Numerical Modeling of Toe-to-Heel Air Injection and Its Catalytic Variant (CAPRI) under Varying Steam Conditions

[Image: see text] There are huge reserves of heavy oil (HO) throughout the world that can be energy-intensive to recover. Improving the energy efficiency of the recovery process and developing novel methods of cleaner recovery will be essential for the transition from traditional fossil fuel usage to net-zero. In situ combustion (ISC) is a less used technique, with toe-to-heel air injection (THAI) and catalytic processing in situ (CAPRI) being specialized novel versions of traditional ISC. They utilize a horizontal producing well and in the case of CAPRI, a catalyst. This paper aims to investigate the impact that injected steam has on both the THAI and CAPRI processes for the purpose of in situ HO upgrading and will help to bridge the gap between the extant laboratory research and the unknown commercial potential. This study also presents a novel method for modeling the THAI–CAPRI method using CMG STARS, proposing an in situ hydrogen production reaction scheme. THAI and CAPRI experimental-scale models were run under three conditions: dry, pre-steam, and constant steam. Starting from a reservoir American Petroleum Institute (API) of 10.5°, THAI reached an average API of ∼16 points, showing no increase in the API output with the use of steam injection. A decreased API output by ∼0.7 points during constant steam injection was achieved due to a high-temperature oxidation-dominant environment. This decreases the reactant availability for thermal cracking. The CAPRI dry run reached an API of 20.40 points and achieved an increased API output for both pre-steaming (∼21.17 points) and constant steaming (∼22.13 points). The mechanics for this increased upgrading were discussed, and catalytic upgrading, as opposed to thermal cracking, was shown to be the reason for the increased upgrading. Both processes produce similar cumulative oil (∼3150 cm(3)) during dry and pre-steamed runs, only increasing to ∼3300 cm(3) with the constant steam injection during THAI and 3500 cm(3) for CAPRI.