Development of stochastically reconstructed 3D porous media micromodels using additive manufacturing: numerical and experimental validation.

We propose an integrated methodology for the design and fabrication of 3D micromodels that are suitable for the pore-scale study of transport processes in macroporous materials. The micromodels, that bear the pore-scale characteristics of sandstone, such as porosity, mean pore size, etc, are designed following a stochastic reconstruction algorithm that allows for fine-tuning the porosity and the correlation length of the spatial distribution of the solid material. We then construct a series of 3D micromodels at very fine resolution (i.e. 16 µ m) using a state-of-the-art 3D printing infrastructure, specifically a ProJet MJP3600 3D printer, that utilizes the Material Jetting technology. Within the technical constraints of the 3D printer resolution, the fabricated micromodels represent scaled-up replicas of natural sandstones, that are suitable for the study of the scaling between the permeability, the porosity and the mean pore size. The REV- and pore-scale characteristics of the resulting physical micromodels are recovered using a combination of X-ray micro-CT and microfluidic studies. The experimental results are then compared with single-phase flow simulations at pore-scale and geostatistic models in order to determine the effects of the design parameters on the intrinsic permeability and the spatial correlation of the velocity profile. Our numerical and experimental measurements reveal an excellent match between the properties of the designed and fabricated 3D domains, thus demonstrating the robustness of the proposed methodology for the construction of 3D micromodels with fine-tuned and well-controlled pore-scale characteristics. Furthermore, a pore-scale numerical study over a wider range of 3D digital domain realizations reveals a very good match of the measured permeabilities with the predictions of the Kozeny-Carman formulation based on a single control parameter, k 0 , that is found to have a practically constant value for porosities ϕ ≥ 0.2 . This, in turn, enables us to customize the sample size to meet REV constraints, including enlarging pore morphology while considering the Reynolds number. It is also found that at lower porosities there is a significant increase in the fraction of the non-percolating pores, thus leading to different k 0 , as the porosity approaches a numerically determined critical porosity value, ϕ c , where the domain is no longer percolating.

Visual Analysis of Displacement Processes in Porous Media using Spatio-Temporal Flow Graphs.

We developed a new approach comprised of different visualizations for the comparative spatio-temporal analysis of displacement processes in porous media. We aim to analyze and compare ensemble datasets from experiments to gain insight into the influence of different parameters on fluid flow. To capture the displacement of a defending fluid by an invading fluid, we first condense an input image series to a single time map. From this map, we generate a spatio-temporal flow graph covering the whole process. This graph is further simplified to only reflect topological changes in the movement of the invading fluid. Our interactive tools allow the visual analysis of these processes by visualizing the graph structure and the context of the experimental setup, as well as by providing charts for multiple metrics. We apply our approach to analyze and compare ensemble datasets jointly with domain experts, where we vary either fluid properties or the solid structure of the porous medium. We finally report the generated insights from the domain experts and discuss our contribution's advantages, generality, and limitations.

Nonuniqueness of hydrodynamic dispersion revealed using fast 4D synchrotron x-ray imaging.

Experimental and field studies reported a significant discrepancy between the cleanup and contamination time scales, while its cause is not yet addressed. Using high-resolution fast synchrotron x-ray computed tomography, we characterized the solute transport in a fully saturated sand packing for both contamination and cleanup processes at similar hydrodynamic conditions. The discrepancy in the time scales has been demonstrated by the nonuniqueness of hydrodynamic dispersion coefficient versus injection rate (Péclet number). Observations show that in the mixed advection-diffusion regime, the hydrodynamic dispersion coefficient of cleanup is significantly larger than that of the contamination process. This nonuniqueness has been attributed to the concentration-dependent diffusion coefficient during the cocurrent and countercurrent advection and diffusion, present in contamination and cleanup processes. The new findings enhance our fundamental understanding of transport processes and improve our capability to estimate the transport time scales of chemicals or pollution in geological and engineering systems.

Direct characterization of solute transport in unsaturated porous media using fast X-ray synchrotron microtomography.

Solute transport in unsaturated porous materials is a complex process, which exhibits some distinct features differentiating it from transport under saturated conditions. These features emerge mostly due to the different transport time scales at different regions of the flow network, which can be classified into flowing and stagnant regions, predominantly controlled by advection and diffusion, respectively. Under unsaturated conditions, the solute breakthrough curves show early arrivals and very long tails, and this type of transport is usually referred to as non-Fickian. This study directly characterizes transport through an unsaturated porous medium in three spatial dimensions at the resolution of 3.25 µm and the time resolution of 6 s. Using advanced high-speed, high-spatial resolution, synchrotron-based X-ray computed microtomography (sCT) we obtained detailed information on solute transport through a glass bead packing at different saturations. A large experimental dataset (>50 TB) was produced, while imaging the evolution of the solute concentration with time at any given point within the field of view. We show that the fluids' topology has a critical signature on the non-Fickian transport, which yet needs to be included in the Darcy-scale solute transport models. The three-dimensional (3D) results show that the fully mixing assumption at the pore scale is not valid, and even after injection of several pore volumes the concentration field at the pore scale is not uniform. Additionally, results demonstrate that dispersivity is changing with saturation, being twofold larger at the saturation of 0.52 compared to that at the fully saturated domain.

Hydro-dynamic Solute Transport under Two-Phase Flow Conditions.

There are abundant examples of natural, engineering and industrial applications, in which "solute transport" and "mixing" in porous media occur under multiphase flow conditions. Current state-of-the-art understanding and modelling of such processes are established based on flawed and non-representative models. Moreover, there is no direct experimental result to show the true hydrodynamics of transport and mixing under multiphase flow conditions while the saturation topology is being kept constant for a number of flow rates. With the use of a custom-made microscope, and under well-controlled flow boundary conditions, we visualized directly the transport of a tracer in a Reservoir-on-Chip (RoC) micromodel filled with two immiscible fluids. This study provides novel insights into the saturation-dependency of transport and mixing in porous media. To our knowledge, this is the first reported pore-scale experiment in which the saturation topology, relative permeability, and tortuosity were kept constant and transport was studied under different dynamic conditions in a wide range of saturation. The critical role of two-phase hydrodynamic properties on non-Fickian transport and saturation-dependency of dispersion are discussed, which highlight the major flaws in parametrization of existing models.

Critical Role of the Immobile Zone in Non-Fickian Two-Phase Transport: A New Paradigm.

Using a visualization setup, we characterized the solute transport in a micromodel filled with two fluid phases using direct, real-time imaging. By processing the time series of images of solute transport (dispersion) in a two fluid-phase filled micromodel, we directly delineated the change of transport hydrodynamics as a result of fluid-phase occupancy. We found that, in the water saturation range of 0.6-0.8, the macroscopic dispersion coefficient reaches its maximum value and the coefficient was 1 order of magnitude larger than that in single fluid-phase flow in the same micromodel. The experimental results indicate that this non-monotonic, non-Fickian transport is saturation- and flow-rate-dependent. Using real-time visualization of the resident concentration (averaged concentration over a representative elementary volume of the pore network), we directly estimated the hydrodynamically stagnant (immobile) zones and the mass transfer between mobile and immobile zones. We identified (a) the nonlinear contribution of the immobile zones to the non-Fickian transport under transient transport conditions and (b) the non-monotonic fate of immobile zones with respect to saturation under single and two fluid-phase conditions in a micromodel. These two findings highlight the serious flaws in the assumptions of the conventional mobile-immobile model (MIM), which is commonly used to characterize the transport under two fluid-phase conditions.

Reservoir-on-a-chip (ROC): a new paradigm in reservoir engineering.

In this study, we design a microfluidic chip, which represents the pore structure of a naturally occurring oil-bearing reservoir rock. The pore-network has been etched in a silicon substrate and bonded with a glass covering layer to make a complete microfluidic chip, which is termed as 'Reservoir-on-a-chip' (ROC). Here we report, for the first time, the ability to perform traditional waterflooding experiments in a ROC. Oil is kept as the resident phase in the ROC, and waterflooding is performed to displace the oil phase from the network. The flow visualization provides specific information about the presence of the trapped oil phase and the movement of the oil/water interface/meniscus in the network. The recovery curve is extracted based on the measured volume of oil at the outlet of the ROC. We also provide the first indication that this oil-recovery trend realized at chip-level can be correlated to the flooding experiments related to actual reservoir cores. Hence, we have successfully demonstrated that the conceptualized 'Reservoir-on-a-Chip' has the features of a realistic pore-network and in principle is able to perform the necessary flooding experiments that are routinely done in reservoir engineering.