Using 3D Printed Reservoir Rock Analogs to Validate Numerical Models

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Canada's natural resource industries access energy sources such as oil sands, coal, bitumen carbonates and shales through in situ processes (e.g. horizontal drilling). During these operations, changes in pressure and temperature affect the earth structures (caprock) that seal and contain the energy sources, which could compromise the safety of the operation and surrounding environment. For example, in 2010, the caprock seal of an operating steam-assisted gravity drainage (SAGD) project on a shallow oil sands reservoir was dramatically ruptured, resulting in a large explosion and the creation of a 75 m x 125 m surface crater in the area. In 2014, another steam extraction-based operation had a breach in the caprock seal, resulting in bitumen seepage to the surface. Energy regulators and industry operators rely on computer simulations/numerical models and field observations to prevent caprock failure. However, current computer models failed to predict these failure cases, highlighting the need to validate and improve existing numerical tools in the laboratory. The proposed research will use novel 3D printing technology to create large-scale synthetic rocks out of sand to study the fundamental geological behaviour of analogue caprock under various high-pressure high-temperature (HPHT) scenarios. Synthetic rocks will be built to specification (i.e. to replicate the caprock's cracks and faults) to ensure the samples are identical to the actual field caprock prior to HPHT testing. Computer model predictions are run simultaneously during the testing. The physical test results are compared to the model's predictions to validate the model's accuracy. From this testing, the maximum operating pressure for the caprock can be determined; this operating pressure dictates what level of pressure is safe during recovery operations as well as the optimal level of pressure to apply to increase resource recovery. The proposed research will enhance the efficient and safe operation of energy recovery projects and assist in improving reservoir surveillance techniques and production optimization activities. University of Alberta (UA) researchers, industry operators and energy regulators will better understand the failure mechanics of caprocks (i.e. the processes that lead to rupturing). UA researchers will also improve existing computer models and/or develop superior models for industry and regulator use to optimize the safe, economic and environmentally sustainable recovery of energy resources in Canada.