1. Introduction
It is known that in recent decades, the level of oil production at large fields in the world, which accounts for more than 60% of reserves, has been falling. The main problem is related to the deterioration of the resource potential of these deposits, most of which have been in operation for more than 30 years. The level of water cut at large deposits that have been put into development for a long time today reaches 70–80%. The current trend is that if nothing is done, oil production will continue to decline, and the commissioning of new smaller deposits will not compensate for this decline. The current situation requires creating new highly efficient methods and technologies for developing hydrocarbon deposits that make production profitable in the context of low oil prices.
Various methods are used to enhance oil recovery: oil displacement by water, polymer flooding, injecting carbon dioxide, in situ combustion, and others [
1,
2,
3]. One of the promising methods of this kind is nanoemulsions (nanofluids), widely used for the development and operation of oil and gas wells [
4,
5,
6,
7,
8]. Nanofluid is a suspension with nanoparticles whose dimensions do not exceed, as a rule, 100 nm. The study of the properties of nanofluids in various applications has become one of the research trends of the last decade. From the perspective of possible applications of nanofluids in oil production, the viscosity, the wetting angle, and the interfacial tension coefficient of the flooding agent play a key role. Here, nanofluid is a unique material since its above-mentioned properties significantly depend on the concentration, size, material, and morphology of nanoparticles. By varying these properties, it is possible to obtain a real tool for controlling the oil displacement process from the reservoir. In particular, this is evidenced by the works that have appeared in recent years, which indicate that using nanofluids can significantly enhance the oil extraction volumes from the reservoir [
4,
5,
6,
7,
8]. Below are just a few concrete examples.
Chandio et al. [
9] have shown that using nanofluid makes it possible to increase the oil recovery factor (ORF). Based on promising laboratory results, from an economic and environmental standpoint, silica is an ideal material for future applications among all nanomaterials due to its properties. Conducted experiments have shown that the concentration of SiO
2 particles of 0.05 wt% is optimal and provides an oil recovery enhancement of 15% compared to displacement by water. At that, a further increase in concentration leads to a decrease in oil recovery. This phenomenon is explained in the work by the clogging of pores and the emergence of particle agglomerates. The paper [
10] states that the addition of silicon nanoparticles to the displacing fluid with a concentration of 0.2 wt% + SDS can increase the ORF on average from 4 to 14% on a sandy rock sample. At the same time, the authors of [
11] revealed that the ORF improved with an increase in the concentration of SiO
2 particles until the optimal concentration was reached. The maximum oil recovery was achieved at a nanoparticle concentration of 0.1 wt%. The final production of the original oil at the field has increased by 13.28%.
A significant part of the research on using nanosuspensions to enhance the ORF when injected into the reservoir is associated with numerical simulations [
12,
13,
14,
15,
16,
17].
One of the first approaches to nanosuspension flow simulation was developed by Ju et al. [
12,
13]. The authors have developed a one-dimensional model of nanofluid flow in a porous medium taking into account the pore colmatation. The simulation results using a 1D model coincided well with the experimental data. It was revealed that the greatest effect of oil recovery enhancing was achieved at a particle concentration of about 3 vol%.
Yin Feng et al. [
12] conducted numerical studies on the effect of parameters, such as the duration and injection volume of nanosuspension on the efficiency of oil recovery. At that, the employed mathematical model took into account the adsorption of nanoparticles but did not account for capillary pressure and change in wettability. Various injection scenarios of nanosuspensions were simulated, namely continuous injection, injection of the oil fringe, and subsequent flushing. Additionally, the effect of injection time, injection rate, and the size of the oil fringe on oil recovery were also studied. The results have shown that when flooding with nanofluids is used after conventional flooding with water as a method of tertiary extraction, early injection of nanofluids improves oil recovery, but leads to large consumption of nanosuspension. A higher injection rate of nanofluids can contribute to increasing the flooding efficiency, but not increasing the resulting oil recovery, and also cause large losses of nanoparticles. Compared with continuous injection, injection to the oil fringe with subsequent washing allows saving the volume of suspension consumed.
A computational study of the effect of the added nanoparticles on the wettability of walls and pore calcification was carried out by Sepehri et al. using the Darcy model [
15]. It has been shown that an increase in the nanofluid concentration and volume can lead to deterioration in the porosity and permeability of the rock, especially in the inlet area.
The article [
16] presents the results of a computational study of the effect of salinity on the efficiency of oil recovery by a nanofluid. At that, unlike other approaches, the nanoparticle transfer equation in this work was solved analytically. The results have shown that the presence of high ionic strength (1 wt% or 0.13 M KCl) and multivalent ions (Ca~, Mg) significantly affects the breakthrough of carbon nanoparticles through the core model at a linear pore velocity of 0.67 cm/min. This is probably due to the charge interaction between the carbon nanoparticles in the suspension and the interaction of carbon nanoparticles with a porous medium. This charge interaction has been drastically reduced by surface modification techniques.
There are very few works in which the effect of nanofluid properties on the efficiency of oil recovery is studied using numerical simulation. An example of such a study is given in the article by Gharibshahi et al. [
17], in which the effect of factors, such as the type of nanoparticles, their concentration, and size, as well as the temperature of the injected fluid is studied using the volume of fluid (VOF) method on the oil displacement process. In the course of the study, it was shown that an increase in particle concentration results in enhanced ORF. While studying the effect of particle sizes, it was shown that a decrease in particle size enhances the ORF. The article presents also the simulation of the effect of the injected fluid temperature on the oil recovery factor. The increase in temperature caused a decrease in the viscosity of the oil and an increase in the recovery factor.
As it was shown above, laboratory experiments and numerical simulations have shown very promising results in the nanofluid-based oil displacement. At the same time, this topic turned out to be so broad that additional research is needed for its in-depth study. In particular, the issue of the effect of initial water saturation on the ORF by nanofluids has not been practically investigated at present. The point is that the injection of nanosuspensions and nanoemulsions should be attributed to the so-called tertiary methods of enhancing oil recovery. This means that before their injection, the oil reservoir has been subjected to conventional flooding for a long time, and thus has already been sufficiently watered. The goal of applying the tertiary methods is to wash out residual oil from the rock. In the above research results, it was shown that flooding of the core with nanosuspensions at zero initial water saturation allows increasing oil recovery by 10–30%. In the present work, for the first time, we proposed to answer the question of how successfully nanosuspensions will cope with an increase in oil recovery at various stages of reservoir flooding. This problem is important for practice since it allows assessing the feasibility of using an injection of nanosuspensions at various stages of field development. From a scientific viewpoint, this problem is also very interesting and differs significantly from those considered earlier. The point is that when oil is displaced by nanosuspension from a core with zero water saturation, we are dealing with the flow of two immiscible fluids (oil and nanosuspension). In case the water is present in a porous medium, the nanofluid mixes with it, thereby changing the concentration of nanoparticles. As was shown earlier, the characteristics of the nanosuspension (viscosity, wettability, and IFT) significantly depend on the concentration, which obviously affects the oil recovery efficiency. There are currently very few works that investigate the flow of two immiscible fluids with changing component concentration in one of them.
Thus, in the present article, systematic studies on the effect of the initial water saturation of the core on the oil displacement efficiency using nanosuspensions were carried out for the first time, based on numerical simulation.
2. Description of the Mathematical Model and Formulation of Simulation
A numerical study of oil displacement from a porous medium using nanosuspensions was carried out in a wide range of initial water saturation. The numerical method was based on the solution of a system of Navier–Stokes equations for a multicomponent incompressible medium. The VOF method was used to describe the immiscible oil–water flow (nanosuspension) in a porous medium [
18]. This model allows simulating an immiscible multicomponent fluid–fluid flow by solving several momentum transfer equations taking into account the volume fraction of each phase.
The density and viscosity of the mixture included in the Navier–Stokes equations are determined as follows:
here
and
are the density and viscosity of oil, respectively, and
and
are the density and viscosity of nanofluids depending on the particle concentration
φ.
The weight conservation equation, in this case, has the standard form:
Here,
is the velocity vector of the mixture, which is determined by solving the momentum equation:
where
p is the static pressure of the mixture and
is the vector of the volumetric force caused by capillary forces.
To simulate the movement of the interface in the course of oil displacement, the following transfer equation is solved:
When oil is displaced from a porous medium, capillary forces are very important. To simulate surface tension, we used the continuous surface force (CSF) algorithm by Brackbill et al. [
19]. In this method, the effects of surface tension are simulated by adding a source to the momentum equation:
where
is IFT,
k is the curvature of the interface, which is determined as:
where
is the vector, normal to the interface, which is determined in the volume of the computational domain as follows:
At the walls of the computational domain, the normal vector is determined using the following expression:
here
is the wetting angle at the wall,
is perpendicular to the wall, and
is directed tangentially to the wall vector.
In computations, we used viscosity
, density
, interfacial tension
, and wetting angle
of the nanosuspension, experimentally measured depending on the concentration φ and nanoparticle size. Experimental data can be found in our recent papers [
20,
21].
To simulate the nanosuspension dilution process during its flow in a porous medium, saturated with water, the equation of nanoparticle concentration transfer (only within the aqueous phase) was additionally introduced:
where
φ is the weight concentration of particles,
D is the diffusion coefficient of nanoparticles.
The diffusion coefficient of nanoparticles in the base fluid was determined from the Einstein–Stokes equation, where
k is Boltzmann constant and
dp is the diameter of nanoparticles:
As shown in [
22,
23] by the molecular dynamics method, the ratio of the Einstein–Stokes equations is quite suitable for describing the diffusion of nanoparticles, only if their sizes are not too small (10–15 nm).
The numerical simulation methodology and the results of its testing are described in detail in the article [
21]. To solve the system of nonlinear differential Equations (3)–(5), the finite-volume method (FVM) was employed. The relationship between the velocity field and pressure was realized using the SIMPLEC algorithm (Semi-Implicit Method for Pressure Linked Equations-Consistent). The PRESTO (PREssure Staggering Option) scheme was used to calculate the continuity balance. An implicit second-order scheme was used to approximate the nonstationary terms of the transfer equations. The second-order central difference scheme was used to approximate the convective terms of the Navier–Stokes equations. To solve the transfer equation for the nanoparticle concentration, a TVD scheme with an HRIC limiter (5) was used.
The possibility of the pore space colmatation by nanoparticles was not taken into account at this stage, which is generally confirmed by the data of numerous experiments.
A two-dimensional model of a porous medium was created for the computational study of the effect of initial water saturation on the oil displacement efficiency. This model was obtained by randomly distributing circles of different diameters in a rectangular computational domain. The length of the computational domain was equal to 4 mm, and height to 2 mm. The permeability and porosity of the computational domain were equal to 52 mD and 30%, respectively. The geometry of the computational domain is shown in
Figure 1.
At the initial moment, the pore space is filled with a mixture of water and oil at different values of water saturation. Water saturation Sw in this case is the ratio of the volume of water to the total volume of the void space. In the computations, the initial water saturation varied widely from 10 to 90%. To form the initial distribution of water and oil, when initializing the computation, the required value of the water phase fraction was set, further, the computation was carried out with a zero inlet velocity until the oil pressure and volume in the computational domain were established. The initial distribution of water and oil in the computational domain obtained in this way was used to calculate oil displacement by water and nanosuspensions. The initial distribution of water (red) and oil for several levels of initial water saturation is shown in
Figure 2. Next, a nanofluid with a given concentration, material, and size of nanoparticles was supplied to the inlet of the computation domain at a given flow rate. The physical properties of nanofluids (density, viscosity, interfacial tension, and wetting angle) were determined from experimental data published in our recent papers [
20,
21]. Displacement fluid velocity was set at the inlet to the computational domain. The no-slip condition was set at the walls of the computational domain. Neumann conditions were set at the outlet from the computational domain. During the simulation, the amount of oil, displaced by the nanofluid, i.e., ORF, and the pressure drop required for pumping of nanofluid were determined.
In the beginning, the effect of the computational grid detailing on the simulation accuracy was studied. Examples of the computational grids used in the computations are shown in
Figure 3. For this, a basic computation option with an initial water saturation of 50% was considered, and computations of the ORF and the pressure drop during displacement by water were carried out. The results of the test computations, presented in
Table 1, show that an increase in the grid detailing was leading to convergence of the results. Thus, a grid consisting of 786,000 nodes was selected for further computations (
Figure 3b).