks. In order to make heavy oil projects economically valuable, it is important to reach sufficient levels of oil production to cover the high costs of used technologies. It is very well known that thermal methods are the ones having the highest positive impact on the heavy oil recovery. The complexity of the physical processes while implementation of such methods represents a significant engineering challenge in terms of planning and finding optimal field development scenario. Modern modeling tool such as detailed integrated model combining the reservoir and the surface network simulators allow the engineers to model the complex physical phenomena and investigate in details different "what-if" scenarios, thus allowing them to find and implement optimal solutions, minimize risks and achieve economical profitability of complex heavy oil projects. However, prior to application of such complex models for making engineering decisions it is crucial to ensure, that they are able to deliver stable and valid results in the entire range of the possible input parameters changes. These changes of parameters can be dictated by either uncertainty of the initial data due to limited availability and quality or by actual variation as the result of complex physical phenomena. This paper describes a challenge of modeling of the shallow heavy oil field Katangli, where for 40 years the cyclic steam injection heavy oil recovery technology has been implemented. In this work, the comprehensive thermodynamic models of the reservoir and the surface infrastructure were built in order to take into account for all necessary physical effects. These models were then combined into the single "reservoir-to-surface" integrated model in order to consider the behavior of the entire system and counter influence of the both parts on each other. While building and calibration those models several important studies were performed with each part of the integrated model, which helped to better understand the process of cycling steam injection, specificities of its application and modeling, and to address issues related to initial data availability, quality and variability and their potential impact on engineering decisions in future.
Horizontal state of mold at continuous casting of steel in horizontal continuous casters (HCC) complicates the melt supply conditions and forming of billets, results in disturbing ofcasting process stability, in forming of zones of chemical and physical inhomogeneity, distortion of the billet geometric form, arising of longitudinal fractures, bleeding at the mold exit. A possibility to increase the quality of the billets, produced at HCCs relates to changing of conditions of the metal solidification, creation of forced melt movement, in particular, by application of electromagnetic field. To increase the casting stability andimprove quality of the billets from alloyed steels a modernization of a HCC accomplished. Within the modernization a system of electromagnetic stirring (EMS) for modernizedmold of the HCC was developed. The modernized mold for horizontal casting is equipped by a build-in two-phased stator of alternative current. The two phased EMS stator built-in into the mold shell, supplied by power from two-phased frequency convertor, developed and manufactured by “Electroprivod i silivaya electronica” LLC (Moscow). A water immersion winding is the main element of the EMS stator. The winding isolation resistance at the first stage of the water immersion stator running was more than 500 m ohm. The technology of the winding manufacturing provides a high coefficient of heat exchange between the copper wires and technical water, usedfor direct cooling. By this, high values of the winding magnetizing force is reached at a small volume that in its turn provides a wide range of stirring intensity control. The developed EMS system enables to decrease considerably the existing drawbacks of HCC.
To avoid defects of continuously casted billets, such as core porosity, shrink liquation, ingot developed dendrite structure and others, various methods of external physical impact on the crystallizing billet are used. One of the most technological and effective of them is the electromagnetic stirring (EMS) of the liquid melt of the crystallizing billet. An analysis of the experience of industrial EMS systems application at steel plants of Russia was accomplished. It was noted, that operating in Russia industrial CCM, intended for production of high quality billets, are equipped mainly by EMS systems of foreign production. The stator of the EMS is located outside a mould body and the bodies of the stator and the mould are manufactured of nonmagnetic steel of austenite class. Such systems are characterized by low reliability and high energy consumption because of their design features (location outside a mould body and necessity to use for them a separate circuit of cooling by a “boiler” water). Bessides, most of the EMS stators of foreign manufacturing are made in nonseparable bodies, hence in case of a failure the expensive rrepair of the stators should be carried out at the foreign plants-manufacturers. At present in Russia the EMS systems are being elaboorrated by specialists of AKKH “VNIIMETMASH”, Moscow. VNIIMETMASH within the frame of import substitution program elaboorated both built-in and external variants of EMS systems for moulds of billet and bloom CCM, the stator coil poles being cooled bby the water of the mould and its winding is made of immersible into water wire with a double insulation. Based on the results of thee study it was determined, that location of the elaborated EMS systems in a mould results in improving of the surface quality, as welll as quality of the subsurface layer and the billet macro-structure, decreasing of the point unevenness and decreasing of number of thee subshell bubbles.
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