Project Overview
Approved for funding through ERA’s Partnership Intake Program in 2023, Rotoliptic developed a high-performance all-metal progressing cavity pump designed for extreme pressure and multi-phase conditions, such as Alberta’s steam-assisted gravity drainage (SAGD) and heavy oil fields. By completion in 2024, successful field trials demonstrated efficiency improvements, reduced CO2 emissions, and reliability in high-viscosity applications. The R200 is now a commercially viable and available product for many types of applications.
Energy Efficient, All-Metal Pump for Oil Production
Rotoliptic pumps are a robust and energy-efficient solution for high-pressure, high-temperature, multiphase environments with a design that eliminates the reliance on elastomers and provides higher efficiency with a simple, two-part, all-metal pump. Both the R65 and R200 were developed to meet the demanding operational needs of oil producers while reducing the energy required during these operations. Building on the success of the smaller R65 pump with a scaled geometry, the R200 was designed to meet higher flow rate demands and higher energy efficiency per unit flow. The R200 was designed pre-project with simulations and successful in-house testing completed. The project focused on further development and commercialization of the R200 pump.
Successful Field Trials Validate R200 Performance
The pump was tested in two real SAGD field demonstrations in Alberta with two different operators. Throughout the project, the R200 was engineered and improved, resulting in a higher stage count to handle twenty percent higher pressures and lift capacities of up to 1300 meters. During the project, challenges were experienced unrelated to the pump design, such as tubing and auxiliary part failures and foreign objects obstructing the pump. Despite these challenges, the trials demonstrated energy efficiency improvements and GHG reductions relative to historical all-metal progressing cavity pumps. Data from over 300 days of field demonstrations validated laboratory results and showcased the pumps’ reliability under demanding conditions, and provided operators with 15 to 30 per cent reductions in energy consumption.
Exploring materials durability and enhancement, the project tested a number of advanced material coatings and metallurgical treatments. Sub-scale destructive testing was completed on several unique material combinations to further improve the pumps’ wear resistance and extend their operational life. The successful trial of a new electrolyte improved consistency and precision in the stator machining process, which enabled longer pump lengths to be tested and longer stator lengths to be achieved. Overall, project results position the R200 for broader market adoption, providing a robust solution for artificial lift in demanding environments.
What’s next?
Learnings from the project will continue to guide knowledge improvements and maximize environmental and economic outcomes. Going forward, Rotoliptic will secure additional distribution partnerships and grow relationships with Albertan partners. Additionally, focusing on scaling production capabilities, broadening customer outreach, and knowledge dissemination of the R200 benefits. Efforts will be made to facilitate R&D work and ensure Rotoliptics’ pump offering is continually improving.