Steady-state two-phase relative permeability measurements in proppant-packed rough-walled fractures

Understanding multiphase flow in fractures filled with minerals and proppants is vital in various subsurface applications. Limited experimental data have led to reliance on correlations lacking physical basis. We conducted experiments to characterize relative permeability in rough-walled fractures packed with unconsolidated porous media. We tested fractures packed with water-wet 40/70 sand (silica) and surface-coated ceramic proppants. Brine and mineral oil were used as the wetting and non-wetting fluid phases, respectively. Steady-state (SS) drainage (non-wetting-phase displacing wetting-phase) and imbibition (wetting-phase displacing non-wetting-phase) tests were performed under a wide range of saturation histories (full-cycle and scanning-curves) to study relative permeability hysteresis of the propped fractures. Every SS drainage or imbibition test consisted of several discrete points at which fluid saturations and the corresponding relative permeability were measured by varying the fractional flow rates of fluids whilst maintaining a constant total flow rate. We analyzed residual non-wetting phase saturations and relative permeability trends to understand two-phase flow behavior in each proppant pack. High-resolution x-ray microtomography was used to understand the pore-scale topology, wettability, and to provide insights about the pore-scale displacement mechanisms involved in this study. The results showed that commonly used models to estimate relative permeabilities of fractures significantly overestimated the SS brine and oil relative permeabilities (denoted as k_rw and k_ro) measured in this study. Further analysis unveiled that the k_ro values during imbibition exceeded their drainage counterparts in both proppants, the ceramic proppant exhibited a lower initial water saturation and a higher end-point k_ro permeability at the end of the drainage displacement, as well as higher k_rw across all flooding processes. Updated fitting parameters for a Brooks-Corey-type relative permeability correlation are introduced. This study presents improved insights, extensive experimentally generated relative permeability data, and an updated relative permeability correlation, which can be collectively utilized to reduce uncertainties associated with continuum-scale forecasts of multiphase flow behavior in fractured subsurface formations.