3D-Printing Replication of Porous Media for Lab-Scale Characterization Research

Abstract

Simplifying fluid-flow physics in conventional reservoirs is convenient by assuming uniform lithology and system-geometry with minimal rock/hydrocarbon interactions. Such simplification restrains mathematical models’ ability to simulate unconventional reservoirs’ actual flow behavior and production performance. Researchers can achieve precise adaption for the physics of fluid flow in porous media if they geometrically characterize the system under study appropriately, and there are minimal interactions indeed. 3D-printed replicas of porous-rock samples obey this criterion. In this work, we used image-processing tools used for creating presentable porous and permeable replicas of different scales and configurations of the petroleum system from lab-scale to field-scale. The workflow of 3D-printed replicas creation is presented for replicas of conventional core samples, naturally and synthetically fractured cores, geological drilling units of multistage fractured horizontal wells, and full-field models, e.g., Norne field in Norway. These samples are ideal for experimentally testing the validity of the analytical or numerical models of oil and gas reservoirs in the laboratory, along with judging the quality of reservoirs’ characterization. These replicas’ ideality of these results from limited uncertainties of the geometry of the system under study and fluid/rock interactions because of the uniform composition. For validation purposes, 3D-printed replicas with different materials and 3D-printing technologies were created based on a reconstructed image-processed CT scan of their original Berea sandstone. These replicas were tested for storage capacity (porosity) and transport capacity (permeability) and compared with their original sample’s capacities. The matched results proved replicas’ ability to be used in oil and gas laboratory experimental research.

Surface modification of stereolithography-based 3D printed structures utilizing ultrasonic-atomised sprays

“…Stereolithography (SLA) is a 3D printing technique gaining more interest within the oil-and-gas community [20,21]. Stereolithography belongs to a family of additive manufacturing technologies that uses a photopolymerization technique.…”

Surface Modification of Stereolithography-based 3D Printed Structures Utilizing Ultrasonic-atomised Sprays

“…The advent of three-dimensional (3D) printing technologies enabled a cost-effective mimicking of complex geometries of rock structures with an acceptable amount of accuracy [2,[7][8][9][10][11][12][13]. Stereolithography (SLA) is a 3D printing technique that is gaining more interest within the oil-and-gas community [14,15]. This technology uses ultraviolet light to cross-link photosensitive monomers or oligomers, producing a threedimensional solid polymer.…”

Simulation and Validation of Porosity and Permeability of Synthetic and Real Rock Models Using Three-Dimensional Printing and Digital Rock Physics

“…Several studies adopted 3D printing technology to generate replicas of real rock samples for destructive tests keeping intact the original samples. − The use of 3D printing can also improve the experimental repeatability of laboratory measurements reducing the statistical experimental errors. , Furthermore, 3D printing was implemented to experimentally study the transport property changes of the rock microstructure due to compaction and dissolution processes . In recent studies, 3D core samples have been printed with different materials and printing technologies to assess the petrophysical properties of the replicas in sandstone reservoir rocks. ,, For example, several 3D printing techniques were used to create rock analogs of real heterogeneous samples in order to assess uniaxial and triaxial compressive measurements . Quantitative measurements showed that strength and deformation characteristics of printed samples were comparable to real data.…”

“…29 In recent studies, 3D core samples have been printed with different materials and printing technologies to assess the petrophysical properties of the replicas in sandstone reservoir rocks. 26,30,31 For example, several 3D printing techniques were used to create rock analogs of real heterogeneous samples in order to assess uniaxial and triaxial compressive measurements. 19 Quantitative measurements showed that strength and deformation characteristics of printed samples were comparable to real data.…”