In situ micro-emulsification during surfactant enhanced oil recovery: A microfluidic study

It is generally believed that the improved efficiency of surfactant enhanced oil recovery (EOR) comes from ultra-low interfacial tension (IFT) between oil and surfactant solution owing to the formation of middle-phase microemulsion. However, hindered visibility in underground porous media prevents direct observation of in situ generation of middle-phase microemulsion during surfactant flooding. Thus, direct visualization of the process is vital, and could clarify its contribution to EOR.

Micro-emulsification of a displacing fluid containing sodium 4-dodecylbenzenesulfonate and alcohol propoxy sulfate with model oil was investigated. Phase diagrams were drawn using salinity scans, and the influence of polymer on emulsification was analyzed. Micro-emulsification was monitored through in situ fluorescent tagging via 2D-microfluidics and ex situ visualization via cryo-electron microscopy and small angle X-ray scattering. Its contribution to the oil recovery factor was quantified by measuring the volume of each phase in the eluates.

On-chip experiments indicated that in situ micro-emulsification occurred when the prescreened surfactant solution flowed in contact with trapped oil. The aqueous phase initially invaded the residual oil, forming a low mobility microemulsion. This microemulsion was then diluted by subsequent displacing fluid, forming a new driving fluid that caused ultra-low IFT in the trapped oil downstream. Under the synergistic effect of micellar solubilization and trapped-oil mobilization, the recovery factor could be increased by up to 40% over waterflooding and 43% on polymer inclusion in the formulation.