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

可持续获取能源、水和食物的核心挑战是我们对水、温室气体（如二氧化碳）或碳氢化合物等流体如何流经地下储层岩石孔隙的理解。流体和岩石之间的孔隙尺度相互作用影响地下水污染物的移动、温室气体的安全捕获以及风能和太阳能等可再生资源的能源储存。虽然数学建模是理解这些过程的关键要素，但需要高质量的实验数据来验证数值模型。多孔岩石的非均质性和复杂性对我们进行这些可重复、控制良好的实验的能力提出了重大挑战。目前，使用聚合物和树脂的3D打印透明微流控芯片可以实现储层岩石中流体流动的实验重复性，但它们缺乏天然岩石的全部物理和化学特性。制造这些微流控芯片在技术上仍然困难且耗时，并且需要在洁净室中专门的实验室基础设施。在几个成功的NSERC研究项目的支持下，包括2014-2019年数百万美元的研究项目，随后新批准的NSERC工业研究主席授予Chalaturnyk博士2020-2025年，我们的研究小组（GeopPrint）正在寻求一种新兴的替代方案，以创建用于实验研究的3d打印岩石。2014年为GeoPrint公司购买的MFlex打印机只允许在一种材料（沙子）上设计岩石模拟物。我们研究的下一步发展涉及打印更真实、更复杂的地质标本，并需要打印多种材料来模拟岩石的自然组成。为了实现这一研究路径，RTI要求在M-Flex 3D打印机上安装一种独特的受专利保护的双粉末重涂器（3D打印机的主要组件）。新的复刻器将能够创建储层岩石的多粉末模型，其中两种材料可以同时进行3d打印。据我们所知，Aerosint最先进的双粉末重涂器是唯一能够在一个模型中沉积多种固体的工具，并且与M-Flex兼容。通过探索岩石非均质性（类型、尺寸、几何形状）对流道的控制，新型复刻器的相关研究结果可以更好地将实验模型与数学模型联系起来。该工具将应用于地下储层的可持续开发，而地下储层是清洁能源的关键。3D打印的世界正在迅速变化，为M-Flex系统获得双粉末重涂器将使GeoPrint处于这一研究领域的前沿。它将使我们能够吸引有才华的HQP，并为学术界和工业界提供前所未有的机会，在多材料印刷方面取得创新突破。

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.