Numerical simulation of species transfer across fluid interfaces in free-surface flows using OpenFOAM

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.

Effect of Pore Space Stagnant Zones on Interphase Mass Transfer in Porous Media, for Two-Phase Flow Conditions

Interphase mass transfer is an important solute transport process in two-phase flow in porous media. During two-phase flow, hydrodynamically stagnant and flowing zones are formed, with the stagnant ones being adjacent to the interfaces through which the interphase mass transfer happens. Due to the existence of these stagnant zones in the vicinity of the interface, the mass transfer coefficient decreases to a certain extent. There seems to be a phenomenological correlation between the mass transfer coefficient and the extent of the stagnant zone which, however, is not yet fully understood. In this study, the phase-field method-based continuous species transfer model is applied to simulate the interphase mass transfer of a dissolved species from the immobile, residual, non-aqueous phase liquid (NAPL) to the flowing aqueous phase. Both scenarios, this of a simple cavity and this of a porous medium, are investigated. The effects of flow rates on the mass transfer coefficient are significantly reduced when the stagnant zone and the diffusion length are larger. It is found that the stagnant zone saturation can be a proxy of the overall diffusion length of the terminal menisci in the porous medium system. The early-stage mass transfer coefficient continuously decreases due to the depletion of the solute in the small NAPL clusters that are in direct contact with the flowing water. The long-term mass transfer mainly happens on the interfaces associated with large NAPL clusters with larger diffusion lengths, and the mass transfer coefficient is mainly determined by the stagnant zone saturation.

Lattice Boltzmann modeling of interfacial mass transfer in a multiphase system

In the present study, a numerical model based on the lattice Boltzmann method (LBM) is proposed to simulate multiphase mass transfer, referred to as the CST-LB model. This model introduced continuum species transfer (CST) formulation by an additional collision term to model the mass transfer across the multiphase interface. The boundary condition treatment of this model is also discussed. In order to verify the applicability, the CST-LB model is combined with the pseudopotential multiphase model to simulate a series of benchmark cases, including concentration jump near the interface, gas dissolution in a closed system, species transport during drainage in a capillary tube, and multiphase species transport in the porous media. This CST-LB model can also be coupled with other multiphase LBMs since the model depends on the phase fraction field, which is not explicitly limited to specified multiphase models.

GeoChemFoam: Direct Modelling of Multiphase Reactive Transport in Real Pore Geometries with Equilibrium Reactions

GeoChemFoam is an open-source OpenFOAM-based toolbox that includes a range of additional packages that solve various flow processes from multiphase transport with interface transfer, to single-phase flow in multiscale porous media, to reactive transport with mineral dissolution. In this paper, we present a novel multiphase reactive transport solver for simulations on complex pore geometries, including microfluidic devices and micro-CT images, and its implementation in GeoChemFoam. The geochemical model includes bulk and surface equilibrium reactions. Multiphase flow is solved using the Volume-Of-Fluid method, and the transport of species is solved using the continuous species transfer method. The reactive transport equations are solved using a sequential operator splitting method, with the transport step solved using GeoChemFoam, and the reaction step solved using Phreeqc, the US geological survey’s geochemical software. The model and its implementation are validated by comparison with analytical solutions in 1D and 2D geometries. We then simulate multiphase reactive transport in two test pore geometries: a 3D pore cavity and a 3D micro-CT image of Bentheimer sandstone. In each case, we show the pore-scale simulation results can be used to develop upscaled models that are significantly more accurate than standard macro-scale equilibrium models.

Computational Modeling of Bubbles Growth Using the Coupled Level Set-Volume of Fluid Method

Understanding the generation, growth, and dynamics of bubbles as they absorb or release dissolved gas in reactive flows is crucial for optimizing the efficiency of electrochemically gas-evolving systems like alkaline water electrolysis or hydrogen production. To better model these bubbly flow systems, we use a coupled level set and volume of fluid approach integrated with a one-fluid transport of species model to study the dynamics of stationary and rising bubbles in reactive two-phase flows. To accomplish this, source terms are incorporated into the continuity and phase conservation equations to allow the bubble to grow or shrink as the species moves through the interface. Verification of the hydrodynamics of the solver for non-reactive systems demonstrates the requisite high fidelity interface capturing and mass conservation necessary to incorporate transport of species. In reactive systems where the species impacts the bubble volume, the model reproduces the theoretically predicted and experimentally measured diffusion-controlled growth rate (i.e., R(t) ∝ t ^0.5). The model is then applied to rising bubbles to demonstrate the impact of transport of species on both the bubble velocity and shape as well as the concentration field in its wake. This improved model enables the incorporation of electric fields and chemical reactions that are essential for studying the physicochemical hydrodynamics in multiphysics systems.

Review-Physicochemical hydrodynamics of gas bubbles in two phase electrochemical systems

Electrochemical systems suffer from poor management of evolving gas bubbles. Improved understanding of bubbles behavior helps to reduce overpotential, save energy and enhance the mass transfer during chemical reactions. This work investigates and reviews the gas bubbles hydrodynamics, behavior, and management in electrochemical cells. Although the rate of bubble growth over the electrode surface is well understood, there is no reliable prediction of bubbles break-off diameter from the electrode surface because of the complexity of bubbles motion near the electrode surface. Particle Image Velocimetry (PIV) and Laser Doppler Anemometry (LDA) are the most common experimental techniques to measure bubble dynamics. Although the PIV is faster than LDA, both techniques are considered expensive and time-consuming. This encourages adapting Computational Fluid Dynamics (CFD) methods as an alternative to study bubbles behavior. However, further development of CFD methods is required to include coalescence and break-up of bubbles for better understanding and accuracy. The disadvantages of CFD methods can be overcome by using hybrid methods. The behavior of bubbles in electrochemical systems is still a complex challenging topic which requires a better understanding of the gas bubbles hydrodynamics and their interactions with the electrode surface and bulk liquid, as well as between the bubbles itself.

Numerical simulation of reaction injection molding with polyurethane foam

In this study, numerical approach for simulation of mold filling is presented. Polyurethane foam formation includes several complex phenomena such as chemical reactions, heat generation and blowing agent evaporation. Foam properties are variable during formation, foam viscosity increases and conductivity reduces. Foam phase is considered compressible and two phases are immiscible. Foam front will be captured by volume of fluid and appropriate governing equations will be implemented in OpenFOAM. This study prepares a numerical model to reduce several experimental runs with expensive prototypes for mold design.