visualization of four-phase flow using micromodels
Transcription
visualization of four-phase flow using micromodels
VISUALIZATION OF FOUR-PHASE FLOW USING MICROMODELS A REPORT SUBMITTED TO THE DEPARTMENT OF PETROLEUM ENGINEERING OF STANFORD UNIVERSITY IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE DEGREE OF MASTER OF SCIENCE By Ashwini A. Upadhyaya September 2001 I certify that I have read this report and that in my opinion it is fully adequate, in scope and in quality, as partial fulfillment of the degree of Master of Science in Petroleum Engineering. __________________________________ Prof. Franklin M. Orr, Jr., (Principal Advisor) iii Abstract The presence of four-phase flow has been acknowledged in numerous papers available in the literature on oil recovery by gas injection. In the reservoir these phases can include an oil-rich liquid phase, a lighter liquid phase comprising primarily of components of the injected gas, a vapor phase rich in carbon dioxide and methane, and water which is always present in most reservoirs (connate or injected). Though most of the issues dealt with in the past are related to thermodynamic calculations and compositional simulation, very little attention is given to the problem of flow behavior. In this work, we have studied the actual fluid configuration and connectivity under the four-phase flow condition with the aid of micromodels. The fluids used are “analog” fluids as the reservoir conditions are difficult to create in the laboratory apparatus. Capillary tubes have also been used to study the phenomenon of corner flow and to ascertain spreading of fluid phases in pore like conditions. The results indicate that in most cases, four phases never seem to occupy a pore space simultaneously. The order in which the phases are injected does seem to have an influence on their configuration and connectivity. This has an important implication on the way the values for their relative permeabilities are calculated. It was also observed that in case of four-phase flow, there was mobilization of discontinuous phases in some cases and this leads to some ambiguity while using relative permeability data. Based on the observations of the configuration and connectivity of the phases, it would be practical to treat four-phase flow as a combination of two three-phase systems or as a pseudo three-phase system, in which the two liquid hydrocarbon-rich phases are lumped together. v Acknowledgments The support of Stanford University Petroleum Research Institute - C (SUPRI-C) and its industrial affiliates towards the funding of this project is gratefully acknowledged. I would like to thank my advisor, Prof. Franklin M. Orr, Jr., for his guidance and assistance in research and for the remarkable support shown by him in face of experimental difficulties. I would like to also thank Prof. Anthony Kovscek and Prof. David DiCalro for extremely valuable suggestions and assistance in the laboratory. Also the help provided by Dr. Louis Castanier in the preparation of the micromodels and Mr. Will Whitted in the laboratory was indispensable. I would also like to acknowledge the training and support provided by the people from the Stanford Nanofabrication Facility (SNF). I would finally like to thank my family, friends and colleagues for their support, without which the completion of this project would have been impossible. I would also like to thank the staff of the department of Petroleum Engineering, especially Yolanda Williams, Ginni Savalli, Stephanie Sorensen and Edi Carrick for assistance rendered. vii Contents Acknowledgments vii Contents ix List of Tables xi List of Figures xiii 1.1. Four-Phase Flow 1.2. Micromodels 1.3. Drainage along Corners of Noncircular Capillaries 2.1. Apparatus : General Description 2.1.1. Injection Pump, Inline Filters and Pressure Gauge 2.1.2. Microscope 2.1.3. Recording and Image Capture Assembly 2.2. Micromodel Holder and Micromodels 2.2.1. Micromodel Pattern Preparation 2.2.2. Wafer Imaging 2.2.3. Wafer etching and Finishing 2.3. Micromodel Holder 2.4. Injection Apparatus 3.1. Analog Fluid System 3.2. Micromodel Apparatus Procedure 3.3. Capillary Tube Apparatus 4.1. Tools to Interpret the Flow Behavior 4.2. Injection of Fluids in Order of their Wettabilities 4.2.1. Injection of Water in a Micromodel Filled with Gas. 4.2.2. Injection of Alcohol in a Micromodel Containing Water. 4.2.3. Injection of Oil in a Micromodel Filled with Water and Alcohol. 4.2.4. Injection of Gas in a Micromodel Previously Filled with Water, Alcohol and Oil, in that order. 4.3. Injection of four phases into the micromodel in changed order of wettabilities. 4.3.1. Injection of Water and Oil in the Micromodel. 4.3.2. Injection of alcohol in a micromodel containing water and oil. 4.3.3. Injection of Gas in a Micromodel Containing Water, Oil and Alcohol. 4.4. Interaction in system with higher interfacial system between alcohol and oil. Nomenclature References A. Relative Permeability Models 19 26 28 31 32 32 33 33 35 37 38 40 41 43 44 45 47 48 48 49 51 60 67 67 67 73 80 96 97 103 ix x List of Tables Table 3.1: Properties of the fluid system 44 Table 4.1: Physical properties of the isobutanol, hexadecane, squalane and air system. 80 xi List of Figures Figure 1.1 : A qualitative pressure-composition (P-X) diagram for CO2/C3/C16 system at 70oF 18 Figure 1.2 : Experimental Apparatus showing the three hydrocarbon phases: Wasson crude oil plus dissolved gas (312 scf/bbl) at 90oF with 80 mole % CO2. 20 Figure 1.3: Pressure-composition diagram of binary mixtures of Maljamar seprator oil and CO2. (Orr, personal communications) 21 Figure 1.4: Ternary composition diagram of a CO2-C1-C16 system at various pressures and 70oF (Orr, personal communications) 22 Figure 1.5: Schematic of Capillary Drainage Setup 28 Figure 1.6: Configuration of fluids in a corner. 29 Figure 2.1: Schematic diagram of micromodel apparatus. 31 Figure 2.2 (b): Repeated pattern of the unit cell, to complete the micromodel. 34 Figure 2.3: Schematic of micromodel with inlet and outlet channels. 36 o Figure 2.4 (a): View of a micromodel mounted at an angle of 45 on an SEM. 38 Figure 2.4 (b): View of the micromodel at an angle and 75X magnification. Note the rough edges of the micromodel. 39 Figure 2.5: Schematic of the micromodel holder. 40 Figure 3.1: Schematic of the capillary tube experiments 46 Figure 4.1: Schematic of a triangular cross section of a pore 47 Figure 4.2: Schematic view of the pore and throat model in a porous medium 48 Figure 4.4: Possible locations of alcohol in water filled pore. 50 Figure 4.5: Configuration of alcohol and water in a micromodel. 51 xiii Figure 4.6: Schematic representation of possible fluid configurations in a pore containing water, alcohol and oil, injected in that order. 52 Figure 4.7: Micromodel photograph of a pore containing water, alcohol and oil, injected in that order. 53 Figure 4.8: Schematic of capillary tube experiments with water, alcohol and oil. 54 Figure 4.9: Photographs illustrating the importance of flow in layers to the drainage process. 57 Figure 4.10: Simultaneous flow of oil and alcohol when oil in injected in a micromodel containing water and alcohol. 60 Figure 4.11: Possible configuration of the four phases in the pore body. 61 Figure 4.12: Gas injection in a micromodel containing water, alcohol and oil. 65 Figure 4.13: Schematic of a four-phase capillary tube experiment. 66 Figure 4.14 : Schematic of a four-phase capillary tube experiment. 67 Figure 4.15 : Schematic showing possible fluid configurations in a pore containing water and oil, injected with alcohol. 68 Figure 4.16: Schematic view of alcohol injected in a pore body containing water and oil, based on the pore body and throat model. 69 Figure 4.17: Micromodel photographs of alcohol injected in a micromodel containing water and oil. 72 Figure 4.18: Schematic view of gas injected in a pore body containing water, oil and alcohol. 73 Figure 4.19: Gas injection in a micromodel containing water, oil and alcohol. 79 Figure 4.20: Micromodel filled with oil and water. 81 Figure 4.21: Possible configurations of fluid phases upon injection of alcohol in a pore containing oil and water, based on the pore and throat model. 82 Figure 4.22: Injection of alcohol in a micromodel containing oil and water. 88 xiv Figure 4.23: Schematic representation of fluid configurations in the pore, upon injection of air in a micromodel containing water, oil and alcohol. 89 Figure 4.24: Gas injection in a micromodel containing water, alcohol and water. 93 xv Chapter 1 1. Introduction Carbon dioxide is not first-contact miscible with most reservoir oils and develops miscibility upon multiple contacts under conditions found in several reservoirs. The criteria for miscibility have been reviewed by various authors. (Grigg, et al. , 1997; Wu and Batycky,1990; Eakin and Mitch, 1998). In certain portions of the reservoir, particularly in low temperature CO2 reservoir fluid systems, complex phase behavior has been observed. This phase behavior is characterized by the presence of a third non-aqueous phase whose composition is rich in the injection gas, especially in reservoirs where the temperature and pressure is near the critical point of CO2 (Shelton and Yarborough, 1977; Orr, et al., 1980; Turek, et al.,1988; Creek and Sheffield,1993). Hence we have the existence of four phases which include an oil-rich liquid phase, injection-gas-rich liquid phase, injection gas and water present in the reservoir. Since water is always present, this phenomenon is also described as L-L-V (liquid-liquid-vapor) behavior. The existence of this situation complicates the calculation of displacement efficiency due to the complex phase equilibrium and also to the uncertainty in flow behavior that arises from complexities in treating the relative permeability values for the various phases. Fig. 1.1 shows the phase diagram of such a condition representing the L-L-V behavior. Shelton and Yarborough (1977) observed similar behavior for a system in which the injection gas was rich in ethane. Additional precipitation of a solid phase, rich in asphaltene was also observed. 17 Figure 1.1 : A qualitative pressure-composition (P-X) diagram for CO2/C3/C16 system at o 70 F (Orr, personal communications) Micromodels were utilized for visualization of four-phase flow, in order to examine the flow behavior on a pore scale, to study the configuration and the orientation of the fluids. A micromodel pattern was designed to represent the cross-section of a porous medium and was used to visualize flow patterns on the pore scale. Capillary tube experiments were performed in conjunction with the above experiments to corroborate and interpret observations made for the micromodels. 18 A brief review of the four-phase flow question is presented, followed by a description of the development of micromodel and capillary tube experiments. Also empirical equations used for relative permeability calculations from literature are presented and their relevance in light of the above observations is presented. 1.1. Four-Phase Flow As already discussed above the existence of four phases in reservoir conditions is an established phenomenon. In certain cases this phenomenon is further complicated by the deposition of a solid phase or a non-soluble phase which does not flow well (Huang, 1992). The solid phase deposited is also known to affect the wettability of the reservoir rock. The additional liquid phase formed has a high CO2 concentration, usually over 90% (Turek, et al., 1988; Creek and Sheffield, 1993) .The formation of this phase is also observed to occur around o the critical point of CO2, which is 87.9 F and 1070 psia. The CO2-rich liquid phase formed also has a density typically in excess of 0.7 gm/cc and has its viscosity in the range of 0.05 to 0.1 cP. Before discussing the complexities of this phase behavior and its influence on operations, it would be instructive to have a look at the phase diagrams and experimental PVT data of this region. Figure 1.2 shows a series of photographs in which these phases are formed in a PVT cell under series of varying conditions (Orr, 2000). 19 Vapour phase 1249 psia CO2 rich liquid phase 1284 psia 1307 psia 1328 psia Crude oil rich phase Figure 1.2 : Experimental Apparatus showing the three hydrocarbon phases: Wasson o crude oil plus dissolved gas (312 scf/bbl) at 90 F with 80 mole % CO2. Figure 1.3 represents the pressure-composition diagram of binary mixtures of Maljamar seprator oil and CO2. The L-L-V region marked in the diagram represents our region of interest. (Orr, et al., 1980). Figure 1.4 represents the ternary composition diagram of a CO2-C1-C16 system at various pressures and at a temperature of 70oF. The formation of the L-L-V region is again observed under a certain set of conditions. (Orr and Jensen, 1984). An observation of the these phase diagrams indicates that the formation of this four-phase region is restricted to a relatively narrow pressure region ranging from a few psi to about 200 psi. The reservoirs under which such phase behavior has been observed are typically low temperature reservoirs and having a high CO2 concentration. Another interesting feature is the fact that this phenomenon has not yet been reported to occur at temperatures in excess of 120oF. 20 Figure 1.3: Pressure-composition diagram of binary mixtures of Maljamar seprator oil and CO2. (Orr, personal communications) 21 Figure 1.4: Ternary composition diagram of a CO2-C1-C16 system at various pressures o and 70 F (Orr, personal communications) This phenomenon has been observed to occur in field applications. For several Permian Basin reservoir fluid and CO2 systems, the pressure and temperature conditions occur in this phase envelope (Fong, et al., 1992). It has also been observed at the conditions that occur in the Schrader Bluff oil field located on Alaska’s North Slope (McKean, et al., 1999). Besides this, several West Texas floods have also shown a similar phase behavior. The existence of such phase 22 behavior presents two complexities, one associated with the flash calculation of the phase compositions and the other associated with assigning values of relative permeabilities to model the flow behavior of this system. In the past due to limited computing resources and relatively less knowledge of such systems, several approximations were made while performing flash calculations. Nghiem and Li (1984) were among the first to incorporate a threephase flash calculation model. Fanchi (1987) suggested that by approximating the L-L-V system (a three-phase hydrocarbon system) to an L-V system (a twophase hydrocarbon system), there was only a small percentage change in the recovery factor. With improving computing power and a better understanding of such systems, handling the thermodynamics of this system seems to be a lesser concern currently. However, little has been done to understand the flow behavior phenomenon associated with such four-phase systems. While considering flow in such systems the number of phases can be as many as five: aqueous, liquid hydrocarbon-rich phase, liquid CO2-rich phase, gaseous CO2-rich phase and the solid precipitates. In most cases the influence of the solid phase on the flow process is ignored as it is assumed not to flow, but it can have significant influence on the flow behavior by changing the wettability of the rock surface on which it deposits (Grigg and Ucok, 1998). In multiphase flow behavior, the saturation, saturation history and the flow properties of each phase affects the values of that of the other phases. The problem of measuring relative permeabilities of the four phases also presents other significant challenges. In such a flow system measuring the saturation, pressure drops and the fluxes of all the phases is not adequate, as there are infinite number of displacement paths given the fact that the displacement involves the variation of three independent saturations and their corresponding saturation history. It is important to note that the relative permeabilities are not just a function of the saturations of the various phases but also depend on the saturation history. Hence it is impractical to measure the values of relative permeabilities for different displacement 23 processes at varying values of saturation, flux and pressure drops, as the number of experiments required for the same would be far too large. A more practical solution is to try to develop an empirical correlation to calculate the relative permeability of the flow system under consideration. In the past attempts to model three-phase relative permeabilities empirically have relied on data from the two-phase experiments, and it would seem to be logical to make such an endeavor in the case of four-phase systems. However the pore occupancy in the case of four-phase flow need not be the same as that for the two-phase systems, and hence an accurate modeling is not possible for relative permeability values of such systems. Hence it is very important to gain an understanding of the flow process at the pore scale and to study the configuration and the connectivity of the fluids at the pore scale. The work done here endeavors to address the problems of fluid distribution on a pore scale and the connectivity of the fluids with the aid of micromodel and capillary tube experiments. Before proceeding with the pore level analysis of this fluid system, it would be useful to review some work already done to address the effect of four-phase flow in low temperature CO2 floods. McKean, et al. (1999), while addressing the issue to the Schrader Bluff CO2 EOR evaluation, have lumped the three hydrocarbon phases (hydrocarbon-rich liquid phase, CO2-rich liquid phase and CO2-rich vapor phase) into two pseudo phases while performing simulation runs. However they noted the limitation of such an approach given that the liquid CO2 phase is very mobile and occupies an appreciable volume fraction in the reservoir. Grigg and Ucok (1998) performed slim tube tests on Sulimar Queen reservoir oil under four-phase conditions to determine the minimum miscibility pressure (MMP) and also showed the effect of temperature and pressure on the development of miscibility. Wang and Strycker (2000) have performed an evaluation of CO2 injection with three hydrocarbon phases. They have attempted to address issues concerned with both phase equilibrium and flow behavior. Their results suggest that commercial simulators such as VIP and GEM are unstable and unable to 24 converge to solutions. This is because of their inability to handle the above phase conditions. They have suggested the use of UTCOMP, which can predict fluid flow performance under the three hydrocarbon phases. To tackle the issue related with the usage of the relative permeability models, they have used theoretical models such as the Baker model, modified Stone II model, Corey model and the modified Corey model. These models and their expressions are listed in Appendix A, and their applicability in light of the experimental observations is discussed subsequently. Based on comparison with slim tube tests it was observed that the modified Corey’s model gave the best fit. Implicit in the above models is the fact that the three-phase water and gas relative permeabilities are the same as those of two-phase flow since they use the twophase oil-water and oil-gas data to predict three-phase oil relative permeabilities. When extending their usage to the four-phase flow situation the three-phase oil relative permeability is shared between the liquid hydrocarbon-rich phase and the liquid CO2-rich gas phase in proportion of their relative volumes. Fong, et al. (1992) in their studies made relative permeability approximations by coupling the two liquid hydrocarbon phases into one pseudo-liquid phase. Based on their algorithm, the percentage variation in recovery is limited to only a few percent. Another important aspect concerning this phenomenon to reservoir flow behavior and recovery is the extent of this zone in the reservoir. In most of fields the pressure and the temperature conditions within the reservoir are sufficient to keep the injected CO2 in the liquid phase, but in the region of the producer wells there is a drawdown of pressure and this might lead to the formation of the fourphase flow situation. If the extent of this four-phase region is not deep within the reservoir then the flow properties in this region will be eclipsed by the large amount of flow coming from the reservoir. However in cases where the above region does have a sufficient extent into the reservoir, the flow properties of this region will become dominant and hence their evaluation is important. 25 1.2. Micromodels Micromodels can be used to study the flow behavior on a pore scale. They are patterns of a porous medium etched on a silicon or glass surface and hence are representative of the two dimensional structure of the porous medium. Mircomodels have been extensively used to study the flow behavior in multiphase flow, oil-foam interaction studies, solution gas drive, contaminant hydrogeology, etc. The patterns used in the construction of the porous medium may be prepared from thin sections of the porous medium to actually represent the medium or in several cases are geometrically constructed as series of repeatable simple of complex geometric figure aggregates. However as the micromodels represent a two dimensional porous medium flow problem, extrapolation of results to the three dimensional flow problem occurring in the real porous medium needs to be done with certain amount of caution. Also it has been observed that a nonuniform etch depth in the micromodels may lead to snap-off situations not consistently predictable with the flow behavior (Rossen, 1999). Another constraint of the micromodels regarding dimensionality is the lower macroscopic connectivity and co-ordination number (Nguyen, et al., 2000). Though both etched glass and silicon micromodels have been used, glass micromodels because of the nature of their fabrications have pores whose sizes are several times larger than the actual size. A brief summary of the use of micromodels for various applications has been listed below (George, 1999). Mattax and Kyte (1961) developed the first etched-glass micromodel. This micromodel comprised of a network of straight, interconnected flow channels. This was a good tool for viewing interfaces in porous media and was used to study the effect of the wettability on waterflood oil production. Davis and Jones(1968) worked on the limitations in etching the micromodels being produced. They used a photosensitive resist, which was resistant to several solvents after exposure to ultraviolet light. As a result of this construction 26 technique more complex micromodels were produced to represent the complex geometry of the pores of the flow media. Owete and Brigham (1987) developed silicon-wafer micromodels which allowed a better control on the etch depth and capture the finer details of complex geometry more accurately. It is important to note that silicon as such is not water wet. Hence to produce water wet micromodels, they are oxidized in air to produce a thin film of silicon dioxide on the surface which is water wet. The flow area of the micromodel is sealed with a glass plate, which is anodically bonded to the silicon wafer, and inlet and outlet ports communicate the flowing fluids. Hornbrook, et al. (1991) produced micromodels that were almost identical replicas of a thin section of a Berea sandstone on a silicon wafer. These models possessed almost identical properties of wettability and roughness as the original porous medium. A limitation of this micromodel was the extent of capture of the thin section of Berea sandstone. A scanning-electron microscope (SEM) image of this thin section is used to produce the pattern on the silicon wafer. Since the SEM image can only cover a limited area, the pattern of the micromodel comprised of a repeated unit cell of the scanned SEM image. This also leads to lack of continuity at the edges of the unit cells. Typically images are “digitally treated” before repeatable unit cell patterns are produced to ensure connectivity at the edge of the unit cells. Keller, et al. (1996) used micromodels to observe the role of oil layers in threephase flow in porous media. Though experiments performed in the micromodels for this study have been done at low to moderate pressures (up to 35 psi pressure), micromodels have also been used for high pressure experiments. The usage of micromodels at elevated pressures requires housing the micromodels in a pressure vessel. Campbell and Orr (1985) were among the first to perform high pressure micromodel experiments. The performed a high pressure visualization study of the displacement of crude oil by CO2. Bahralolom and Orr (1986) also performed 27 some of the earlier high pressure glass micromodel experiments while comparing N2 and CO2 flow mechanisms in multi-contact miscible displacements. George (1999) has provided a good review of micromodels used in high-pressure conditions. 1.3. Drainage along Corners of Noncircular Capillaries Though the micromodels serve as an excellent tool for micromodel visualization certain features associated with the flow behavior remain ambiguous. The layers of fluids formed in some cases are extremely thin and not clearly visible under magnification. To ensure the connectivity and the spreading of layers of fluids, drainage experiments using noncircular capillaries are performed. The concept is simply illustrated in Figure 1.5. Air Oil Water Figure 1.5: Schematic of Capillary Drainage Setup As shown in the above figure, the fluids are loaded in the capillary tube in the order of water, oil, air and oil again, starting from below. If oil spreads as a layer between water an air, it will drain from the region above the air on the top. It has been observed that all oils having a positive spreading coefficient spread as a layer between water and air and hence drainage occurs. In many cases, even nonspreading oils have been observed to spread between the water and air, 28 because of the corner pore geometry (Fenwick, D.H. and Blunt, M.J., 1996; Zhou, et al., 1997). Spreading is generally ascertained with a calculated property called the spreading co-efficient (Cs). This is a function of the interfacial tensions of the various phases at the interface and for the oil-water-gas system is defined as: Cs = σgw – (σow + σgo) Cs – spreading coefficient of oil between water and gas σij - interfacial tension between phases I and j It is instructive to consider the connection between corner flow in capillary tubes and flow in porous media. Porous media are often made up of grains having sharp corners and surfaces. These corners are extremely important in helping fluids connect in numerous cases. The use of noncircular capillary tubes is an attempt to represent the sharp corners present in the porous medium, and hence draw useful analogies of the spreading of fluids, based on the drainage behavior in the capillary tubes. Fig. 1.6 shows an example of this spreading behavior. Pore Corner Pore Body Oil spreads as a layer between water and alcohol Oil Alcohol Water Figure 1.6: Configuration of fluids in a corner. The spreading of fluids in the corner is not just governed by their spreading coefficient but also by the corner angle of the pore. Zhou, et al. (1997) have 29 provided an excellent review of hydrocarbon drainage along corners of noncircular capillary tubes. They have derived mathematical expressions to calculate the rate of drainage along the corners and drawn useful analogies leading to the calculation of three-phase relative permeabilities. 30 Chapter 2 2. Experimental Apparatus Micromodel and capillary tube experiments were performed to the study the phenomenon of four-phase flow on a pore scale. This section of the report discusses the details and the procedures used in setting up the apparatus, its calibration and operation. 2.1. Apparatus : General Description Figure 2.1 represents a schematic of the setup of the micromodel apparatus. All the experiments were carried out under constant volumetric flow rates for the liquids and at constant pressure for the gas. All the tubing used in the apparatus was of polyethylene and 1/16” in diameter. A brief description of the apparatus is given below, while important aspects related with the fabrication and the preparation of the micromodels are listed in section 2.2. Inlet from ISCO Pump or Gas Cylinder Video Imaging Assembly Coiled Tube Assembly Micromodel Holder Outlet Pressure Gauge Micromodel Micro-filter Figure 2.1: Schematic diagram of micromodel apparatus. 31 2.1.1. Injection Pump, Inline Filters and Pressure Gauge All the liquids injected in the apparatus were injected at constant volumetric rate. This was regulated by the use of a ISKO pump (model no. 100DM). The least count of this pump for constant volumetric rate control was 0.0001 ml/minute. Inline filters are essentially swagelock lock filters with a cartridge of 2 micron pores, to filter out small particles which can clog the micromodel. The pressure gauge is used to record the pressure of the injected fluid and is used only during the injection of the gas. In case of injection of the liquids, all conditions are monitored from the injection pump. 2.1.2. Microscope A Nikon Optiphot-M with a phototube allowing for imaging was used in the apparatus. The properties of the optical lens used in the objective are listed in table 2.1. The working distance is the distance between the tip of the lens and the focal plane of the objective. The lens of 5X magnification is used to track the motion of the fluids in the micromodel, while the other lenses are used to focus on a specific portion of a micromodel to study fluid motion there. Model Magnification Working Numerical Viewable Aperture Diameter Distance (µ µm) (mm) 5X 5X 20.0 0.1 3000 0.4LWD 20X 6.0 0.4 800 0.5ELWD 40X 10.1 0.5 375 Table 2.1 : Properties of optical lenses. 32 2.1.3. Recording and Image Capture Assembly The recording assembly consists of an output from the video camera to a video cassette recorder (VCR), recorded at a speed of 30 frames a second. The images from the VCR could be transferred to a Macintosh computer with the aid of a Sipgot II tape video capture board. 2.2. Micromodel Holder and Micromodels The micromodel holder used in this case was a simple assembly for low pressure systems and was fabricated from aluminum. The micromodels are essentially a two dimensional representation of the porous medium on a silicon wafer. Initially micromodels were etched on a glass surface to visualize the flow patterns, but because of limitations discussed previously, glass micromodels have been replaced with silicon micromodels for experimental studies involving the visualization of flow behavior on the pore scale. Typically micromodels are made up of a repeated pattern of an SEM image of a reservoir rock thin section. However such a pattern needs some digital modification at the edges to ensure continuity in the porous medium. In our study, the pattern etched on the surface of the micromodel was made from a random hand drawn pattern to represent the two-dimensional structure of a porous medium. This pattern has grains ranging from the size of 30 to 200 µm. All the features of a porous medium were incorporated in the unit cell, which include small and large pores, channels and very narrow throats. Fig 2.2 (a) shows the unit cell which was repeated several times over in the preparation of a pattern, whose dimensions are 5cm X 5cm. Figure 2.2 (b) shows the repeating unit cells used in the micromodel. 33 Figure 2.2 (a): Pattern of the unit cell used in the construction of the micromodel. The region within the box represents one unit cell. Figure 2.2 (b): Repeated pattern of the unit cell, to complete the micromodel. 34 An important feature of the above pattern is the arrangement of the edges, which sit together like a jigsaw puzzle when the unit cell is repeated. Another important feature of the micromodel is the presence of a channel at the inlet and the outlet ports. These channels ensure that flow in the micromodel is linear along the edges and not like a five-spot pattern. Figure 2.3 represents a schematic of the micromodel employed in our experiments with the inlet and outlet channels. There are various stages to the construction of this micromodel, which are presented in reasonable detail to facilitate refabrication in the future. The micromodels were constructed in the Stanford Nanofabrication Facility (SNF), where equipment and raw material necessary for their construction is readily available. Once we have a pattern design of a micromodel on a glass-chrome plate called the mask (see section 2.2.1 below), the fabrication involves the following steps: • Imaging : The silicon wafer is coated with a photosensitive chemical which is then exposed to ultraviolet light through the mask on top. This produces an impression of the mask on the exposed wafer, which is then developed. • Etching: This developed wafer is then etched with hydrofluoric acid to produce a micromodel with an etch depth of around 25-30 µm on the silicon wafer. • Cleaning and Bonding: The silicon wafer with the etched pattern is then cleaned in a sulfuric acid cleaning solution and then bonded to a glass plate to create a flow medium. The following sections discuss the above procedure in greater detail and list the precautions, which need to be taken to manufacture good micromodels. 2.2.1. Micromodel Pattern Preparation The unit cell used, which is repeated in the micromodel, is made by a random hand-drawn pattern, incorporating various features of porous media and is also of comparable dimension. The preparation of the pattern is done using the software, L-EDIT, available at the SNF lab. This produces a file, which is 35 compatible with the mask-making machine. In the preparation of this pattern, there are two tasks: • Design of the repeatable unit cell having the features of the porous medium on it. • Design of the inlet and outlet ports and channels of the entire micromodel assembly. The file that is compatible for the preparation of this micromodel is available with the SUPRI-C group and can be opened using the software L-EDIT. Subsequent modifications to the flow pattern or the micromodel ports and channels is a relatively easy task. Inlet Outlet Figure 2.3: Schematic of micromodel with inlet and outlet channels. To communicate fluids through the micromodel, inlet and outlet ports are provided. These are represented by the small square boxes in Figure 2.3 at the four corners of the micromodel. Though only two diagonal ports are necessary for these experiments, the four-corner design was done to incorporate the need of future experiments, which could require a combination of four inlet and outlet 36 ports. Once the pattern is prepared with the aid of the software, it is reproduced on a glass chrome plate and is called the mask. The process of mask manufacturing is a complicated one and is best handled by people in the fabrication facility. 2.2.2. Wafer Imaging The silicon wafers used for the manufacture of micromodels are of the type KTest. Another variety of wafers commonly available is K-Prime, but this just differs in the value of resistivity and is substantially more expensive. The wafers are coated with a 1.65 µm thick layer of Shipley 3612 photoresist without edgebead removal (edgebead removal is the process in which a small ring of the photoresist around the edge of the wafer is removed). Before coating the wafer with photoresist it is important to make sure that the wafers are dry and do not contain any moisture in them. If the wafers are new and out of a sealed box, they should be used for coating immediately. If the wafers are old and being used a long time after opening the seal of the box, before coating them with photoresist, they need to be put in a singe oven at a temperature of 150oC for 20 minutes. It is also important to note to use the special polymer cartridge in the singe oven to prevent melting of the regular PVC cartridges. Once the wafers are coated with photoresist they should be exposed to the ultraviolet light within a period of one to two hours. At no point of the process should they be taken out of the room with special lighting. This is done to prevent the pre-exposure of the resist-coated wafers. The mask used in the process of exposing the wafer to the ultraviolet light needs to be cleaned every time before use, to prevent exposing dirt marks and dust particles. The cleaning procedure involves cleaning the mask with acetone, methanol and isopropanol, strictly in that order. Subsequent to this the mask needs to be washed with de-ionized water and a N2 jet in a special mask cleaning apparatus. During the process of exposing the resist coated wafer to ultraviolet light it is important to make sure that the mask and the wafer are aligned, so as to prevent 37 the pattern for being off center on the wafer. The exposure time of the wafer to the ultraviolet light should vary between 3 to 4 seconds. These exposed wafers are then developed in Shipley MF-319 and LDD-26W developing chemicals. 2.2.3. Wafer etching and Finishing The developed wafers are then etched using hydrofluoric acid. Given the hazardous chemicals involved in the process, it is best handled by the welltrained technicians at the fabrication facility. The wafers are typically etched to a depth between 20 to 30 µm. Figure 2.4 (a) and Figure 2.4 (b) show the photographs of the etched wafers taken from an SEM (Scanning Electron Microscope). Figure 2.4 (a): View of a micromodel mounted at an angle of 45o on an SEM. 38 25 microns Figure 2.4 (b): View of the micromodel at an angle and 75X magnification. Note the rough edges of the micromodel. The etched wafers should be washed before further use with a cleaning solution comprising of NoChromix and sulfuric acid for 15 minutes. After washing them o in water they are heated on a hot plate at 700 F for 30 minutes. This is done to oxidize the silicon to form a thin film of silicon dioxide on the surface. Silicon is not water wet, but silicon dioxide is water wet. The wafers are they bonded to a glass plate with drilled holes for the inlet port to the silicon wafer to complete the flow system. A process called anodic bonding does this bonding. The glass plate o (pyrex) placed on the silicon wafer is heated to 700 F. A wire gauze with a weight is placed on the assembly of the wafer and glass on the hot plate and a potential of 1000 volts is applied for 1 hour. At these elevated temperatures the positive sodium ions on the glass plate become very mobile and are attracted to the negative electrode on the glass surface where they are neutralized to form a bond. Terry (1975) provides a good description of the bonding process. Pyrex is well suited for this application because of the close proximity of its thermal expansion co-efficient (3.25 x 10-6 / oC) compared to that of silicon (2.56 x 10-6 / o C). Detailed properties of pyrex are present in Appendix B (Sagar and Castanier, 1997). 39 2.3. Micromodel Holder The micromodel is placed in a holder which has conduits connected to the plumbing of the setup as show in Figure 2.1. This holder is fabricated from aluminum and consists of an inlet and an outlet port, which communicate with the micromodel at the drilled sections of the pyrex glass plate. The ports are sealed with viton O rings. These rings need replacement after a few runs. Figure 2.5 shows a schematic of the micromodel holder. Upper portion of the micromodel holder Lower portion of the micromodel holder Outlet port Groove for O ring Viewing window Inlet port Figure 2.5: Schematic of the micromodel holder. 40 Inlet port to micromodel 2.4. Injection Apparatus The fluids used in the process are pre-equilibrated fluids. These fluids are injected into the apparatus using an ICSO syringe pump (model 100DM, with ISCO pump controller), using water as the pushing fluid. Since there is a need to keep the injected fluids in pre-equilibrated form, we need to avoid the mixing of the water of the pump and the injected fluids. One way to achieve this is by using a piston cylinder in-between, which separates the pushing fluid and the injected fluid. Another technique adopted in our apparatus is to use a spirally wound thin tube of a large length in the plumbing. Because of the near plug flow nature (parabolic flow profile) of the flow in the thin tubing, given the low injection rates and the small rates of diffusion at the interface of contact, this method ensures that fluid at the other end of the spirally wound tube remains in its preequilibrated form. 41 Chapter 3 3. Experimental Procedure 3.1. Analog Fluid System In the experiments performed, the fluids used were not the fluids found in reservoirs at severe conditions of temperature and pressure. To facilitate and easier handling of the fluids used to observe four-phase flow, an analog fluid system was used. The fluids used were water, isobutanol (alcohol), hexadecane and carbon dioxide. Table 3.1 lists the properties of these fluids. This fluid system has typically very low values of interfacial tension between the oil and the alcohol phases, analogous to the oil and liquid carbon dioxide phase found in the reservoir. In another system of fluids used, squalane was added to adjust the interfacial properties of the fluid system. For both these systems, it was assumed that interfacial properties of the injected gas (CO2) could be approximated to that of air (which was used in the measurement of the interfacial tensions). The properties of this fluid system is also listed in Table 3.1 43 Property Water Isobutyl Alcohol Hexadecane Air Initial Solution 5.0 ml 10.0 ml 10.0 ml - Water - 3.47 3.54 30.7 Isobutyl - - 0.1 24.9 - - - 22.4 Composition Interfacial Tensions (dynes/cm) Alcohol Hexadecane Table 3.1: Properties of the fluid system 3.2. Micromodel Apparatus Procedure After the micromodel is placed in the holder and the plumbing of the apparatus done, carbon dioxide is first passed through the micromodel. This is done to drive out the air present in the apparatus, so that subsequent filling of the apparatus with liquids will leave fewer bubbles in the micromodel due to the solubility of CO2 in the liquids. It is very important to have an inline swagelock filter of cartridge specification of 2 µm in place to prevent the clogging of the micromodel. At this point the flow rate of carbon dioxide through the apparatus is measured by using an inverted cylinder in a trough of water, and an approximate calculation of the permeability of the micromodel is done. However given the compressible nature of the gas more reliable permeability calculations are performed by using a single-phase fluid through the micromodel. These 44 micromodels have a permeability value of around 165 mD based on the singlephase experiments involving water. Woody, et al. (1996) have presented a good review of computation of permeability for micromodels which have a quarter five spot pattern system. After passing carbon dioxide through the micromodel for 1 to 2 hours, the fluids can be introduced. Again it is important to use the inline filter while passing fluids through the micromodel and ensuring to use a different cartridge for each fluid to avoid interfacial tension effects of the various fluids. The fluids are passed through the apparatus at a predetermined flow rate. Typically this flow rate was maintained at a value of around 0.001 ml/minute. It is extremely important to set an upper pressure limit of around 30–35 psi for the low-pressure micromodel apparatus, to prevent the micromodels from breaking in case of an unexpected pressure rise caused by the obstruction of the micromodel or the plumbing. The fluids are then passed through the micromodel in various orders to study the effect of the various phases. Water, the wetting phase is always introduced in the beginning. 3.3. Capillary Tube Apparatus The utility of the capillary tube experiments in studying the spreading nature of various fluids has been discussed in the previous sections. The capillaries used for the process are triangular with 0.9mm side length. The fluids in the capillary are loaded in various combinations to study the spreading behavior of the fluids in this system. The capillaries used for this process need to be completely water wet and hence are thoroughly cleaned with a mixture of sulfuric acid and NoChromix. The capillary tube is completely injected with the equilibrated water, and then the various phases are loaded from the other end by injecting them with a syringe having a thin needle. It is important to note that the capillary tube is initially injected with water throughout its length to ensure that water is always present in the corners of the capillary tube. Subsequent phases injected push out the water from the other end of the capillary tube as they fill in. Once 45 the phases are loaded in the capillary tube, it is put in the vertical position and drainage of the various layers is observed. Figure 3.1 shows a schematic of the above process. Air Oil Alcohol Water Figure 3.1: Schematic of the capillary tube experiments 46 Chapter 4 4. Experiments Performed and Observations 4.1. Tools to Interpret the Flow Behavior In the course of the explanations, it will be convenient to represent the observations about fluid configuration and connectivity with the aid of the following diagrams. Figure 4.1 represents a triangular cross section of a hypothetical pore. Since the pores found in a porous medium have grooves and corners, a triangular cross section is a reasonable approximation of this physical aspect. Pore Corner Pore Body Oil Alcohol Water Figure 4.1: Schematic of a triangular cross section of a pore Figure 4.2 represents the porous medium from the perspective of the pore body and throat model. The larger spaces in the porous media are called the pore bodies or pores, while the narrower constrictions are called the throats. A pore is typically surrounded by a number of throats leading to it. In this conceptual picture only two throats are connecting to a pore. 47 Pore Throat Figure 4.2: Schematic view of the pore and throat model in a porous medium Besides this we also make use of capillary tube experiments to interpret and corroborate the observations from the micromodels. The schematic for this has been explained in the previous section. 4.2. Injection of Fluids in Order of their Wettabilities The first set of experiments performed in the study was done by introducing the phases in order of their wettabilities, namely water, alcohol, oil and gas. The wettability of the liquids is established by studying the curvature of the interface of various combinations of the phases, in absolutely clean glass capillary tubes. The wettability of the fluids was ascertained to be water, alcohol, oil and air, in decreasing order of wettability. The most important aspect of the study was to study the orientation or the configuration of the various phases and their connectivities. This behavior has an influence of determining theoretical and practical models for calculating the relative permeabilities of such system. 4.2.1. Injection of Water in a Micromodel Filled with Gas. Initial injection of water in the micromodel showed certain important features related with the wettability of the micromodel and the importance of corner flow. Figure 4.3 shows a picture representing the entry of water into a micromodel 48 containing CO2 initially. As can be seen from the figures, the water moves ahead from the physical front in the form of thin films (see the box region in Figure 4.3), in the corners of the pore structure of the micromodel. This is indicative of corner flow, a mechanism that arises due to capillarity and has significant influence in maintaining the connectivity of phases and their drainage from a porous medium. Grain Gas in Pore Body Water In Film Throat Water Figure 4.3: Corner flow during imbibition of water in the micromodel. 4.2.2. Injection of Alcohol in a Micromodel Containing Water. Subsequent injection of alcohol in a micromodel filled with water presents a choice of configurations for the location of the alcohol. Figure 4.4 represents the possibilities of the location of the alcohol in the pore body. These possible configurations include water being completely displaced with alcohol, alcohol occupying the corners of the throat or alcohol occupying the center of the micromodel leaving water in the corners. Given that the medium is water wet, the most probable option is the last one mentioned above. 49 Water Injection into an empty pore Alcohol Injection Alcohol Water Figure 4.4: Possible locations of alcohol in water filled pore. Figure 4.5 represents a condition of the micromodel after alcohol injection and indicates that alcohol, which is the non wetting phase compared to water, pushes water out of the larger space of the pore and occupies the central portion of the pore body. Water is still present in the pore body, but is pushed towards the edge of the pore and occupies these spaces. Water is also present in the narrower throats of the medium. In the Figure 4.5 it is almost impossible to locate the water film present in the corner of the pore body. This is because of the very thin film of water present in the corners. However water is clearly visible in the smaller throats. 50 Grains of porous medium, lighting effect causes darker appearance. Water in smaller throats Water in Alcohol film Alcohol Water Figure 4.5: Configuration of alcohol and water in a micromodel. 4.2.3. Injection of Oil in a Micromodel Filled with Water and Alcohol. Subsequent injection of oil into this micromodel containing water and alcohol presents a plethora of possible situations within the pore structure, which are represented schematically in Figure 4.6. Because oil is a nonwetting phase, it is possible that it would not displace water from the corners and the narrower throats. However, it is uncertain whether the oil would completely displace the alcohol, spread as a film between alcohol and water or occupy the central portion of the pore space, thus resulting in a film of alcohol between oil and water. 51 Alcohol Water Oil Figure 4.6: Schematic representation of possible fluid configurations in a pore containing water, alcohol and oil, injected in that order. The observations in this case are inferred from looking at the micromodel apparatus and corroborated by the capillary tube experiments. Figure 4.7 shows a photograph from the micromodel assembly showing the presence of three layers of fluids within a pore body in the micromodel. This indicates that oil, the least wetting phase among water, alcohol and oil, occupies the position in the center of the pore and pushes the alcohol as a layer between the oil and water. Though the spreading coefficient of alcohol between oil and water would seem to indicate nonspreading behavior, spreading of alcohol is observed. This is because fluids are know to spread even in face of adverse spreading coefficient, due to the geometry of the pore spaces and the corners in particular (Keller, et al., 1997). 52 Oil Alcohol Water Figure 4.7: Micromodel photograph of a pore containing water, alcohol and oil, injected in that order. Simultaneously the capillary tube experiments also corroborate this observation. Figure 4.8 represents a schematic of a capillary tube experiment loaded with fluids in the order of water, alcohol, oil and alcohol, from bottom-up. It was observed that after some time, the alcohol layer above the oil drained, which indicates that alcohol forms a layer between water (always present in the corners of the capillary tube given the way the experiments are conducted) and oil even in face of an unfavorable spreading coefficient. 53 Air + Oil Alcohol Water Oil Alcohol Water Alcohol drains as a layer between oil and water Figure 4.8: Schematic of capillary tube experiments with water, alcohol and oil. Figure 4.9 indicates another set of observations observed during the three-phase flow. The series of photographs indicates the drainage of alcohol in layers, as oil is injected into the micromodel. It is also very important to note the thinness of the layers of alcohol, which highlights the importance of flow in layers, and the contribution of this flow to the drainage process. In the series of photographs, as oil is injected into the system, simultaneous displacement of water and alcohol (already in the micromodel) is observed. It can be seen in the photographs that alcohol flows from region A to region B (marked in the photographs) through a thin film. Subsequently alcohol is also drained from region B by another thin layer of alcohol. 54 Grains of porous medium Water (present in sharp corners) Region A Alcohol Thin Region B of layer alcohol, draining Oil Figure 4.9 (a) Water pushing alcohol out of pore Alcohol being pushed out from the pore space (region A) Alcohol Region B Thin film of alcohol connecting the alcohol being displaced from region A to B. Oil 55 Figure 4.9 (b): Alcohol forms a thin film between water(present in corners) and oil. Alcohol pushed out by water from Region A Alcohol Region B Thin alcohol film between water and oil, draining alcohol from region B Direction of alcohol drainage Oil Figure 4.9 (c): Alcohol drained through connecting film demonstrating importance of flow in layers and the connectivity of fluids through layers. Region A Region B 56 Figure 4.9 (d): Alcohol draining from region B. Region A now completely filled with water. Alcohol drained from region A and B, as a thin layer between water and oil. Oil Figure 4.9 (e): Alcohol drained out from regions A and B. Figure 4.9: Photographs illustrating the importance of flow in layers to the drainage process. Figure 4.10 shows another phenomenon observed during the displacement of alcohol by oil, as oil is injected into the micromodel. The interfacial tension between the alcohol and the oil is relatively low, and the flowing oil at the center of the pore body drags the alcohol film along with it. This leads to a succession of snap-off events of the oil phase by the alcohol phase. 57 Oil flowing at the center of the pore Alcohol film between oil and water Water Figure 4.10 (a): Oil injection into micromodel containing water and oil. Alcohol draining from upper regions being dragged by draining oil due to low interfacial tension Oil Figure 4.10 (b) 58 Alcohol draining from upper regions being filled with oil now. Oil Figure 4.10 (c) Oil Snap-off type appearance of flow. Oil phase is surrounded alcohol phase, thus giving an impression of a snap-off. Alcohol Figure 4.10 (d) 59 Oil Alcohol Figure 4.10(e) Figure 4.10: Simultaneous flow of oil and alcohol when oil in injected in a micromodel containing water and alcohol. 4.2.4. Injection of Gas in a Micromodel Previously Filled with Water, Alcohol and Oil, in that order. When gas is injected into the three-phase system described in the previous section, an interesting question regarding the configuration of the four phases in the pore body arises. Figure 4.11 shows the possible configuration of fluids within the pore body in such a scenario. Since gas is the least wetting phase, it needs to be seen whether the gas displaces all of the other nonwetting phases, or only one of them preferentially based on their wettability, or whether the gas occupies the center of the pore, thus giving rise to the possibility of the existence of four phases within a single pore. 60 Alcohol Gas Water Oil Figure 4.11: Possible configuration of the four phases in the pore body. Figure 4.12 shows a series of photographs of the micromodel containing water, alcohol and oil as gas is being injected in it. The photographs indicate that gas, which is the least wetting phase, occupies the central portion in the pore body. The alcohol forms a film between oil regions (marked by an oval in the photographs below) and also forms a layer between the gas and oil (marked by the rectangular regions in the photographs). These rectangular regions are interesting because, one could argue the presence of four phases within the pore, as water is always assumed to be present as a thin film in the corners. However four phases are not explicitly visible within the pore structure. As gas flows for a longer period of time, these alcohol films vanish as the alcohol is almost completely displaced from the porous medium. Thus the primary phases flowing through the porous medium are oil and gas. The alcohol present as a film between water and oil, connects as a film and is displaced from the porous medium to a lower saturation. 61 Oil Alcohol Water Figure 4.12 (a) Alcohol Gas Oil Figure 4.12 (b) 62 These rectangular marked regions show a transient four-phase zone in a pore, assuming a thin water film is always present at the wall and not explicitly visible. However these alcohol films eventually vanish. Oil Alcohol Gas Figure 4.13 (c) Alcohol Gas Oil Figure 4.12 (d) 63 Gas Figure 4.12 (e) Oil Figure 4.12 (f) 64 Alcohol Oil Alcohol Gas Figure 4.12 (g) Figure 4.12: Gas injection in a micromodel containing water, alcohol and oil. The capillary tube experiments also support the interpretation given above. Oil does not seem to spread as a layer between alcohol and gas. Figure 4.13 shows a schematic of a capillary tube experiment with the tube filled with water, alcohol, oil, air, alcohol and oil, in the order from bottom up. It is observed that the alcohol drains first and then the oil drains second. The drainage process is not simultaneous. This illustrates that oil does not spread between alcohol and air, and hence four phases in the order of gas, oil, alcohol and water are not observed in the pore body. Also alcohol and oil both spread as layers between water and air, which is observed from three-phase flow. 65 Air Oil Alcohol Water Alcohol Water Gas Oil Figure 4.13: Schematic of a four-phase capillary tube experiment. Since alcohol is denser than oil, one might argue that the oil has no additional impetus to flow before the alcohol drains in the above experiment. Hence the above experiment was performed in a slightly reversed order of fluid configurations as illustrated by the schematic diagram in figure 4.14. It was again observed that the alcohol layer on the top drains first, followed by the oil layer. This clearly indicates that oil does not spread as a layer between air and alcohol. Both these capillary tube experiments suggest that the four-phase flow situation is composed of two three-phase systems. Ahead of the gas front, there is a flow of water, oil and alcohol. In the gas region, there seems to be a flow dominated by gas and oil, with some of the alcohol connecting up and being displaced by the injected gas. 66 Air Oil Alcohol Water Alcohol Water Gas Oil Figure 4.14 : Schematic of a four-phase capillary tube experiment. 4.3. Injection of four phases into the micromodel in changed order of wettabilities. 4.3.1. Injection of Water and Oil in the Micromodel. In the next set of experiments performed, the fluids were injected into the micromodel in changed order of wettabilities. The order of injection of the fluids was water, oil, alcohol and gas. As expected, injection of oil into a micromodel containing water pushed the water to the corners of the pores and the narrower throats. 4.3.2. Injection of alcohol in a micromodel containing water and oil. The injection of the alcohol now presents a range of possibilities as illustrated by Figure 4.15. Among the more probable configurations, the alcohol can spread as a film between the water and oil or occupy the central portion of the pore pushing the oil as a film between water and alcohol. 67 Alcohol Water Oil Figure 4.15 : Schematic showing possible fluid configurations in a pore containing water and oil, injected with alcohol. It was observed before that the alcohol spreads between oil and water, and hence it would seem to be logical to expect that the alcohol would demonstrate a similar behavior in this case. Since water is always present in the corners, Figure 4.16 shows a schematic of the possible configurations of the fluids based on the pore body and throat model. Based on the previous set of observations (section 4.2), the expected configuration would be the one in which the alcohol spreads as a layer between water and oil. 68 Alcohol Water Oil Figure 4.16: Schematic view of alcohol injected in a pore body containing water and oil, based on the pore body and throat model. Figure 4.17 shows a series of photographs from the micromodel experiment describing the process of the injection of alcohol in a micromodel containing water and oil. It is observed that the alcohol flows through the central portion of the pores and pushes the oil aside. However the alcohol does not flow as a continuous phase. This discontinuous flow behavior of alcohol is because of the unstable configuration in which the alcohol occupies the center of the pore. All the capillary tube experiments indicate the spreading of alcohol between oil and water, and oil was never observed to spread as a layer between alcohol and water. Hence this flow behavior is assumed to stem from the low interfacial tension between the alcohol and oil, because of which the alcohol is preferentially able to flow through the center of the pores which present a lower flow resistance to the alcohol compared to its flow in the form of a film, where the flow resistance is higher. 69 + Oil Alcohol Oil Water Alcohol Note the discontinuity between the phases Figure 4.17 (a) Oil Alcohol Water Figure 4.17 (b): Succession of snaps showing flow of alcohol in a micromodel containing water and oil. Note that alcohol flows as a discontinuous phase. 70 Alcohol Oil Figure 4.17 (c) Figure 4.17 (d) 71 Oil Alcohol Figure 4.17 (e) Figure 4.17 (f) Figure 4.17: Micromodel photographs of alcohol injected in a micromodel containing water and oil. 72 4.3.3. Injection of Gas in a Micromodel Containing Water, Oil and Alcohol. Figure 4.18 represents a schematic of the possible configurations, when gas is injected into the above system. It is important to ascertain whether four phases exist in the pore or if the gas displaces one of the phases preferentially based on the wettability. The two configurations on the right, present the most probable configurations based on previous observations. Water Oil Alcohol Gas Figure 4.18: Schematic view of gas injected in a pore body containing water, oil and alcohol. Figure 4.19, represents the photographs of the micromodel with gas being injected into the above system. It is observed that as gas is injected into the system, simultaneous drainage of oil and alcohol occurs. It is important to note that the alcohol, which is present as a discontinuous phase in the micromodel, continues to flow as a discontinuous phase through the oil. The gas breaks through the higher permeability channels of the micromodel as seen in the photographs. This essentially leaves three phases in the pore body. Water, the most wetting phase, remains closest to the pore surface, and oil spreads as a 73 layer between the water and the gas. Most of the alcohol is drained out in a discontinuous phase flow, but a small fraction of the original alcohol remains trapped in a few isolated pores. This largely simplifies the problem to that of a three-phase situation involving water, oil and air. In the photographs below, simultaneous displacement of oil and alcohol is observed. It is also seen that for some time, alcohol appears to be a continuous phase at the center of the pore. However this is because of all the alcohol draining from the upstream region and the large amount of alcohol drainage gives it the appearance of a continuous phase flow. The flow of the alcohol phase is still discontinuous. By the time gas enters the pore, most of the alcohol is displaced. 74 Water Oil Alcohol (discontinuous) Figure 4.19 (a): Displacement of water, oil and alcohol by gas. Oil Figure 4.19 (b): Alcohol is present as a discontinuous phase surrounded by water. 75 Oil Alcohol Figure 4.19 (c): Note the flow of alcohol as a discontinuous phase, contrasted to the previous photograph (Fig. 4.19 (b)). Figure 4.19 (d) 76 Alcohol Oil arrows indicate continuous flow path of alcohol Figure 4.19 (e): Due to drainage of large quantity of alcohol from the upstream region, alcohol appears to flow as a continuous phase at the center of the pore. Trapped Alcohol Oil Gas 77 Figure 4.19 (f) Rectangular regions: Here oil spreads as a thin layer between water and gas. Trapped Alcohol Gas Figure 4.19 (g) Oil Gas Figure 4.19 (h) 78 Water Gas Oil Gas Figure 4.19 (i) Gas Water Oil Gas Figure 4.19 (j) Figure 4.19: Gas injection in a micromodel containing water, oil and alcohol. 79 4.4. Interaction in system with higher interfacial system between alcohol and oil. In the previous section it was observed that though the capillary tube experiments suggested the spreading of alcohol between water and oil, when alcohol was injected in a micromodel containing oil and water, the alcohol flowed as a discontinuous phase through the central portion of the pore body, and did not form a layer between the oil and water. This behavior could perhaps be attributed to the low interfacial tension between alcohol and oil. To determine whether the flow behavior of alcohol observed in the previous section was due to the low interfacial tension between alcohol and oil, the experiment in the previous section was repeated with a fluid system having a higher interfacial tension between the oil and the alcohol. The system of fluids used is the same as before, but addition of squalane modified values of interfacial tension. The system of fluids used had the following composition and properties: Property Water Isobutyl Alcohol Hexadecane + Air Squalane Initial Solution 5.0 ml 14.0 ml 2.0 ml - Composition + 4.0 ml Interfacial Tensions (dynes/cm) Water - 2.91 3.94 30.6 Isobutyl Alcohol - - 1.28 22.4 Hexadecane + - - - 26.2 Squalane Table 4.1: Physical properties of the isobutanol, hexadecane, squalane and air system. 80 The fluids were injected in the micromodel in an order similar to that in the previous section, i.e., water, oil, alcohol and air. Water injection was again characterized by flow in corners and the presence of a thin film of water ahead of the waterfront. Subsequently oil is injected into the water filled micromodel. The injected oil, which was nonwetting, occupied the central portion of the pore body and pushed the water as a film against the pore walls and in the smaller throats of the porous medium as shown in Figure 4.20. Oil Water Figure 4.20: Micromodel filled with oil and water. Subsequent injection of alcohol into the system presents the range of fluid configurations shown in Figure 4.21. The alcohol might either displace the oil completely, flow through the central portion of the pore pushing the oil aside as a film or flow as a film between water and oil. It is also important to note that though there is a change in the values of the spreading coefficients, their signs remain the same. 81 Alcohol Water Oil Figure 4.21: Possible configurations of fluid phases upon injection of alcohol in a pore containing oil and water, based on the pore and throat model. Based on spreading behavior previously discussed, the configuration on the extreme left seems to be the most probable one. However because of the low interfacial tensions between alcohol and oil in the previous experiments, it was observed that alcohol flowed through the center of the pore in the form of discontinuous drops. However in this system, where the interfacial tension between alcohol and oil is substantially higher, it was observed that alcohol does flow as a film between the oil and the water, resulting in some oil being trapped in the center of the pore. In certain regions of the porous medium, piston-like displacement of the oil by the alcohol was also observed, but the flow was largely comprised of flow of alcohol in thin films. Figure 4.22 shows a series of photographs of the micromodel during the injection of alcohol. The photographs were taken seconds apart and can be considered as a series of snapshots of the video (separated apart by frames of appx.1 second). It can be seen that as alcohol was injected into the porous medium, some amount of alcohol and water is drained from the upstream regions. Ovoid 82 marked regions in the photographs clearly show the flow of water in layers, while rectangular marked regions show the flow of alcohol in layers. It would be interesting to note the importance of flow in layers, highlighted by the abrupt appearance of a phase in a certain region of the micromodel. Oil Water Figure 4.22 (a): Micromodel containing water and oil. 83 Oil Abrupt appearance of water phase due to flow of water in a thin layer close to the pore body. (contrast to previous photograph which does not show this water region) Figure 4.22 (b): Flow of water in layers. Water draining from upstream regions displaces oil and occupies the narrower throats of the porous medium. Figure 4.22 (c) 84 Oil Water Note abrupt appearance of water phase (compare to previous photograph). This is due to flow of water in thin layers. Figure 4.22 (d) Oil Alcohol Water Figure 4.22 (e) Note sudden appearance of alcohol between oil and water, suggesting flow of alcohol in a layer. 85 Water Trapped oil, surrounded by alcohol. Bypassed region Alcohol Figure 4.22(f) Appearance of alcohol phase due to flow in layers. Figure 4.22 (g) 86 oil Alcohol Water Oil Figure 4.22 (h) The alcohol region, slowly gets displaced through layers not clearly visible. Note the alcohol region in upper snap, but displaced out in the lower picture. Figure 4.22 (i) 87 Trapped oil Water Alcohol Bypassed oil Figure 4.22: Injection of alcohol in a micromodel containing oil and water. Capillary tube experiments also corroborate these observations. In a capillary tube filled with water, alcohol, oil and alcohol in that order, it was observed that the upper alcohol region drains below, flowing as a layer between oil and water. When the photographs in Figure 4.22 are compared to those in Figure 4.19, the difference in the two systems in obvious. In all the photographs in Figure 4.19, the alcohol phase (system with low interfacial tension between alcohol and oil) is seen to flow at the center of the pore as a discontinuous phase. However in Figure 4.22 photographs, the alcohol phase is seen to clearly spread as a layer between the oil and water and forms a continuous phase throughout the porous medium. Injection of gas into the micromodel containing alcohol, oil and water presents some possible configurations of fluid phases as illustrated in Figure 4.23. It is important to verify at this point about the existence of four phases within the pore 88 structure. Thus it is important to observe if the gas occupies the central portion of the pore with the remaining liquid hydrocarbon phases or if it drains both of them or either of them preferentially based on their wettabilities. Water Oil Alcohol Gas Figure 4.23: Schematic representation of fluid configurations in the pore, upon injection of air in a micromodel containing water, oil and alcohol. Figure 4.24 is a series of photographs from the micromodel that shows the fluid configuration and connectivities after injection of gas. Ahead of the gas front, there is three-phase flow of oil, water and alcohol. Oil present as a discontinuous phase trapped by layers of alcohol is mobilized and flows as discontinuous drops (contrast this to previous fluid system in which alcohol was the discontinuous phase and flowed in a similar manner). By the time the gas front reaches a certain portion of the porous medium, most of the oil is displaced from there and subsequent flow is characteristic of three-phase flow involving water, alcohol and gas. The following photographs illustrate the above observations. The initial photographs show the three-phase flow of water, oil and alcohol while the latter photographs show the invasion of the pores by gas, and associated flow behavior. The ovoid marked regions represent oil flowing in a discontinuous manner. 89 Alcohol Trapped Oil Water Figure 4.24 (a): Micromodel containing water, oil and alcohol. Oil being mobilized due to gas injection upstream Figure 4.24 (b) 90 Oil being drained from upstream connecting up and draining. Figure 4.24 (c) Figure 4.24 (d) 91 Just before gas invasion of this pore space. Oil lcohol Figure 4.24 (e) Gas Gas Gas Oil Alcohol Figure 4.24 (f) 92 Gas Gas Gas Alcohol Oil Figure 4.24 (g) Figure 4.24: Gas injection in a micromodel containing water, alcohol and water. In the photographs in Figure 4.24, one cannot see four phases existing in the pore space simultaneously. After gas invasion of the pores, here exist three phases within the pore space. These phases are water, alcohol and gas. This is clearly evident from the rectangular region marked Figure 4.24 (g). 93 Chapter 5 5. Discussion and Conclusions An experimental apparatus for the visualization of four-phase flow was set up, and experiments were performed at a constant flow rate of injection of the fluids. Pore scale flow events related with the configuration and the connectivity of the fluids were observed and certain conclusions regarding the four-phase flow phenomenon can now be made. It was observed that the saturation history is very important in determining the orientation and connectivity of the fluid phases in the porous medium, ie., the order of filling of the fluids in the porous medium is important in determining the configuration of the fluids in the pore space. In the system in which the interfacial tension between the oil and the alcohol was very low, it was observed that though spreading of the alcohol between water and oil is the favorable situation (as illustrated from the capillary tube experiments and the micromodel experiments with order of filling of fluids being water, alcohol and oil); when the fluids are injected in a different order of their wettabilities, the alcohol phase can occupy the central portion of the pores as a discontinuous phase. Subsequent injection of gas into the system causes this discontinuous alcohol phase to be mobilized and the alcohol phase is displaced ahead of the gas front. However in the system where the interfacial tension between the alcohol and oil phase is higher it is observed that the alcohol phase spreads between the water and the oil for the same experiment as above. This highlights that for the system with lower interfacial tension between the hydrocarbon phases, the order of injection of the phases is important. In most reservoir systems where four-phase flow is observed, a liquid carbon dioxide phase exists, which has a relatively low interfacial tension with respect to the oil phase in the reservoir. This could 94 perhaps correspond to our analog system in which the interfacial tension between oil and alcohol is relatively low. This assumption is based on the observation that when liquid carbon dioxide is injected in a micromodel containing oil, one can see the flow of liquid carbon dioxide as a discontinuous phase under certain conditions. Hence we could relate the injection of alcohol in section 4.3 to the liquid CO2-rich phase, which was also observed to flow as a discontinuous phase. The four-phase analogies could be made, given the above assumptions. Based on the observations, much of the four-phase flow field can be treated as a combination of two three-phase flow situations. Ahead of the gas front, interactions were primarily restricted to the liquid phases (water-oil-alcohol), while at the gas front and behind the interactions were primarily between water, a liquid hydrocarbon phase (oil or alcohol) and gas. A closer observation shows that there are two primary phases flowing during gas injection, alcohol and gas or oil and gas. However the presence of water occupying the smaller throats and the corners and crevices of pores has an influence on the area available in the pore cross-section for flow, and hence it is more prudent to treat four phase flow as a combination of three phase flows and not as a combination of two phase flows. It would be necessary to qualify the previous hypothesis given the limitations of the experimental approach. Since the fluids were injected in successive order, only one of the two liquid hydrocarbon phases was present in larger quantity. In a real reservoir development scenario, the saturations of the two liquid hydrocarbon phases might be appreciable and comparable, and the hypothesis of approximating the four-phase flow as a combination of two threephase flows might not be applicable. The zones in which four phases were present simultaneously were small in the experiments reported here. For those zones, an appropriate relative permeability model is to be determined yet. The presence of four phases in a pore would imply a smaller area of cross-section of the pore available to flow for the various phases, and would also impact the connectivity of the various phases and hence their displacement pattern. 95 One way to tackle the problem of relative permeabilities for reservoir development would be to break down the four-phase flow problem into a combination of two three-phase flow problems, one ahead of the gas front and the other behind it. A possible way of tracking the gas front would be by tracking the saturations of the gas in the various blocks of the reservoir simulator. However such an approach would be limited by the presence of a diffuse front and also an abrupt change in the relative permeability values of the phases at the front. It was also interesting to note that ahead of the gas front, there was mobilization of the discontinuous phase (oil or alcohol). In the system having low interfacial tension between the oil and the alcohol though alcohol was a disconnected phase, it was observed to flow freely; even in the three-phase situation of injection of alcohol in a porous medium containing water and oil. In the system having a higher interfacial tension between the oil and alcohol, it was observed that ahead of the gas front, the disconnected oil phase was also mobilized. This -3 -2 is because the capillary number for the flow is in the range of 10 to 10 in both the cases, and hence the viscous forces and the capillary forces are almost equal. When phases flow in a discontinuous manner, the concept of relative permeability breaks down (relative permeability can be thought of as a fraction of cross-section of porous medium available to a particular continuous phase to flow). These observations seem to suggest that the use of a pseudo liquid phase (combining the two liquid hydrocarbon phases into one) in certain previous reservoir developments might be a plausible idea. Based on observed flow behavior it should be possible to do reservoir simulations by using three-phase relative permeabilities of water, oil and gas, by making certain modifications in the three-phase relative permeabilities (see Appendix A). These modifications as discussed by Wang and Strycker (2000), split the relative permeability value of the oil phase into two fractions, based on the saturations of the two liquid hydrocarbon phases (eq. A-11, A-22). 96 The presence of four phases within a single pore cannot be ruled out completely, though it was largely absent for most of the experiments performed. In the system having a low interfacial tension between the oil and alcohol, four phases in a pore were observed for a short transition period (when order of injection was water, alcohol, oil and gas). In that case the four-phase problem was a combination of two three-phase problems, alcohol spreading between oil and water, and oil spreading between alcohol and air, both being favorable conditions. However as the alcohol phase was displaced, these films were no longer observed. In none of the other cases, were four phases observed in a pore space simultaneously. It is important to recognize that most of these observations are strictly restricted by the regime of flow, capillary dominated or viscous dominated, as well as the regions of the porous medium in which the observation was made. In our experiments, four phases were injected in succession into a porous medium, while one could expect the simultaneous formation of four phases in the regions of the reservoir where there is a sudden pressure drawdown. Hence when gas is injected in the experimental setup, there is predominantly a flow of two phases, which might be different from a reservoir scenario which might involve the flow of two liquid hydrocarbon-rich phases and a gas-rich phase. Hence the short transition region of four-phase flow observed in one set of experiments, might exist in the presence of larger fractions of the two liquid hydrocarbon phases. Besides this there is also the inherent limitation of the two dimensional nature of the micromodels. As a follow up to this work, it would be useful to perform core flood experiments with the fluid phases and measure the saturations and flow rates along with pressure drops and compare the observations with a combination of three phase relative permeabilities, ahead and behind the gas front. It would also be very useful to be able to develop a technique to distinguish the various liquid phases in the micromodel, by the use of certain dyes or use of refractive properties of the phases involved. 97 Nomenclature 98 Cs = spreading coefficient of oil between water and gas σij = interfacial tension between phases I and j References 1. Bahralolom, I.M. and Orr, F.M.: “Solubility and Extraction in Multiple-Contact Miscible Displacements: Comparison of N2 and CO2 Flow Visualization Experiments,” paper SPE 15079 presented at the 56th California Regional Meeting of the Society of Petroleum Engineers held in Oakland, CA, April 24,1986. 2. 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Wang, Xiaowei and Strycker, A.: “Evaluation of CO2 Injection with Three Hydrocarbon Phases,” SPE 64723, presented at the SPE International Oil and Gas Conference and Exhibition in China, Bejing, 7-10 November, 2000. 30. Woody, F., Blunt, M.J. and Castanier, L.M.: “Pore Level Visualization of Foam Flow in a Silicon Micromodel,” SUPRI TR100, Stanford University, January 1996. 31. Wu, R.S. and Batycky, J.P.: “Evaluation of Miscibility from Slim Tube Tests,” The Journal of Canadian Petroleum Technology (Nov.-Dec. 1990) Vol. 29, No.6,63. 32. Zhou, D., Blunt, M.J. and Orr, F.M.: “Hydrocarbon Drainage along Corners of Noncircular Capillaries,” Journal of Colloidal and Interface Science, 187,1121(1997) 102 Appendix A A. Relative Permeability Models The various models used for computation of four-phase relative permeabilities by Wang and Strycker (2000) are listed below. Based on their observation, the modified Corey Model gives the best fit. In all these models the three-phase oil relative permeability is obtained from two-phase oil-water and oil-gas data. The values of water and gas relative permeabilities are the same as the two-phase data. The two liquid hydrocarbons share their relative permeabilities with the calculated oil relative permeability in proportion of the relative volumes. Baker Model The three-phase oil relative permeability is interpolated as follows, Kro = ( Sw − Swr ) Krow + ( Sg − Sgr ) Krog …………………….(A-1) ( Sw − Swr ) + ( Sg − Sgr ) Where, Krow and Krog are the two-phase relative permeabilities calculated as, o row ( o rog ( Krow = K Krog = K So − Sorw e ) ow ………………….……………(A-2) 1 − Swr − Sorw 1 − S * g − Slrg e ) og ………………………….……..(A-3) 1 − Slrg − Sgr Where, Swr – residual water saturation in oil-water two-phase system. Sorw – oil residual saturation in the oil-water two-phase system. 103 o o K row, K rog – end point relative permeabilities of oil in the oil-water and oil-gas two phase systems respectively. (maximum oil relative permeability). Sgr – residual gas saturation in the oil-gas two-phase system. Sorg – residual oil saturation in the oil-gas two-phase system. Slrg = Swr + Sorg , total residual liquid saturation to gas phase during two phase of oil and gas. S*g = 1- So – min(Sw,Swr) eow – empirical term to theoretically fit oil-water relative permeability curves. eog - empirical term to theoretically fit oil-gas relative permeability curves. The water and gas relative permeabilities are calculated by, ( Sw − Swr )ew …………………………..(A-4) 1 − Swr − Sorw Krg = Korg ( Sg − Sgr )eg ………………..…….(A-5) 1 − Swr − Sorg − Sgr Krw = K o rw Where, K o rw - end point water relative permeability value Korg – end point gas relative permeability value Modified Stone II Model This is the Stone’s model presented above which has been normalized by Nolen and is described as follows, Kro = Korow K ……………………………………………(A-6) 104 K=( Krow Krog + Krw )( + Krg ) – ( Krw + Krg ) …….(A-7) Korow Korow The oil-water two-phase permeability is calculated as, Krow = Korow ( 1 − Sw − Sorw e ) ow …………………….…(A-8) 1 − Swr − Sorw The oil-gas two-phase relative permeability is calculated as, Krog = K o rog ( 1 − Sg − Swr − Sorg e ) og ………………....(A-9) 1 − Swr − sorg − Sgr Krw and Krg, the water and gas relative permeabilities are calculated from the Baker model. For the Baker and the modified Stone II model, the two liquid hydrocarbon phases share the relative permeabilities in proportion to their relative volumes, i.e. on their saturation weighted basis: Kro = Kro ( So ) ……………………………….….(A-10) So + S 4 Kr4 = Kro ( S4 ) ……………………………….….(A-11) So + S 4 Corey’s Model In this model, the relative permeabilities of the various phases depend on their own saturations and are computed as follows, Krj = Korj ( Sj − Sjr Np 1 − ∑ Slr )ej ………………..)(A-12) l =1 Where, 105 Krj – Relative permeability of phase j Korj – Phase j end point relative permeability at Sj = 1 - ∑ Skr , (Skr,Sjr, residual k \= j saturation of phase k or j, \= is representation for ≠) ej – Corey exponent for phase j In absence of three-phase oil exponent and end point relative permeability data, the following can be used, Koro = bKorow + (1-b)Korog ………………(A-13) eo = beow + (1-b) eog ……………………(A-14) b=1- Sg …………….…….(A-15) 1 − Swr − Sorg Modified Corey’s Model Dria, et al. (1993) modified the Corey’s model and the three-phase relative permeabilities are calculated as: Krw = K o rw (Swe)ew ………………..(A-16) Where, Swe – Effective saturation of water phase o 2 e o Kro = K ro(Soe) [ 1 – (1 – Soe) ] ……………….(A-17) Krg = Korg (Sge)2 [1 – (1-Sge)eg ] …………..(A-18) Where, 106 Swe = Sw − Swr ……………………..…(A-19) 1 − Swr − Sor Soe = So − Sor …………………………(A-20) 1 − Swr − Sor Sge = Sg − Sgr …………………..(A-21) 1 − Swr − Sor − Sgr Also, Kr4 = Kor4 (S4e)2[1 – (1-S4e)e4] ………..…(A-22) S4e = S 4 − S 4r …………….….(A-23) 1 − Swr − Sor − S 4 r 107