The pore sizes of shale and other unconventional plays are of the order of tens of nanometers. Based on the fundamental theory of thermodynamics, several studies have indicated that, in such small pores, phase behavior is affected by the capillary pressure and surface forces and is different from that characterized in PVT cells. No experimental evidence of this phenomenon, however, has been presented in the literature. In this study, we apply nanofluidic devices to visualize phase changes of pure alkane and an alkane mixture under nanoconfinement as a means to approach oil/gas phase behaviors in nanoporous rocks. Pure alkane starts vaporizing in the micro-channels first, and then the meniscus flashes into the nanochannels immediately after the complete vaporization of the liquid in the micro-channels. The vaporization of the ternary hydrocarbon mixture, however, is very different from pure alkane. Although the liquid starts to vaporize in the microchannels first, as expected, the meniscus cannot propagate into the nano-channels in a comparable time scale as the pure alkane. The reason is that the liberation of lighter components from the liquid phase to the gas phase in the micro-channels increases the apparent molecular weight of the liquid in the nano-channels, suppressing the bubble point of the remaining fluid. A modified flash calculation procedure that uses the sizes of micro-channels and nano-channels as the characteristic lengths and assumed contact angle can reproduce the vaporization propagation sequence in the experimental observations. Experiments and modeling presented in this paper provide the proof of the concept and promote the understanding of phase behavior in nanoporous unconventional reservoirs.

Proper application of surfactants during hydraulic fracturing operations not only enhances initial production of a reservoir, but also helps sustain its long-term production. The most commonly used surfactant for low-permeability reservoirs is a non-emulsifying surfactant (NES). This study shows that a weakly emulsifying surfactant (WES) is better in solubilizing oil globules via self-association, and appears to be more efficient at mobilizing oil through tight pore throats than NES. The fundamental difference between these two surfactant types was found to be the emulsion tendency. The performance of the two surfactants was compared using a microfluidic based Rock-on-a-Chip (ROC) device with pore sizes comparable to shale formation rocks. The ROC allowed direct visualization of oil recovery by surfactants with controlled pore geometries and surface chemistry. Results showed that the WES yielded higher oil recovery efficiency at equal driving pressure compared to a non-surfactant-bearing control fluid and the NES. As a result of the laboratory testing indications, a multiple well trial program was conducted in two separate areas of the Eagle Ford shale. Early production results suggest that wells treated with the WES exhibited enhanced productivity compared to those treated with the NES.

For liquids-rich shale plays, surfactants have proven to be a critical component in hydraulic fracturing fluid systems for enabling enhanced oil and gas recovery. The industry's most commonly used surfactant is a non-emulsifying surfactant (NES), but it has been previously demonstrated that a weakly emulsifying surfactant (WES) appears to be more efficient at mobilizing oil through tight pore throats. In this study, fundamental differences between those two surfactant types were further demonstrated using a Reservoir-on-a-Chip (ROC) approach, which allows direct visualization of oil recovery with the various surfactant fluids, allowing for the testing on both homogenous and heterogeneous pore structures with various geometries. The laboratory testing showed that, compared to a non-surfactant-bearing control fluid and the NES, the WES showed higher oil recovery efficiency at equal driving pressure. As a result of the laboratory testing indications, a multiple well trial program was conducted in two separate areas of the Eagle Ford shale. Production data from the wells stimulated using a WES-bearing fracturing fluid were normalized in terms of lateral lengths and fracturing stages, and compared to the offset wells stimulated using a NES-bearing fracturing fluid. Early production results suggest that wells treated with the WES exhibited enhanced productivity compared to those treated with the NES.

Inductive wear debris sensor has been widely used in real time machine lubricant oil condition monitoring and fault forecasting. However, the small sensing zone, which is designed for high sensitivity, of the existing sensors leads to low throughput. In order to improve the throughput, a novel multichannel wear debris sensor that is based on phase division multiplexing is presented. By introducing the phase shift circuit into the system, multiple sensing coils could work at different initial phases. Multiple signals of sensing coils could be combined into one output without information loss. Synchronized sampling is used for data recording, and output signals of multiple sensing coils are extracted from the recorded data. A four-channel wear debris sensor system was designed to demonstrate our method. Subsequently, crosstalk analysis, pseudo-dynamic testing and dynamic testing were conducted to check the sensing system. Results show that signals of four sensing coils could be simultaneously detected and the detection limit for ferrous wear debris is 33 μm. Using the presented method, real time wear debris detection in multiple channels could be achieved without increasing the number of excitation source and data acquisition equipment.

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