Microwave Heating for Microcrack Core Manufacturing
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Solution Overview
Problem
Current methods for manufacturing big-model low-permeability microcrack cores are complex, costly, and fail to accurately replicate the random patterns of microcracks in reservoir strata, limiting their practicality in simulating oil and gas reservoir development.
Innovation Solution
A method involving baking stones with a thin oil film, mixing with quartz sand and cement, and applying confining pressure to create a cement sample with randomly distributed microcracks, allowing for control over permeability and porosity, using readily available and inexpensive materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional heating methods are used to generate microcracks, then microcracks can be formed, but the heating is uneven and heat energy transmission is slow
Solution Approach 1:
The patent replaces traditional thermal heating methods with microwave heating technology. Microwaves directly energize water molecules within the rock core material, generating heat internally and uniformly throughout the sample volume rather than conducting heat from the surface inward. This substitution of heating mechanism resolves both the uneven heating and slow heat transmission problems of traditional methods.
2Temperature
If microwave heating method is used to generate microcracks, then heating uniformity and speed are improved, but radiation security problems occur if improperly used
Solution Approach 1:
The patent carefully controls microwave heating parameters including power level, heating duration, and frequency to achieve optimal microcrack generation while maintaining safety. By adjusting these parameters, the system generates sufficient thermal energy to create realistic microcracks without exceeding safety thresholds that would cause radiation hazards.
3Shape
If uniform splitting method is used to stimulate microcracks, then the core can be divided into two equal parts, but the crack surface is straight and smooth and does not comply with actual microcrack patterns
Solution Approach 1:
The patent replaces mechanical splitting methods with microwave-induced thermal heating. The microwaves heat the core material internally, causing differential thermal expansion and stress that naturally fractures the material along irregular paths resembling authentic microcracks. This produces realistic crack surfaces with varying orientations and morphologies rather than straight, uniform splits.
4Length of moving object
If sand wire cutting method is used to control crack width, then the crack width can be controlled by adjusting sand wire thickness, but the crack surface pattern does not comply with actual pattern
Solution Approach 1:
The patent replaces the mechanical sand wire cutting method with microwave thermal heating. The microwaves penetrate the core and heat it throughout, creating internal thermal stresses that cause the material to fracture naturally. This process controls crack development through thermal physics rather than mechanical cutting, producing realistic crack patterns while still achieving width control through parameter adjustment.
5Quantity of substance
If triaxial compression method is used to generate multiple cracks, then multiple microcracks can be formed, but many devices are required and the operation method is complicated
Solution Approach 1:
The patent replaces the complex triaxial compression apparatus with a microwave heating system. The microwave generator produces electromagnetic radiation that penetrates the core sample and heats it uniformly throughout. This single device accomplishes what previously required multiple mechanical components and complex loading systems, significantly simplifying the experimental setup while generating multiple realistic microcracks.
6Quantity of substance
If edible oatmeal is used to stimulate microcracks in cement samples, then microcracks can be formed, but the pattern is relatively simplex
Solution Approach 1:
The patent replaces the edible oatmeal inclusion method with microwave thermal heating. Instead of relying on physical inclusions to create simple crack patterns, the microwaves heat the cement matrix internally, generating thermal stresses that produce complex, realistic microcrack networks. This eliminates the need for artificial inclusions and creates naturally occurring fracture patterns.
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
This method enables the cost-effective and simple production of large-scale cores with varied microcrack patterns, effectively simulating the permeability and porosity of carbonate rocks and sandstones, enhancing the realism of oil and gas reservoir simulation experiments.
Implementation Method 1
the microwave heating method can generate the problem of radiation security if it is improperly used
Data Source
AI summary
A manufacturing method of a big-model low-permeability microcrack core includes: (1) determining the size of a microcrack core to be manufactured; (2) placing stones in a baking oven to bake for 24h under 120° C., placing the stones into a mixer, mixing and spraying oil, enabling the oil to seep into the stone, evenly forming a thin oil film on stone's surface; (3) mixing the oil sprayed stone with quartz sand and cement, adding water to mix evenly to obtain cement paste; (4) spreading butter on core mold's inner surface to form a thin butter film, pouring the cement paste into the core mold to obtain a cement sample; (5) loading confining pressure outside the core according to the requirements of porosity and permeability of the mold to adjust a pore permeability value; (6) obtaining the big-model core with microcrack after the cement sample is dried and formed.