Modeling Oil Recovery in Mixed-Wet Rocks: Pore-Scale Comparison Between Experiment and Simulation

Pore-scale simulation of low-salinity waterflooding in mixed-wet systems: effect of corner flow, surface heterogeneity and kinetics of wettability alteration

The initial wettability state of the candidate oil reservoirs for low-salinity waterflooding (LSWF) is commonly characterized as mixed-wet. In mixed-wet systems, both the two-phase flow dynamics and the salt transport are significantly influenced by the corner flow of the wetting phase. Thus this study aims at comprehensive evaluation of LSWF efficiency by capturing the effect of corner flow and non-uniform wettability distribution. In this regard, direct numerical simulations under capillary-dominated flow regime were performed using the OpenFOAM Computational Fluid Dynamics toolbox. The results indicate that corner flow results in the transport of low-salinity water ahead of the primary fluid front and triggers a transition in the flow regime from a piston-like to multi-directional displacement. This then makes a substantial difference of 22% in the ultimate oil recovery factors between the 2D and quasi-3D models. Furthermore, the interplay of solute transport through corners and wettability alteration kinetics can lead to a new oil trapping mechanism, not reported in the literature, that diminishes LSWF efficiency. While the findings of this study elucidate that LSWF does exhibit improved oil recovery compared to high-salinity waterflooding, the complicating phenomena in mixed-wet systems can significantly affect the efficiency of this method and make it less successful.

Novel fabrication of mixed wettability micromodels for pore-scale studies of fluid-rock interactions

Wettability plays a crucial role in multiphase fluid flow in porous media, impacting various geological applications such as hydrocarbon extraction, aquifer remediation, and carbon dioxide sequestration. Microfluidic methods have attracted interest for their capacity to explore and visualize essential multiphase flow dynamics at the pore level, mimicking actual rock pore structures. However, creating micromodels with representative mixed wettability is currently a challenge. Existing technology is limited to producing micromodels with a singular wettability, either water-wet or oil-wet, leaving a gap in representing mixed-wet scenarios. In this study, we introduce a novel method to fabricate microfluidic devices with controlled spatial distribution of wettability at the micro-scale, mimicking actual configurations of mixed-wet rocks arising from varied mineralogy and pore structures. The proposed method combines the soft lithography process with thin film deposition techniques. The micromodels were designed to mimic the pore network of actual reservoir rocks, and a silicon substrate served as the foundation for the photolithography process optimization and wettability alteration methodology. Perfluorodecyltrichlorosilane coating was applied using molecular vapor deposition technology for surface wettability modification. The coated parts of the microdevice substrate altered the localized wetting state of the silicon towards hydrophobic, while the wettability remained unchanged in the non-coated areas. We utilized surface measurements, including contact angle, X-ray photoelectron spectroscopy, transmission electron microscopy, scanning electron microscopy, and atomic force microscopy, to assess the wettability, composition, thickness, shape, roughness, and overall quality of the coating. Our fabrication process successfully produced a microfluidics device with tailored mixed-wet attributes at the micro-scale, which is, to our best knowledge, the first achievement in the field. This method enables the replication of mixed-wet characteristics commonly seen in various applications, such as carbonates and shales within underground rocks, providing a more accurate examination of fundamental multiphase fluid dynamics and rock interactions at the pore level.

How Heterogeneous Pore Scale Distributions of Wettability Affect Infiltration into Porous Media

Wettability is an important parameter that significantly determines hydrology in porous media, and it especially controls the flow of water across the rhizosphere—the soil-plant interface. However, the influence of spatially heterogeneous distributions on the soil particles surfaces is scarcely known. Therefore, this study investigates the influence of spatially heterogeneous wettability distributions on infiltration into porous media. For this purpose, we utilize a two-phase flow model based on Lattice-Boltzmann to numerically simulate the infiltration in porous media with a simplified geometry and for various selected heterogeneous wettability coatings. Additionally, we simulated the rewetting of the dry rhizosphere of a sandy soil where dry hydrophobic mucilage depositions on the particle surface are represented via a locally increased contact angle. In particular, we can show that hydraulic dynamics and water repellency are determined by the specific location of wettability patterns within the pore space. When present at certain locations, tiny hydrophobic depositions can cause water repellency in an otherwise well-wettable soil. In this case, averaged, effective contact angle parameterizations such as the Cassie equation are unsuitable. At critical conditions, when the rhizosphere limits root water uptake, consideration of the specific microscale locations of exudate depositions may improve models of root water uptake.

Understanding the role of wettability distribution on pore-filling and displacement patterns in a homogeneous structure via quasi 3D pore-scale modelling

Most numerical simulation studies have focused on the effect of homogenous wettability on fluid flow dynamics; however, most rocks display spatially heterogeneous wettability. Therefore, we have used direct numerical simulations (DNS) to investigate wettability heterogeneity at pore-scale. We have built a quasi-3D pore-scale model and simulated two-phase flow in a homogenous porous media with homogenous and heterogeneous wettability distributions. Five different heterogeneous wettability patterns were used in this study. We observed that heterogenous wettability significantly affects the evolution of fluid interface, trapped saturation, and displacement patterns. Wettability heterogeneity results in fingering and specific trapping patterns which do not follow the flow behaviour characteristic of a porous medium with homogenous wettability. This flow behaviour indicates a different flow regime that cannot be estimated using homogenous wettability distributions represented by an average contact angle. Moreover, our simulation results show that certain spatial configurations of wettability heterogeneity at the microscale, e.g. being perpendicular to the flow direction, may assist the stability of the displacement and delay the breakthrough time. In contrast, other configurations such as being parallel to the flow direction promote flow instability for the same pore-scale geometry.

Pore-by-Pore Modelling, Validation and Prediction of Waterflooding in Oil-Wet Rocks Using Dynamic Synchrotron Data

We predict waterflood displacement on a pore-by-pore basis using pore network modelling. The pore structure is captured by a high-resolution image. We then use an energy balance applied to images of the displacement to assign an average contact angle, and then modify the local pore-scale contact angles in the model about this mean to match the observed displacement sequence. Two waterflooding experiments on oil-wet rocks are analysed where the displacement sequence was imaged using time-resolved synchrotron imaging. In both cases the capillary pressure in the model matches the experimentally obtained values derived from the measured interfacial curvature. We then predict relative permeability for the full saturation range. Using the optimised contact angles distributed randomly in space has little effect on the predicted capillary pressures and relative permeabilities, indicating that spatial correlation in wettability is not significant in these oil-wet samples. The calibrated model can be used to predict properties outside the range of conditions considered in the experiment.

Pore-Scale Simulation of Particle Flooding for Enhancing Oil Recovery

The particles, water and oil three-phase flow behaviors at the pore scale is significant to clarify the dynamic mechanism in the particle flooding process. In this work, a newly developed direct numerical simulation techniques, i.e., VOF-FDM-DEM method is employed to perform the simulation of several different particle flooding processes after water flooding, which are carried out with a porous structure obtained by CT scanning of a real rock. The study on the distribution of remaining oil and the displacement process of viscoelastic particles shows that the capillary barrier near the location with the abrupt change of pore radius is the main reason for the formation of remaining oil. There is a dynamic threshold in the process of producing remaining oil. Only when the displacement force exceeds this threshold, the remaining oil can be produced. The flow behavior of particle–oil–water under three different flooding modes, i.e., continuous injection, alternate injection and slug injection, is studied. It is found that the particle size and the injection mode have an important influence on the fluid flow. On this basis, the flow behavior, pressure characteristics and recovery efficiency of the three injection modes are compared. It is found that by injecting two kinds of fluids with different resistance increasing ability into the pores, they can enter into different pore channels, resulting in the imbalance of the force on the remaining oil interface and formation of different resistance between the channels, which can realize the rapid recovery of the remaining oil.

Three-phase flow displacement dynamics and Haines jumps in a hydrophobic porous medium

We use synchrotron X-ray micro-tomography to investigate the displacement dynamics during three-phase—oil, water and gas—flow in a hydrophobic porous medium. We observe a distinct gas invasion pattern, where gas progresses through the pore space in the form of disconnected clusters mediated by double and multiple displacement events. Gas advances in a process we name three-phase Haines jumps, during which gas re-arranges its configuration in the pore space, retracting from some regions to enable the rapid filling of multiple pores. The gas retraction leads to a permanent disconnection of gas ganglia, which do not reconnect as gas injection proceeds. We observe, in situ, the direct displacement of oil and water by gas as well as gas–oil–water double displacement. The use of local in situ measurements and an energy balance approach to determine fluid–fluid contact angles alongside the quantification of capillary pressures and pore occupancy indicate that the wettability order is oil–gas–water from most to least wetting. Furthermore, quantifying the evolution of Minkowski functionals implied well-connected oil and water, while the gas connectivity decreased as gas was broken up into discrete clusters during injection. This work can be used to design CO₂ storage, improved oil recovery and microfluidic devices.

Pore-by-pore modeling, analysis, and prediction of two-phase flow in mixed-wet rocks

A pore-network model is an upscaled representation of the pore space and fluid displacement, which is used to simulate two-phase flow through porous media. We use the results of pore-scale imaging experiments to calibrate and validate our simulations, and specifically to find the pore-scale distribution of wettability. We employ energy balance to estimate an average, thermodynamic, contact angle in the model, which is used as the initial estimate of contact angle. We then adjust the contact angle of each pore to match the observed fluid configurations in the experiment as a nonlinear inverse problem. The proposed algorithm is implemented on two sets of steady state micro-computed-tomography experiments for water-wet and mixed-wet Bentheimer sandstone. As a result of the optimization, the pore-by-pore error between the model and experiment is decreased to less than that observed between repeat experiments on the same rock sample. After calibration and matching, the model predictions for capillary pressure and relative permeability are in good agreement with the experiments. The proposed algorithm leads to a distribution of contact angle around the thermodynamic contact angle. We show that the contact angle is spatially correlated over around 4 pore lengths, while larger pores tend to be more oil-wet. Using randomly assigned distributions of contact angle in the model results in poor predictions of relative permeability and capillary pressure, particularly for the mixed-wet case.

Dynamics of water injection in an oil-wet reservoir rock at subsurface conditions: Invasion patterns and pore-filling events

We use fast synchrotron x-ray microtomography to investigate the pore-scale dynamics of water injection in an oil-wet carbonate reservoir rock at subsurface conditions. We measure, in situ, the geometric contact angles to confirm the oil-wet nature of the rock and define the displacement contact angles using an energy-balance-based approach. We observe that the displacement of oil by water is a drainagelike process, where water advances as a connected front displacing oil in the center of the pores, confining the oil to wetting layers. The displacement is an invasion percolation process, where throats, the restrictions between pores, fill in order of size, with the largest available throats filled first. In our heterogeneous carbonate rock, the displacement is predominantly size controlled; wettability has a smaller effect, due to the wide range of pore and throat sizes, as well as largely oil-wet surfaces. Wettability only has an impact early in the displacement, where the less oil-wet pores fill by water first. We observe drainage associated pore-filling dynamics including Haines jumps and snap-off events. Haines jumps occur on single- and/or multiple-pore levels accompanied by the rearrangement of water in the pore space to allow the rapid filling. Snap-off events are observed both locally and distally and the capillary pressure of the trapped water ganglia is shown to reach a new capillary equilibrium state. We measure the curvature of the oil-water interface. We find that the total curvature, the sum of the curvatures in orthogonal directions, is negative, giving a negative capillary pressure, consistent with oil-wet conditions, where displacement occurs as the water pressure exceeds that of the oil. However, the product of the principal curvatures, the Gaussian curvature, is generally negative, meaning that water bulges into oil in one direction, while oil bulges into water in the other. A negative Gaussian curvature provides a topological quantification of the good connectivity of the phases throughout the displacement.

Using energy balance to determine pore-scale wettability

HYPOTHESIS

Based on energy balance during two-phase displacement in porous media, it has recently been shown that a thermodynamically consistent contact angle can be determined from micro-tomography images. However, the impact of viscous dissipation on the energy balance has not been fully understood. Furthermore, it is of great importance to determine the spatial distribution of wettability. We use direct numerical simulation to validate the determination of the thermodynamic contact angle both in an entire domain and on a pore-by-pore basis.

SIMULATIONS

Two-phase direct numerical simulations are performed on complex 3D porous media with three wettability states: uniformly water-wet, uniformly oil-wet, and non-uniform mixed-wet. Using the simulated fluid configurations, the thermodynamic contact angle is computed, then compared with the input contact angles.

FINDINGS

The impact of viscous dissipation on the energy balance is quantified; it is insignificant for water flooding in water-wet and mixed-wet media, resulting in an accurate estimation of a representative contact angle for the entire domain even if viscous effects are ignored. An increasing trend in the computed thermodynamic contact angle during water injection is shown to be a manifestation of the displacement sequence. Furthermore, the spatial distribution of wettability can be represented by the thermodynamic contact angle computed on a pore-by-pore basis.

Evaluation of methods using topology and integral geometry to assess wettability

HYPOTHESIS

The development of high-resolution in situ imaging has allowed contact angles to be measured directly inside porous materials. We evaluate the use of concepts in integral geometry to determine contact angle. Specifically, we test the hypothesis that it is possible to determine an average contact angle from measurements of the Gaussian curvature of the fluid/fluid meniscus using the Gauss-Bonnet theorem.

THEORY AND SIMULATION

We show that it is not possible to unambiguously determine an average contact angle from the Gauss-Bonnet theorem. We instead present an approximate relationship: 2πn(1-cosθ)=4π-∫κ_G12dS₁₂, where n is the number of closed loops of the three-phase contact line where phases 1 and 2 contact the surface, θ is the average contact angle, while κ_G12 is the Gaussian curvature of the fluid meniscus which is integrated over its surface S₁₂. We then use the results of pore-scale lattice Boltzmann simulations to assess the accuracy of this approach to determine a representative contact angle for two-phase flow in porous media.

FINDINGS

We show that in simple cases with a flat solid surface, the approximate expression works well. When applied to simulations on pore space images, the equation provides a robust estimate of contact angle, accurate to within 3°, when averaged over many fluid clusters, although individual values can have significant errors because of the approximations used in the calculation.

Dynamics of fluid displacement in mixed-wet porous media

We identify a distinct two-phase flow invasion pattern in a mixed-wet porous medium. Time-resolved high-resolution synchrotron X-ray imaging is used to study the invasion of water through a small rock sample filled with oil, characterized by a wide non-uniform distribution of local contact angles both above and below 90°. The water advances in a connected front, but throats are not invaded in decreasing order of size, as predicted by invasion percolation theory for uniformly hydrophobic systems. Instead, we observe pinning of the three-phase contact between the fluids and the solid, manifested as contact angle hysteresis, which prevents snap-off and interface retraction. In the absence of viscous dissipation, we use an energy balance to find an effective, thermodynamic, contact angle for displacement and show that this angle increases during the displacement. Displacement occurs when the local contact angles overcome the advancing contact angles at a pinned interface: it is wettability which controls the filling sequence. The product of the principal interfacial curvatures, the Gaussian curvature, is negative, implying well-connected phases which is consistent with pinning at the contact line while providing a topological explanation for the high displacement efficiencies in mixed-wet media.

Pore-scale numerical simulation of low salinity water flooding using the lattice Boltzmann method

HYPOTHESIS

The change of wettability toward more water-wet by the injection of low salinity water can improve oil recovery from porous rocks, which is known as low salinity water flooding. To simulate this process at the pore-scale, we propose that the alteration in surface wettability mediated by thin water films which are below the resolution of simulation grid blocks has to be considered, as observed in experiments. This is modeled by a wettability alteration model based on rate-limited adsorption of ions onto the rock surface.

SIMULATIONS

The wettability alteration model is developed and incorporated into a lattice Boltzmann simulator which solves both the Navier-Stokes equation for oil/water two-phase flow and the advection-diffusion equation for ion transport. The model is validated against two experiments in the literature, then applied to 3D micro-CT images of a rock.

FINDINGS

Our model correctly simulated the experimental observations caused by the slow wettability alteration driven by the development of water films. In the simulations on the 3D rock pore structure, a distinct difference in the mixing of high and low salinity water is observed between secondary and tertiary low salinity flooding, resulting in different oil recoveries.

Mechanisms of Microscopic Displacement During Enhanced Oil Recovery in Mixed-Wet Rocks Revealed Using Direct Numerical Simulation

We demonstrate how to use numerical simulation models directly on micro-CT images to understand the impact of several enhanced oil recovery (EOR) methods on microscopic displacement efficiency. To describe the physics with high-fidelity, we calibrate the model to match a water-flooding experiment conducted on the same rock sample (Akai et al. in Transp Porous Media 127(2):393–414, 2019. 10.1007/s11242-018-1198-8). First we show comparisons of water-flooding processes between the experiment and simulation, focusing on the characteristics of remaining oil after water-flooding in a mixed-wet state. In both the experiment and simulation, oil is mainly present as thin oil layers confined to pore walls. Then, taking this calibrated simulation model as a base case, we examine the application of three EOR processes: low salinity water-flooding, surfactant flooding and polymer flooding. In low salinity water-flooding, the increase in oil recovery was caused by displacement of oil from the centers of pores without leaving oil layers behind. Surfactant flooding gave the best improvement in the recovery factor of 16% by reducing the amount of oil trapped by capillary forces. Polymer flooding indicated improvement in microscopic sweep efficiency at a higher capillary number, while it did not show an improvement at a low capillary number. Overall, this work quantifies the impact of different EOR processes on local displacement efficiency and establishes a workflow based on combining experiment and modeling to design optimal recovery processes.

Quantification of Uncertainty and Best Practice in Computing Interfacial Curvature from Complex Pore Space Images

Recent advances in high-resolution three-dimensional X-ray CT imaging have made it possible to visualize fluid configurations during multiphase displacement at the pore-scale. However, there is an inherited difficulty in image-based curvature measurements: the use of voxelized image data may introduce significant error, which has not-to date-been quantified. To find the best method to compute curvature from micro-CT images and quantify the likely error, we performed drainage and imbibition direct numerical simulations for an oil/water system on a bead pack and a Bentheimer sandstone. From the simulations, local fluid configurations and fluid pressures were obtained. We then investigated methods to compute curvature on the oil/water interface. The interface was defined in two ways; in one case the simulated interface with a sub-resolution smoothness was used, while the other was a smoothed interface extracted from synthetic segmented data based on the simulated phase distribution. The curvature computed on these surfaces was compared with that obtained from the simulated capillary pressure, which does not depend on the explicit consideration of the shape of the interface. As distinguished from previous studies which compared an average or peak curvature with the value derived from the measured macroscopic capillary pressure, our approach can also be used to study the pore-by-pore variation. This paper suggests the best method to compute curvature on images with a quantification of likely errors: local capillary pressures for each pore can be estimated to within 30% if the average radius of curvature is more than 6 times the image resolution, while the average capillary pressure can also be estimated to within 11% if the average radius of curvature is more than 10 times the image resolution.