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

Area of Science:

• Petroleum Engineering
• Geoscience
• Additive Manufacturing

Background:

• Conventional reservoir modeling simplifies physics, limiting accuracy for unconventional reservoirs.
• Accurate fluid flow simulation requires precise geometric characterization and minimal rock-fluid interactions.
• 3D-printed porous rock replicas offer a solution by providing geometrically accurate models with uniform composition.

Purpose of the Study:

• To present a workflow for creating 3D-printed porous rock replicas for diverse petroleum system scales.
• To demonstrate the utility of these replicas for experimental validation of reservoir models.
• To validate the accuracy of 3D-printed replicas by comparing their properties to original rock samples.

Main Methods:

• Utilized image-processing tools to generate porous and permeable 3D-printed replicas.
• Created replicas representing various scales and configurations: core samples, fractured cores, wellbore sections, and full-field models.
• Fabricated replicas using different materials and 3D-printing technologies based on CT scans of Berea sandstone.

Main Results:

• Successfully created 3D-printed replicas of conventional cores, fractured cores, and geological drilling units.
• Validated replica accuracy by testing porosity and permeability, showing matched results with original Berea sandstone samples.
• Demonstrated that 3D-printed replicas can be effectively used in laboratory experimental research for oil and gas reservoirs.

Conclusions:

• 3D-printed porous rock replicas provide a reliable method for studying fluid flow in petroleum reservoirs.
• These replicas minimize uncertainties related to system geometry and fluid/rock interactions, enhancing experimental validity.
• The developed workflow enables the creation of accurate, lab-scale to field-scale models for advancing reservoir characterization and simulation techniques.