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PETROLEUM SOCIETY

CANADIAN INSTITUTE OF MINING, METALLURGY & PETROLEUM PAPER 2007-118

A Theoretical Model for Optimizing Surfactant


Usage in a Gas Well Dewatering Process
H. LI, D. YANG
Petroleum Technology Research Centre (PTRC), University of Regina

Q. ZHANG
China University of Petroleum (East China)

This paper is to be presented at the Petroleum Society’s 8th Canadian International Petroleum Conference (58th Annual Technical
Meeting), Calgary, Alberta, Canada, June 12 – 14, 2007. Discussion of this paper is invited and may be presented at the meeting if
filed in writing with the technical program chairman prior to the conclusion of the meeting. This paper and any discussion filed will
be considered for publication in Petroleum Society journals. Publication rights are reserved. This is a pre-print and subject to
correction.

Abstract it is found that the surfactant usage can be optimized and that
the foam dewatering technique performs better in wells with
Liquid loading significantly affects the production high productivity, high gas-liquid ratio and small size tubing.
performance of a gas well. The available dewatering techniques
include velocity string, foaming, gas lift, plunger lift and other
artificial lift methods, among which the foam-aided dewatering Introduction
method is the simplest and most economical one by effectively
utilizing the natural reservoir energy. It has always been a Liquid loading is one of the severe problems encountered in
challenging task to determine the surfactant usage due to its a mature gas reservoir. As pressure in the reservoir depletes,
cost and continuous consumption during the dewatering liquid tends to accumulate in the wellbore due to the inability of
process. In this paper, a method is developed and applied to the gas to lift the reservoir liquid to the surface. The
optimize the surfactant usage in a gas well dewatering process. accumulated liquid column, which imposes a backpressure to
More specifically, surface tension and foam density are the reservoir, significantly reduces gas production rate. Once
measured at different surfactant concentrations. With a pre- the gas production rate is reduced, it becomes more difficult to
determine a calibration curve of the surface tension and foam remove the liquid by the gas itself in a gas well. Eventually, the
density versus the surfactant concentration, the minimum liquid loading will kill the well and affect the ultimate gas
critical velocity is determined as a function of the surfactant recovery in the gas reservoir. For example, in the Sichuan Gas
concentration by using the modified Turner’s droplet model. Field, China, the average gas recovery is 40~60% in a water-
Then, a mathematical model is formulated to optimize the foam drive gas reservoir, whereas the recovery is up to 90% in a dry
dewatering performance by maximizing the gas production rate gas reservoir[1].
per unit rate of the foaming agents. A field case is presented to Different measures have been adopted to solve the liquid
illustrate the optimization procedure of the model developed in loading problem in a gas well[2, 3]. In practice, at the early stage
this paper. In comparison with the existing empirical methods, of the liquid loading, a small tubing or coiled-tubing is used to

1
increase the gas velocity and surfactants can be injected to According to the Turner’s model, the minimum critical gas
unload a gas well by foam. It should be noted that these velocity, V gc , can be calculated as[18]
σ 1 4 (ρ l − ρ g )1 4
techniques take full advantages of the natural reservoir energy.
However, if the reservoir energy declines to a certain value at Vgc = k (1)
which it is not sufficient to unload the produced liquid out of ρ 1g 2
the well, artificial lifting methods must be utilized. These
methods include the wellhead boosting, gas lift, plunger lift, jet where σ is the gas-liquid surface tension, dyne/cm; ρ l and
pump, and the combination of the above-mentioned lifting ρg are densities of liquid and gas, lbm/ft 3 , respectively; and
methods[4, 5]. Obviously, the liquid unloading methods that
utilize the reservoir energy are more economical, among which k is the coefficient of the critical velocity,
the foaming method is the simplest one. In principle, the foam (ft/sec) × (lbm/ft 3 )0.25 /(dyne/cm) 0.25 .
aids the gas well to unload the liquid by reducing surface The parameter k can be expressed as
tension and density of the liquid phase and reducing the size of
liquid droplets as well. It has been found from laboratory 4mg c gN we
k=4 (2)
experiments that the foam can reduce the minimum critical 3Cd
velocity of gas by several orders of magnitudes[6, 7].
Successful case studies pertaining to the foam-aided where g is the acceleration due to gravity (32.17 ft/s 2 ); N we is
dewatering techniques can be found elsewhere[7-12]. In principle, the Weber number, representing the ratio of the inertial force to
effects of the foam on gas dewatering are mainly related to the the surface tension; Cd is the drag coefficient; m and g c are
following factors: 1) gas production rate and gas-liquid ratio2]; the conversion factors, respectively.
2) quality and stability of the foam under reservoir conditions, The drag coefficient Cd is related to the particle Reynolds
which are dependant on the temperature, pressure, salinity of
water, and the appearance of liquid hydrocarbons[10]; and 3) number, N Re = dv ρ g µ g , and the shape of the liquid droplets.
dosage of surfactant (concentration of foaming agent) and cost For a typical field application, the particle Reynolds number is
of surfactant in relation to the produced gas and liquid[13]. Also, in the range of 10 4 ~ 105 [22]. This is the range where the drag
efforts have been made to improve performance of the foam
coefficient has a constant value of 0.44 for a spherical droplet or
dewatering process by reducing the surfactant loss with
of 1.00 for a flat droplet. It is assumed in the Tuner method that
downhole injection tools[14, 15] and by enhancing the foamability
the critical Weber number, NWe , is 30 and the drag
the surfactants and stability of foam[2, 3]. Although performance
of the surfactant solution and foam can be evaluated in the coefficient, Cd , is 0.44, so k = 1.593 . Although Tuner
laboratory at high pressures and elevated temperatures[16, 17], the suggested an upward 20% adjustment is needed for determining
usage of surfactant in the field operations is still mainly the k value, Coleman, et. al.[18] found that the theoretically
determined by using the empirical methods due to the complex calculated values without a 20% upward adjustment fit their
downhole environment. This may lead to unstable production
experimental data better. Thus, k = 1.593 is used for
performance and/or higher production costs.
In this paper, a new method is developed and applied to determining the MCV of the gas in this study.
optimize the surfactant usage in a gas well dewatering process. The corresponding minimum gas flow rate for a well to
First, a calibration curve of the surface tension and foam density continuously remove the liquids, Qgc , can be calculated by[18]
the surfactant concentration is established by using the 2402 pd h2 v gc
Q gc = (3)
experimental data. Then, the minimum critical velocity is
determined as a function of the surfactant concentration by
(T + 460 )z
using the modified Turner’s droplet model. Theoretically, a where Qgc is the minimum gas production rate, Mscf/d ; p is
mathematical model is formulated for optimizing the foam pressure, psia ; d h is the hydraulic diameter of the flow area,
dewatering performance by choosing the ratio of the gas
production rate to the foaming agent rate as the objective ft ; T is the temperature, °F; and z is the gas compressibility
function. Once the objective function is maximized, the factor.
determined surfactant usage is the optimum value for the gas
dewatering process. Finally, a case study is presented and Effect of Surfactants on Foam Properties
sensitive analysis has been made to quantify the effects of major
Surfactant is a substance that can absorb at an interface and
lower the surface tension of a liquid, σ [23]. Many surfactants
parameters on the gas dewatering performance.

can reduce surface tension of water to about 30 dyne/cm from


Theoretical Model its original value of 72 dyne/cm . The reduction of liquid
surface tension is a function of the adsorption of surfactant,
Minimum Critical Velocity property of the liquid solution, type of surfactant, surfactant
The minimum critical velocity (MCV) is defined by the rate concentration, pressure and temperature[8, 24]. Figure 1 depicts
at which the largest drop of liquid that can exist will move the experimentally measured surface tension and foam-density
upward. Numerous methods have been proposed to determine as a function of the surfactant concentration[8]. The experiment
the MCV for gas well unloading process. These methods was conducted with a commercial available surfactant product.
include the spherical droplet model[18, 19], flat droplet model[20], It can be seen from this figure that, with the increase of
liquid film movement model[18], and minimum kinetic energy surfactant concentration, the surface tension decreases sharply
model[21], among which the Turner’s droplet model[18] has at first, and then remains almost constant after the surfactant
received wide acceptance in the upstream oil and gas industry. concentration reaches its CMC. As shown in Figure 1, the foam
density decreases as the surfactant concentration increases.

2
Determination of Surfactant Concentration The water production rate, Qw , can be expressed as
Qg
In practice, application of foaming agent is mainly Qw = (8)
constrained by choosing an economical foamer due to its GLR
relative large usage of surfactants. The type of surfactants for a where GLR is the gas liquid ratio, Mscf/bbl .
gas well can be selected via compatibility tests in the laboratory So the required amount of surfactant can be obtained by
and the proposed screening criteria[10]. However, a proper using the following equation[13]
concentration of surfactant used in the fluid is difficult to be Qs = Cnρ l (Qw + Qi ) (9)
determined in the laboratory experiments, which is usually
calculated by using the empirical methods. This may lead to where Qs is the surfactant dosage, lb/d ; Qi is the surface
unstable production performance and/or higher production surfactant injection rate, which is usually considered as a
costs. Here, a theoretical model is proposed to accurately constant during gas well operation, bbl/d ; and n is the
determine the surfactant concentration as a function of the gas conversion factor, n = 5.61ft 3 /bbl .
production rate. It is assumed that the gas density, ρ g , is Finally, substituting Equation (8) into Equation (9), and the
negligible since the density of foamed liquid is hundreds times objective function can be obtained as follows,
of the density of gas[8]. Thus, Equation (1) could be rewritten as Qg GLR
= (10)
σ 1 4 ρ 1f 4 Qs ⎛ Q ⎞
Vgc = k (4) Cnρ l ⎜⎜1 + i ⎟⎟
ρ 1g 2 ⎝ Qw ⎠
As shown in Figure 1, the surface tension, σ , and foam Obviously, the object is to maximize the gas production rate
density, ρ f , are considered to be dependant on the mass at a minimum consumption rate of the surfactant used for foam
generation. The detailed procedures for optimizing the
percentage concentration of the surfactant, C , for a given surfactant usage for a gas well dewatering process are described
surfactant at atmospheric pressure and temperature, as follows.
respectively[8, 23, 25]. Since both of these two functions decrease 1) Select the proper type of surfactant for a certain gas well
monotonically, the multiplication of these two functions also via compatibility tests according to the USBM testing
yields a monotonic decreasing function. This is termed the procedures[27];
calibration curve of the surface tension and foam density versus 2) Surface tension and foam density are measured at different
the surfactant concentration, as shown in Figure 2, thus surfactant concentrations. Then the calibration curve of the
σρ f = f (C ) (5) surface tension and foam density versus the surfactant
In addition, the gas well is to be unloaded when gas concentration can be obtained;
velocity, Vg , is equal to its MCV, Vgc , thus substituting 3) Set the initial value of pwf (e.g., 0.1 × pr ), use Equations
Equation (5) into Equation (4), and rearranging yields (7) and (8) to calculate the gas production rate, Qg , and the
Vg4 ρ g2
f (C ) =
water production rate;
(6) 4) The gas flowing velocity can be determined by the
k4
following equation[18]
It is found from Equations (5) and (6) that f ( C ) acts as a
Qg z (T + 460 )
bridge between the experimental data and the theoretical MCV Vg = (11)
model. Therefore, a simple and practical solution can be 2402 pd n2
obtained to determine the surfactant concentration. For a given 5) Calculate the value of f (C ) using Equation (6);
gas production velocity, Vg , f ( C ) can be determined by using 6) Using the graphical solution or interpolation method from
Equation (6), and then the corresponding surfactant the pre-determined calibration curve to obtain the
concentration, C , is determined by using the interpolation corresponding surfactant concentration C ;
method or graphical solution from the pre-determined 7) Calculate the dosage of the surfactant, Qs , using Equation
calibration curve as shown in Figure 2. (9);
8) Calculate the object function, Qg / Qs in Equation (10).
Determination of Surfactant Usage 9) Increase Pwf by an incremental interval and Step 3 is
The performance of the foam dewatering process is repeated until p wf is equal to pr and no gas is produced.
evaluated by using the gas production rate per unit consumption
Then the optimization process is terminated. The surfactant
rate of the injecting surfactant, Qg / Qs , as the objective
concentration, C , corresponded to the maximum value of
function. Assuming that a gas well, with a constant reservoir the object function is regarded as the optimum dosage of
pressure, pr , produces gas and water only, that there is no the surfactant.
condensate, and that the producing gas-liquid ratio is constant,
then the inflow performance relationship (IPR) of the gas well
can be described as[26] Case Study
pr2 − pwf2 = Ag Qg (7)
where pwf is the flowing bottomhole pressure, psia; Ag is the Field Background
2
gas production resistance factor, psia /(Mscf/d) ; and Qg is the The Chishui Gas Field, located in Guizhou province of
China, is a mature field with a production history of more than
gas production rate, Mscf/d . 30 years. Since many gas wells in this gas field have suffered

3
from severe liquid loading problem, different gas dewatering flow to slug flow[2]. Since the Turner model was developed on
techniques have been applied for unloading the liquid and thus the basis of the mist flow regime, it is not suitable to use this
increasing the gas production. For demonstration purpose, the model to determine the MCV at a low gas-liquid ratio when the
method developed in this study has been used to analyze the slug flow occurs. It is suggested from field applications that the
optimum usage of the surfactant, compared to the existing foam-aided dewatering process is more suitable for gas wells
empirical methods. The physical properties of a gas well are with the gas-liquid ratio between 1 and 8 Mscf/bbl[2].
listed in Table 1. No condensate is produced from this well. A
surfactant solution is continuously injected down the annular Effect of Gas Well Production Resistance
space by a surface injection pump with the pumping capacity of
0.6 bbl/d .
Factor and Tubing Diameter
The objective function versus the flowing bottomhole
Comparison of the MCV Obtained by Using pressure at two gas production resistance factors and GLR =6.2
Mscf/bbl is depicted in Figure 6. It is shown that the objective
Different Methods function increases as the production resistance factor decreases.
The above-mentioned procedures are used to determine the This is mainly due to the increase of the gas well productivity.
operation parameters for the foam-aided dewatering process. As This means that less surfactant needs to be used for the foam-
shown in Figure 3, the surfactant mass concentration is found to aided dewatering process. This finding is consistent with that
be 0.083% when the gas production rate is 507.8 Mscf/d . The from field applications[7].
other foaming operation parameters are listed in Table 2. Also, Figure 7 shows the relationship between the calculated
the MCVs obtained from other models[18,19,20] are listed in Table dosage of surfactant and the tubing diameters at the gas
3. As can been seen from Table 3, the calculated MCV in this production rate of 507.8 Mscf/d and GLR = 6.2 Mscf/bbl . It
study is smaller than those obtained from the Turner’s model can be seen that the objective function decreases as the tubing
and Coleman’s model. This is mainly because the model diameter increases. This is because a lower gas velocity is
developed in this study considers the reduction of surface expected in tubing with a larger diameter, and thus increases the
tension and the foam density due to dissolution of surfactant. consumption of the surfactant.
On the other hand, the MCV is found to be the lowest by using
the Li’s model due to its consideration of droplet deformation.
Conclusions
Optimum Condition for Implementing Foam In this paper, a pragmatic method is developed and applied
Dewatering to optimize the surfactant usage in a gas well dewatering
process. Also, detailed procedures are provided for optimizing
For the gas well dewatering process, f (C ) is plotted as a the usage of surfactants for foam dewatering process by
function of the flowing bottomhole pressure, pwf , in Figure 4. choosing the ratio of the gas production rate to the surfactant
consumption rate as the objective function. The calculated
It is worthwhile to mention that the function f (C ) , calculated MCV in this study is smaller than those obtained from the
by the theoretical model, is found to be in the range of 0.52 ~ Turner’s model and Coleman’s model. This is mainly because
4.0×104 in figure 4, whereas the function f (C ) obtained from the model used in this study considers the surface tension and
the experiments is in the range of 1050~4957 (see Figure 2). the foam density as a function of surfactant concentration. A
This means that the foam-aided dewatering process is not field case is presented for design and analysis of the technique
always feasible for unloading liquid for a gas well. In principle, developed in this study. It is found that the surfactant usage is
the foam-aided dewatering technique performs better at a determined as a function of gas production rate and that the
moderate gas velocity, Vg . This is because the liquid droplets foam dewatering process performs better in wells with high
productivity, high gas-liquid ratio and small tubing.
can be lifted by the gas itself without surfactant when the gas
velocity is relatively large prior to the occurrence of the liquid
loading. On the other hand, there is no sufficient energy for the
gas to lift the foamed liquid to the surface if the gas velocity is Acknowledgment
too low. The authors acknowledge the Chishui Gas Field, Southern
Figure 5 shows the relationship between the gas production Exploration and Production Company, SINOPEC, for
rate and the objective function. It can be seen that the objective permission to publish this paper.
function increases as the gas production rate increases. This is
mainly ascribed to the fact that a well with high gas rate
possesses more native energy than those with low gas rate. In
this way, a well with a high gas rate is easier to bring liquid NOMENCLATURE
droplets out of the well with the aid of surfactant. Thus, the
foam-aided dewatering process has a better performance at the
early stage of well loading process when the gas well still Notation
maintains a relative high gas production rate. Also, the Ag = gas production resistance factor,
relationship between the gas-liquid ratio and the objective
function is also plotted in Figure 5. Obviously, the object psia 2 /(Mscf/d) ;
function decreases as the gas-liquid ratio decreases at a given C = surfactant mass percentage
gas production rate. This is because more foam is needed when concentration, %;
there is more liquid in the wellbore. It should be noted that a Cd = drag coefficient;
low gas-liquid ratio not only increases the dosage of surfactants
but may also changes the flow regime in the wellbore from mist d = diameter of conduit, ft ;

4
dc = diameter of case, in ; Pressure Low Production Gas Wells; Drilling &
Production Technology, Vol. 23, No. 6, pp. 90-91,
dh = hydraulic diameter of the area of flow, November 2000.
ft ; 6. Saleh, S. and Al-Jamae’y, M., Foam-Assisted Liquid
g = acceleration due to gravity, 32.17 ft/s 2 ; Lifting in Low Pressure Gas Wells; paper SPE 37425,
presented at the SPE Production and Operations
gc = conversion factors, 32.17 lbm ⋅ ft/lbf ⋅ s 2 ; Symposium, Oklahoma, OK, March 1997.
GLR = gas-liquid ratio, Mscf/bbl ;
7. McWilliams, J.P. and Gonzales, D., Downhole Capillary
k = coefficient of critical velocity, Surfactant Injection System Pilot on Low Pressure Gas
(ft/sec) × (lbm/ft 3 )0.25 /(dyne/cm)0.25 ; Wells in the San Juan Basin; paper SPE 94293,
m = 0.00006852 (lbf/ft)/(dyne/cm) ; presented at the SPE Production and Operations
n = 5.61 ft 3 /bbl ; Symposium, Oklahoma, OK, April 2005.
8. Campbell, S., Ramachandran, S., and Bartrip, K.,
N Re = particle Reynolds number; Corrosion Inhibition/Foamer Combination Treatment of
N we = Weber number; Enhanced Gas Production; paper SPE 67325, presented
at the SPE Production and Operations Symposium,
p = pressure, psia ;
Oklahoma, OK, March 2001.
p wf = flowing bottomhole pressure, psia; 9. Campbell, S., and Bartrip, K., Ramachandran, S.,
pr = reservoir pressure, psia ; Corrosion Inhibition and Production Improvement via
Chemical Treatment; Paper 1051, presented at the
Qg = gas production rate, Mscf/d ; NACE Corrosion Conference, Houston, TX, March
Qgc = minimum gas production rate, Mscf/d ; 2001.
10. Jelinek, W. and Schramm L.L., Improved Production
Qi = surface surfactant injection rate, bbl/d ; From Mature Gas Wells by Introducing Surfactants into
Qs = surfactant dosage, bbl/d ; Wells; Paper IPTC/SPE 11028, presented at the
International Petroleum Technology Conference, Doha,
Qw = water production rate, bbl/d ; Qatar, November 2005.
T = temperature, °F ; 11. Geng, X., Zhao, X., Guo, H., and Wang, J., The
V = velocity, ft/s ; Reproduction Technology with Foam Displacement
Vg = gas production velocity, ft/s ; Fluid in Watered-Out Well; Drilling & Production
Technology, Vol. 27, No. 1, pp. 58-59, January 2004.
V gc = minimum critical gas velocity, ft/s ; 12. Bowman, C.W. and Collins, J.A., Increasing the
z = gas compressibility factor; Production From Marginal Gas Wells; paper SPE
100514, presented at the SPE International Oilfield
Greek symbols Corrosion Symposium, Aberdeen, Scotland, May 2006.
13. Vosika, J.L., Use of Foaming Agents To Alleviate
σ = surface tension, dyne/cm ; Liquid Loading in Greater Green River TFG Wells;
paper SPE/DOE 11644, presented at the SPE/DOE
ρf = density of foam, lbm/ft 3 ;
Symposium on Low Permeability, Denver, CO, March
ρg = density of gas, lbm/ft 3 ; 1983.
14. Silverman, S.A., Butler, W., Ashby, T., and Snyder, K.,
ρl = density of liquid, lbm/ft 3 ;
Concentric Capillary Tubing Boosts Production of Low
µg = gas viscosity, mPa ⋅ s . Pressure Wells; Petroleum Engineering International,
Vol. 70, No. 10, pp 71-73, October 1997.
15. Awadzi, J., Babbitt, J., Holland, S., Snyder, K., Saucer,
T., and Latter, K., Downhole Capillary Soap Injection
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6
Table 1 Physical properties for a gas well
Parameter Unit Value Parameter Unit Value
Qg Mscf/d 507.8 GLR Mscf/bbl 6.2
Qw bbl/d 82.2 ρl lbm/ft 3
68.67
Qi bbl/d 0.60 ρg lbm/ft 3
0.045
pr psia 864.4 T °F 113
p wf psia 377.1 dc In 5.0
2
Ag psia /( Mscf/d) 1191.3 dh In 2.5

Table 2 Foaming operation parameters


Parameter Unit Value
C mass% 0.083
Qs lb/d 26.48
Q g / Qs Mscf/lb 19.2

Table 3 Comparison of the MCVs obtained from different models


Turner’s model[18] Coleman’s model[19] Li’s model[20] This study

MCV (ft/s) 14.01 11.68 5.19 10.45

70 80

Surface tension
Foam density 70
60
Surface Tension (dyne/cm)

60

Foam Density (lbm/ft3)


50
50

40 40

30
30

20

20
10

10 0
0.0 0.1 0.2 0.3 0.4 0.5

Surfactant Concentration (mass%)

Figure 1 Effect of surfactant concentration on surface tension and foam density[8].

7
Surface Tension × Foam Density (dyne/cm)(lbm/ft3)
6000

5000

4000

3000

2000

1000

0
0.0 0.1 0.2 0.3 0.4 0.5

Surfactant Concentration (mass%)

Figure 2 The calibration curve of surface tension and foam density versus the surfactant concentration.

15 600
Critical gas velocity
14 585
Gas production rate

Gas Production Rate (Mscf/d)


13 570
Critical Gas Velocity (ft/s)

12 555

11 540

10 525
507.8
9 510

8 495

7 480

6 0.083 465

5 450
0.0 0.1 0.2 0.3 0.4 0.5

Surfactant Concentration (mass%)

Figure 3 The critical gas velocity versus the surfactant concentration.

8
105 700
Function f(C)
IPR
600
104

Gas Production Rate (Mscf/d)


500
103
4
f(C)=Vg4ρg /k
2

400
102
300

101
200

100
100

10-1 0
100 200 300 400 500 600 700 800

Flowing Bottomhole Pressure (psia)

Figure 4 Function f(C) and inflow performance relationship (IPR) for a gas well.

120
GLR=8.0 Mscf/bbl
GLR=6.2 Mscf/bbl
100 GLR=5.0 Mscf/bbl
Objective Function (Mscf/lb)

80

60

40

20

0
450 460 470 480 490 500 510 520 530 540 550

Gas Prodution Rate (Mscf/d)


Figure 5 The objective function versus gas production rate at different gas liquid ratios.

9
120
2
Ag=893.5 psia /(Mscf/d)
Ag=1191.3 psia2/(Mscf/d)
Objective Function (Mscf/lb) 100

80

60

40

20

0
300 350 400 450 500 550 600

Flowing Bottomhole Pressure (psia)

Figure 6 The objective function versus the flowing bottomhole pressure at two production resistance factors and GLR =6.2 Mscf/bbl.

120

100
Objective Function (Mscf/lb)

80

60

40

20

0
2.3 2.4 2.5 2.6 2.7 2.8

Tubing Diameter (in)


Figure 7 The objective function versus the tubing diameter at Qg =507.8 Mscf/d and GLR =6.2 Mscf/bbl.

10

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