Search Results (137)

A multiphase model of hydrothermal liquefaction (HTL) using the computational fluid dynamics coupling discrete element method (CFD-DEM) is used to simulate biocrude oil production from sludge flocs in a continuous stirred tank reactor (CSTR). Additionally, the influence of the agitator speed and the slurry flow rate on dynamic biocrude oil production is investigated through full transient CFD analysis in a scaled-up CSTR study. The kinetics of the HTL mechanism as a function of temperature, pressure, and residence time distribution were employed in the model through a user-defined function (UDF). The multiphysics simulation of the HTL process in a stirred tank reactor using the Lagrangian–Eulerian (LE) approach, along with a standard k-ε turbulence model, integrated HTL kinetics. The simulation accounts for particle–fluid interactions by coupling CFD-derived hydrodynamic fields with discrete particle motion, enabling prediction of individual particle trajectories based on drag, buoyancy, and interphase momentum exchange. The three-phase flow using a compressible non-ideal gas model and multiphase interaction as design requirements increased process efficiency in high-pressure and high-temperature model conditions. Full article

Due to post-cementing hydraulic fracturing and other operational stresses, inadequate mechanical properties or suboptimal design of the cement sheath can lead to tensile failure and microcrack development, compromising both hydrocarbon recovery and well integrity. In this study, three field-deployed cement slurry systems were compared on the basis of their basic mechanical properties such as compressive and tensile strength. Laboratory-scale physical simulations of hydraulic fracturing during shale oil production were conducted, using dynamic permeability as a quantitative indicator of integrity loss. The experimental results show that evaluating only basic mechanical properties is insufficient for cement slurry system design. A more comprehensive mechanical assessment is re-quired. Incorporation of an expansive agent into the cement slurry system can alleviate the damage caused by the microannulus to the interfacial sealing performance of the cement sheath, while adding a toughening agent can alleviate the damage caused by tensile cracks to the sealing performance of the cement sheath matrix. Through this research, a microexpansive and toughened cement slurry system, modified with both expansive and toughening agents, was optimized. The expansive agent and toughening agent can significantly enhance the shear strength, the flexural strength, and the interfacial hydraulic isolation strength of cement stone. Moreover, the expansion agents mitigate the detrimental effects of microannulus generation on the interfacial sealing, while the toughening agents alleviate the damage caused by tensile cracking to the bulk sealing performance of the cement sheath matrix. This system has been successfully implemented in over 100 wells in the GL block of Daqing Oilfield. Field application results show that the proportion of high-quality well sections in the horizontal section reached 88.63%, indicating the system’s high performance in enhancing zonal isolation and cementing quality. Full article

The cement sheath is critical for ensuring the long-term safety and operational efficiency of oil and gas wells. However, complex geological conditions and operational stresses during production can induce cement sheath deterioration and cracking, leading to reduced zonal isolation, diminished hydrocarbon recovery, and elevated operational expenditures. This study investigates the development of a novel microbial self-healing well cement slurry system, employing fly ash as microbial carriers and sustained-release microcapsules encapsulating calcium sources and nutrients. Systematic evaluations were conducted, encompassing microbial viability, cement slurry rheology, fluid loss control, anti-channeling capability, and the mechanical strength, permeability, and microstructural characteristics of set cement stones. Results demonstrated that fly ash outperformed blast furnace slag and nano-silica as a carrier, exhibiting superior microbial loading capacity and viability. Optimal performance was observed with additions of 3% microorganisms and 3% microcapsules to the cement slurry. Microscopic analysis further revealed effective calcium carbonate precipitation within and around micro-pores, indicating a self-healing mechanism. These findings highlight the significant potential of the proposed system to enhance cement sheath integrity through localized self-healing, offering valuable insights for the development of advanced, durable well-cementing materials tailored for challenging downhole environments. Full article

Sustainable deepwater drilling for oil and gas offers significant potential. In this work, we synthesized a nanoscale collapse-prevention agent by grafting didecyldimethylammonium chloride onto spherical nano-silica and characterized it using Fourier-transform infrared spectroscopy, thermogravimetric analysis, zeta-potential, and particle-size measurements, as well as SEM and TEM. Adding 1 wt% of this agent to a bentonite slurry only marginally alters its rheology and maintains acceptable low-temperature flow properties. Microporous-membrane tests show filtrate passing through 200 nm pores drops to 55 mL, demonstrating excellent plugging. Core-immersion studies reveal that shale cores retain integrity with minimal spalling after prolonged exposure. Rolling recovery assays increase shale-cutting recovery to 68%. Wettability tests indicate the water contact angle rises from 17.1° to 90.1°, and capillary rise height falls by roughly 50%, reversing suction to repulsion. Together, these findings support a synergistic plugging–adsorption–hydrophobization mechanism that significantly enhances wellbore stability without compromising low-temperature rheology. This work may guide the design of high-performance collapse-prevention additives for safe, efficient deepwater drilling. Full article

Grouting, as a widely applicable and versatile foundation treatment technology, plays a crucial role in addressing seepage control problems in cover layers due to its flexibility and convenience. The effectiveness of grouting largely depends on slurry diffusion; however, due to the opaque nature of geotechnical media, the diffusion mechanism of slurry in the cover layers remains insufficiently understood. To investigate this, a visual grouting model device was designed and fabricated, and grouting tests were conducted using transparent soil materials to simulate the cover layers. The slurry diffusion patterns and the velocity field within the transparent soil were analyzed. The results show that, based on refractive-index matching, fused quartz sand of specific gradation and white mineral oil were selected as simulation materials for the cover layers. A stable slurry suitable for transparent grouting was also chosen to satisfy visualization requirements. The transparent soil grouting model, integrated with a Digital Image Correlation (DIC) monitoring system, has the advantages of demonstrating simple operation, real-time monitoring, and high precision. These tests verify the feasibility of visualizing slurry diffusion in cover layers. Furthermore, step-pressure grouting tests preliminarily reveal the dynamic mechanism of slurry diffusion. The results suggest that, in the cover layer, the cover layer in this grouting test is mainly splitting grouting, accompanied by compaction grouting. These methods offer new insights and methods for model testing of cover layer grouting mechanisms. Full article

Understanding the rheological properties of fresh cement slurries is essential to maintain optimal pumpability, achieve dependable zonal isolation, and preserve long-term well integrity in oil and gas cementing operations and the 3D printing cement and concrete industry. However, accurately and efficiently modeling the rheological behavior of cement slurries remains challenging due to the complex fluid properties of fresh cement slurries, which exhibit non-Newtonian and thixotropic behavior. Traditional numerical solvers typically require mesh generation and intensive computation, making them less practical for data-scarce, high-dimensional problems. In this study, a physics-informed neural network (PINN)-based framework is developed to solve the governing equations of steady-state cement slurry flow in a tilted channel. The slurry is modeled as a non-Newtonian fluid with viscosity dependent on both the shear rate and particle volume fraction. The PINN-based approach incorporates physical laws into the loss function, offering mesh-free solutions with strong generalization ability. The results show that PINNs accurately capture the trend of velocity and volume fraction profiles under varying material and flow parameters. Compared to conventional solvers, the PINN solution offers a more efficient and flexible alternative for modeling complex rheological behavior in data-limited scenarios. These findings demonstrate the potential of PINNs as a robust tool for cement slurry rheological modeling, particularly in scenarios where traditional solvers are impractical. Future work will focus on enhancing model precision through hybrid learning strategies that incorporate labeled data, potentially enabling real-time predictive modeling for field applications. Full article

Understanding the displacement mechanism of cement slurry in drilling fluid is crucial for enhancing the safety of oil well cementing and mitigating geotechnical risks. This study investigated the oil well cementing process by simulating the displacement of drilling fluid by cement slurry in the annular space between the well casing and the surrounding formations using computational fluid dynamics (CFD). The volume-of-fluid (VOF) method in ANSYS-Fluent was employed to track the interfaces between drilling fluid, spacer fluid, and cement slurry. The study simulated fluid motion during drilling operations in the oil and gas industry, considering both smooth and irregular annular geometries around wells. The results show that the efficiency of cement slurry in displacing drilling fluid is higher in Case-2 (irregular outer walls) than in Case-1 (smooth outer walls). Under various inlet velocity conditions in Case-2, an optimal filling rate was achieved at an inlet velocity of 0.5 m/s. When the inlet velocity of the cement slurry was 0.2 m/s, a higher cement content was observed compared to 0.05 m/s, although some recirculation regions were more likely to form at this velocity. Full article

The aim of this study is to develop a simple and reliable laboratory testing procedure for evaluating the bond strength of cement–formation sheaths that considers cement slurry composition and contamination as well as formation strength and formation surface conditions (roughness and contamination). Additionally, a simple and practical empirical correlation is developed for predicting cement–rock bond strength based on the routine mechanical properties of hard-set cement and formation rock. Cement slurries composed of Yamama cement type 1 and 25% local Saudi sand, in addition to 40% fresh water, are used for all investigations in this study. Oil well cementing is a crucial and essential operation in the drilling and completion of oil and gas wells. Cement is used to protect casing strings, isolate zones for production purposes, and address various hole problems. To effectively perform the cementing process, the cement slurry must be carefully engineered to meet the specific requirements of the reservoir conditions. In oil well cementing, the cement sheath is a crucial component of the wellbore system, responsible for maintaining structural integrity and preventing leakage. Shear bond strength refers to the force required to initiate the movement of cement from the rock formation or movement of the steel casing pipe from the cement sheath. Cement–formation sheath bond strength is a critical issue in the field of petroleum engineering and well cementing. Cement plays a crucial role in sealing the annulus (the space between the casing and the formation) and ensuring the structural integrity of the well. The bond strength between the cement and the surrounding geological formation is key to preventing issues such as fluid migration, gas leaks, and wellbore instability. To achieve the study objectives, sandstone and sandstone–cement composite samples are tested using conventional standard mechanical tests, and the results are used to predict cement–formation sheath bond strength. The utilized tests include uniaxial compression, direct tensile, and indirect tensile (Brazilian) tests. The predicted cement–rock sheath bond strength is compared to the conventional laboratory direct cement–formation sheath strength test outcomes. The results obtained from this study show that the modified uniaxial compression test, when used to evaluate cement–formation shear bond strength using cement–rock composite samples, provides reliable predictions for cement–formation sheath bond strength with an average error of less than 5%. Therefore, modified uniaxial compression testing using cement–rock composite samples can be standardized as a practical laboratory method for evaluating cement–formation sheath bond strength. Alternatively, for a simpler and more reliable prediction of cement–formation sheath bond strength (with an average error of less than 5%), the empirical correlation developed in this study using the standard compressive strength value of hard-set cement and the standard compressive strength value of the formation rock can be employed separately. For the standardization of this methodology, more generalized research should be conducted using other types of oil well cement and formation rocks. Full article

In slurry shield tunneling projects, leakage from floating seals frequently leads to abnormal failures of disc cutters. To investigate the leakage characteristics at the floating seal end faces of the cutters, a numerical method is proposed for analyzing the dynamic leakage behavior of the floating seal end faces, considering the effects of wear. The elastohydrodynamic lubrication problem of the floating seal was addressed using the Reynolds equation and the slicing method, leading to the development of a computational model for the pressure and thickness distribution of the oil film on rough surfaces. Based on the Archard wear equation, a dynamic surface roughness model considering wear was established. Furthermore, a numerical model for dynamic leakage of the floating seal end faces in shield machine cutters, incorporating wear effects, was developed. Simulated friction and wear tests of the floating seal end faces, along with cutter seal leakage experiments, were conducted for validation. The results demonstrate that the dynamic surface roughness model considering wear can effectively predict the roughness evolution of worn surfaces. The trend of the theoretical leakage rate is generally consistent with that of the experimental results, verifying the effectiveness of the proposed model. Full article

Cement bond quality is critical to ensuring the long-term safety and structural integrity of oil and gas wells. However, due to the complex interdependencies among geological conditions, operational parameters, and fluid properties, accurately predicting cement bond quality remains a considerable challenge. To improve the accuracy and practical applicability of cement bond prediction, this study develops an intelligent prediction model. A Wide and Deep neural network architecture is adopted, into which two key parameters of the cement slurry’s power-law rheological model—the consistency coefficient and the flow behavior index—are embedded. A temperature correction mechanism is incorporated by integrating the correction equations directly into the network structure, allowing for a more realistic representation of the cement slurry’s behavior under downhole conditions. The proposed model is designed to simultaneously predict the bonding quality at both the casing–cement sheath and cement sheath–formation interfaces. It is trained on a field dataset comprising 30,000 samples from eight wells in an oilfield in western China. On the test set, the model achieved prediction accuracies of 87.29% and 87.49% at the two interfaces, respectively. Furthermore, field testing conducted during a third-stage cementing operation of a well demonstrated a prediction accuracy of approximately 90%, indicating strong adaptability to real-world engineering conditions. The results demonstrate that the temperature-corrected neural network effectively captures the flow characteristics of the cement slurry. The proposed model meets engineering application requirements and serves as a reliable, data-driven tool for optimizing cementing operations and enhancing well integrity. Full article

The selective separation of aromatics from slurry oil (SLO)—a low-value byproduct of fluid catalytic cracking—remains a major industrial challenge. This study investigates the use of subcritical water (Sub-CW) as a green and tunable solvent to extract aromatics from SLO in a semi-batch system operating at 250–325 °C. At 325 °C and a water-to-oil mass ratio of 6:1, the extract yield reaches 16 wt%, with aromatic hydrocarbons accounting for over 90 wt% of the extract, predominantly composed of 3- to 4-ring polycyclic aromatic hydrocarbons. Comprehensive characterization via simulated distillation, SARA analysis, FT-IR, and ¹H-NMR confirms the selective enrichment of aromatics and effective separation from saturates and asphaltenes. To elucidate the molecular basis of this selectivity, principal component analysis of Hansen solubility parameters was performed. The results revealed a temperature-dependent solubility trend in Sub-CW, whereby the affinity for hydrocarbons follows the order aromatics > cycloalkanes > alkanes. This solubility preference, supported by both experimental data and theoretical analysis, offers new insight into subcritical solvent design and provides a basis for process intensification in SLO valorization. Full article

This paper discusses the thermal and exergy efficiency analysis of the hydrothermal liquefaction (HTL) process, which converts sewage sludge into biocrude oil in a continuous plug–flow reactor using a linear Fresnel solar collector. The investigation focuses on the influence of key operational parameters, including slurry flow rate, temperature, pressure, residence time, and the external heat transfer coefficient, on the overall efficiency of biocrude oil production. A detailed thermodynamic evaluation was conducted using process simulation principles and a kinetic model to assess mass and energy balances within the HTL reaction, considering heat and mass momentum exchange in a multiphase system using UDF. The reactor’s receiver, a copper absorber tube, has a total length of 20 m and is designed in a coiled configuration from the base to enhance heat absorption efficiency. To optimize the thermal performance of biomass conversion in the HTL process, a Computational Fluid Dynamics–Discrete Element Method (CFD-DEM) coupling numerical method approach was employed to investigate improved thermal performance by obtaining a heat source solely through solar energy. This numerical modeling approach allows for an in-depth assessment of heat transfer mechanisms and fluid-particle interactions, ensuring efficient energy utilization and sustainable process development. The findings contribute to advancing solar-driven HTL technologies by maximizing thermal efficiency and minimizing external energy requirements. Full article

Oil sands tailings consist of a combination of sand, fine particles, water, and residual unextracted bitumen in varying ratios. The management of these mine waste tailings is largely influenced by their consolidation behavior. Large strain consolidation testing, such as the multi-step large strain consolidation (MLSC) test, is commonly used to determine consolidation properties but requires considerable time. A benchtop centrifuge (BTC) apparatus was proposed to derive the consolidation parameters of the following three clay-rich oil sands tailings slurries: two samples of high-plasticity fluid fine tailings (FFT) and one of low-plasticity FFT. Comparison with the MLSC tests illustrates that the BTC-derived compressibility data closely matched the MLSC test’s compressibility curve within the BTC stress range. However, the hydraulic conductivity from the BTC test was an order of magnitude higher than that from the MLSC test. The consistency of the BTC method and the validation of scaling laws were confirmed through modeling-of-models tests, showing a consistent average void ratio regardless of the specimen height or gravity scale. The influence of the small radius of the BTC was found to be minimal. The limitations of the BTC in the physical modeling of the consolidation behavior are discussed and their impact on the interpretation of the observed consolidation behavior is addressed. Overall, the BTC test provides a rapid method to gain insight on high-water-content slurries’ large strain consolidation behavior. Full article

Ebullated bed vacuum residue hydrocracking is a well-established technology providing a high conversion level of low-value residue fractions in high-value light fuels. The main challenge in this technology when processing vacuum residues derived from different crude oils is the sediment formation rate that leads to equipment fouling and cycle length shortening. With the severity enhancement, the asphaltenes become more aromatic and less soluble which leads to sediment formation when the difference between solubility parameters of asphaltenes and maltenes goes beyond a threshold value. Although theoretical models have been developed to predict asphaltene precipitation, the great diversity of oils makes it impossible to embrace the full complexity of oil chemistry by any theoretical model making it impractical for using it in all applications. The evaluation of process data of a commercial ebullated bed vacuum residue hydrocracker, properties of different feeds, and product streams by intercriteria and regression analyses enabled us to decipher the reason for hydrocracked oil sediment content rising from 0.06 to 1.15 wt.%. The ICrA identified the presence of statistically meaningful relations between the single variables, while the regression analysis revealed the combination of variables having a statistically meaningful effect on sediment formation rate. In this study, vacuum residues derived from 16 crude oils have been hydrocracked as blends, which also contain fluid catalytic cracking heavy cycle oil and slurry oil (SLO), in a commercial H-Oil plant. It was found that the hydrocracked oil sediment content decreased exponentially with fluid catalytic cracking slurry oil augmentation. It was also established that it increased with the magnification of resin and asphaltene and the reduction in sulfur contents in the H-Oil feed. Full article

This study investigates the effect of incorporating modified calcium carbonate whiskers, treated with tetraethyl orthosilicate (TEOS), to enhance the mechanical properties and sealing integrity of oil well cement under high-temperature and high-pressure (HTHP) conditions. Traditional cement systems are prone to brittleness and cracking under dynamic loads, leading to compromised wellbore sealing performance. Our findings demonstrate that fiber-toughened cement slurry improves the toughness and sealing performance of the cement annulus, maintaining gas tightness and mechanical integrity under cyclic alternating pressures at 150 °C. Specifically, the inclusion of 5% modified whisker fibers improves compressive strength by 24.5% and flexural strength by 43.3% while maintaining stable rheological and thickening properties. These results support the hypothesis that modified whisker fibers enhance the durability and sealing integrity of cement wellbores under extreme conditions, providing a practical solution for challenging cementing applications. Full article