Artificial Core Preparation Using Quartz Sand and Epoxy Resin
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Solution Overview
Problem
Current methods for preparing artificial cores in petroleum geological exploration fail to accurately simulate natural rock cores due to inappropriate control over porosity and hardness, leading to inconsistent results and low efficiency in experimental research.
Innovation Solution
A method involving the use of quartz sand with different grain sizes, epoxy resin, and clay minerals, where the sand is agitated in a three-dimensional rotational manner to ensure consistent porosity and permeability, and a specific cementing agent is prepared to achieve uniformity and simulate natural rock core properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional artificial core methods (quartz sand and epoxy resin cemented core, quartz sand filled core, quartz sand and aluminum phosphate cemented core) are used, then the artificial core can be manufactured with controlled porosity and hardness, but the artificial core fails to accurately simulate natural rock core properties due to inappropriate control on porosity and hardness
Solution Approach 1:
The patent applies parameter changes by systematically adjusting multiple parameters including quartz sand particle size distribution (using four different mesh sizes: 20-40, 40-60, 60-80, 80-100 mesh), epoxy resin content (10-20% by weight), curing agent content (2-5% by weight), and mixing ratios to achieve optimal porosity (20-40%) and hardness that accurately simulate natural rock core properties. This multi-parameter optimization resolves the contradiction between manufacturing control and simulation accuracy.
Solution Approach 2:
The patent uses composite materials by combining quartz sand (with specific particle size distribution), epoxy resin, curing agent, and optional clay minerals (5-15% by weight) to create an artificial core material that replicates the complex structure and properties of natural rock. The composite nature of this mixture enables simultaneous control over porosity, hardness, permeability, and other critical properties, thereby improving both manufacturing precision and simulation reliability.
2Ease of operation
If manual mixing and agitation of quartz sand is performed, then the preparation process is simple and easy to operate, but the porosity and permeability values of artificial core are inconsistent due to nonuniform agitation
Solution Approach 1:
The patent transitions from manual two-dimensional mixing to three-dimensional rotational agitation using a specialized apparatus. The agitation device rotates the mold in multiple directions (horizontal rotation at 10-20 rpm and vertical rotation at 5-10 rpm), creating comprehensive three-dimensional mixing that ensures uniform distribution of quartz sand particles and epoxy resin throughout the mold, thereby achieving consistent porosity and permeability while maintaining operational simplicity.
Solution Approach 2:
The patent replaces manual mixing mechanics with a mechanical agitation system that provides controlled, repeatable three-dimensional rotation. This mechanical substitution eliminates the variability and inconsistency of manual mixing while maintaining ease of operation through automated rotation at specified speeds, thereby improving manufacturing precision without sacrificing operational simplicity.
3Reliability
If natural rock core is used for experimental testing, then the physical properties realistically reflect underground oil and gas reservoir, but the cost of underground coring is high and experimental repeatability is poor
Solution Approach 1:
The patent creates accurate copies of natural rock core by synthesizing artificial core materials that replicate the pore structure, permeability, and physical properties of natural rock. The artificial core serves as a cost-effective copy that maintains the essential characteristics needed for realistic simulation of underground oil and gas reservoir conditions, thereby improving experimental productivity while preserving reliability.
Solution Approach 2:
The patent optimizes parameters such as quartz sand particle size distribution, epoxy resin content, and clay mineral addition to match the physical properties of natural rock core. By carefully adjusting these parameters, the artificial core achieves realistic permeability (0.1-10 μm²), porosity (20-40%), and hardness that reflect underground reservoir conditions, enabling reliable experiments at lower cost and with higher repeatability.
4Manufacturing precision
If benchmark sand with quartz sand of different particle sizes is used, then the pore diameter can reach micron level, but the artificial core greatly differs from natural rock core due to inappropriate control on porosity and hardness
Solution Approach 1:
The patent applies local quality by using a multi-size particle distribution where different mesh sizes (20-40, 40-60, 60-80, 80-100 mesh) serve different functions: coarser particles provide structural framework while finer particles fill voids to create appropriate porosity. This localized functional assignment within the composite material enables simultaneous achievement of micron-level pore diameter control and natural rock-like porosity (20-40%), resolving the contradiction between manufacturing precision and reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method produces artificial cores with consistent hardness and permeability, closer to natural rock cores, enhancing the scientific and practicality of simulation experiments and improving experimental efficiency.
Implementation Method 1
cementing agent comprising quartz sand, epoxy resin and a curing agent
Implementation Method 2
agitated in a three-dimensional rotational manner to ensure consistent porosity and permeability
Implementation Method 3
pouring the cementing agent into a mold to gain an artificial core
Data Source
AI summary
The present disclosure provides a method and device for preparing an artificial core for petroleum geological exploration. The method includes: step 1, establishing a relation curve between a median grain diameter of quartz sand and a permeability, determining a type and a usage amount of epoxy resin, and preparing a cementing agent according to a principle that the epoxy resin has a direct ratio with a specific surface; step 2, based on a method of controlling a core permeability, preparing benchmark sand with quartz sand of different grain sizes in a certain ratio, fabricating a low-permeability core by adjusting a ratio of the benchmark sand to fine sand, and fabricating a high-permeability core by adjusting a ratio of the benchmark sand to coarse sand; step 3, separately and proportionally weighing quartz sand of different grain diameters and putting them into a magnetic tray, manually mixing and agitating for later use.