Multi-material 3D printing of reservoir rock analogues for sustainable energy recovery and storage

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Central to the challenge of sustainable access to energy, water, and food is our understanding of how fluids such as water, greenhouse gases (e.g. CO2), or hydrocarbons flow through the pores of subsurface reservoir rocks. Pore-scale interactions between fluids and rocks influence the movement of groundwater contaminants, safe capture of greenhouse gases, and energy storage from renewable resources such as wind and solar. While mathematical modelling forms a key element of understanding these processes, high-quality experimental data are required to validate numerical models. Heterogeneity and complexity of porous rocks impose significant challenges in our ability to conduct these repeatable, well-controlled experiments. Experimental repeatability in fluid flow through reservoir rocks is currently approached with 3D printing transparent microfluidic chips using polymers and resins, but they lack a full spectrum of physical and chemical properties of natural rocks. Generating these microfluidic chips remains technically difficult and time-consuming, and it requires specialized laboratory infrastructure in a clean room. Supported by several successful NSERC research programs including a multi-million dollar research program from 2014-2019, followed by a newly approved NSERC Industrial Research Chair awarded to Dr. Chalaturnyk for 2020-2025, our research group (GeopPrint) is pursuing an emerging alternative to the creation of 3D-printed rocks that are employed in experimental studies. The MFlex printer purchased for GeoPrint in 2014 allows for designing rock analogues in one material only (sand). The next evolution in our research involves printing more realistic, complex geological specimens and requires the capability to print multiple materials to simulate natural composition of rocks. To enable this research path, an RTI request is for a unique patent-protected dual-powder recoater (a major component of the 3D printer) that would be installed on the M-Flex 3D printer. The new recoater will enable creation of multi-powder models of reservoir rocks, where two materials may be 3D-printed simultaneously. To our knowledge, this state-of-the-art dual-powder recoater from Aerosint is the only tool capable of depositing multiple solids in one model that would be compatible with the M-Flex. Results of the related research with a new recoater could better connect experimental and mathematical models by exploring controls of rock heterogeneities (type, size, geometry) on flow paths. This tool will have applications in the sustainable development of subsurface reservoirs that are key for cleaner energy sources. The world of 3D printing is changing quickly, and the acquisition of the dual-powder recoater for the M-Flex system will place GeoPrint at the forefront of this research area. It will allow us to attract talented HQP's and provide an unprecedented opportunity for academics and industry to forge innovative breakthroughs in multi-material printing.