Droplet fragmentation: 3D imaging of a previously unidentified pore-scale process during multiphase flow in porous media

Significance Fluid displacement processes in carbonate rocks are important because they host over 50% of the world's hydrocarbon reserves and are aquifers supplying water to one quarter of the global population. A previously unidentified pore-scale fluid displacement event, droplet fragmentation, is described that occurs during the flow of two immiscible fluids specifically in carbonate rocks. The complex, heterogeneous pore structure of carbonate rocks induces this droplet fragmentation process, which explains the increased recovery of the nonwetting phase from porous carbonates as the wetting phase injection rate is increased. The previously unidentified displacement mechanism has implications for (i) enhanced oil recovery, (ii) remediation of nonaqueous liquid contaminants in aquifers, and (iii) subsurface CO2 storage. Using X-ray computed microtomography, we have visualized and quantified the in situ structure of a trapped nonwetting phase (oil) in a highly heterogeneous carbonate rock after injecting a wetting phase (brine) at low and high capillary numbers. We imaged the process of capillary desaturation in 3D and demonstrated its impacts on the trapped nonwetting phase cluster size distribution. We have identified a previously unidentified pore-scale event during capillary desaturation. This pore-scale event, described as droplet fragmentation of the nonwetting phase, occurs in larger pores. It increases volumetric production of the nonwetting phase after capillary trapping and enlarges the fluid−fluid interface, which can enhance mass transfer between the phases. Droplet fragmentation therefore has implications for a range of multiphase flow processes in natural and engineered porous media with complex heterogeneous pore spaces.