Natural fractures provide the main path for fluid flow in tight oil reservoirs and can control the flow direction in the subsurface. Tight sandstones commonly have intense mechanical anisotropy, which means that fracture development in such tight formations may vary widely with respect to fracture orientations. However, the prediction of the degree of fracture development for each orientation is challenging. Focusing on the tight sandstones of the Chang 4 and 5 Member in the Jiyuan oil field, Ordos Basin, China, a new approach was presented for better prediction of the tectonic fracture occurrence in different directions based on fracture characterization, controlling factor, and formation mechanism analysis. First, fracture types, characteristics, formation time, and controlling factors were determined using data from outcrops, cores, and image logs. Then, triaxial tests were conducted to measure the mechanical parameters of rock samples in different directions that assessed the mechanical anisotropy of the formation and its impact on the development of fracture networks in the basin. Next, finite element numerical simulations of the paleotectonic stress field during fracturing were performed based on the fracture formation mechanism and controlling factors (lithology, bed thickness, sedimentary microfacies, and rock anisotropy). Finally, according to the failure criteria established using the measured mechanical parameters, the failure ratio and strain energy were calculated. These criteria could be employed to predict the fracture occurrence and the degree of development of each fracture network. The simulation predictions in this work are in good agreement with observed data from outcrops, cores, and image logs.

Simplifying fluid-flow physics in conventional reservoirs is convenient by assuming uniform lithology and system-geometry with minimal rock/hydrocarbon interactions. Such simplification restrains mathematical models’ ability to simulate unconventional reservoirs’ actual flow behavior and production performance. Researchers can achieve precise adaption for the physics of fluid flow in porous media if they geometrically characterize the system under study appropriately, and there are minimal interactions indeed. 3D-printed replicas of porous-rock samples obey this criterion. In this work, we used image-processing tools used for creating presentable porous and permeable replicas of different scales and configurations of the petroleum system from lab-scale to field-scale. The workflow of 3D-printed replicas creation is presented for replicas of conventional core samples, naturally and synthetically fractured cores, geological drilling units of multistage fractured horizontal wells, and full-field models, e.g., Norne field in Norway. These samples are ideal for experimentally testing the validity of the analytical or numerical models of oil and gas reservoirs in the laboratory, along with judging the quality of reservoirs’ characterization. These replicas’ ideality of these results from limited uncertainties of the geometry of the system under study and fluid/rock interactions because of the uniform composition. For validation purposes, 3D-printed replicas with different materials and 3D-printing technologies were created based on a reconstructed image-processed CT scan of their original Berea sandstone. These replicas were tested for storage capacity (porosity) and transport capacity (permeability) and compared with their original sample’s capacities. The matched results proved replicas’ ability to be used in oil and gas laboratory experimental research.

Hydraulic fracturing technology requires securing sufficient water resources to access and unlock the pores of unconventional formations. Therefore, successful treatment depends on the fracture fluids, which mainly consist of water-based fluids with a low percentage (around 1%) of chemical additives. However, the oil and gas industry is among the largest freshwater consumers: three to six million gallons of water per well based on the number of fracturing stages. As a result, traditional water resources from subsurface and surface supplies are getting depleted, and freshwater is becoming more difficult to access with higher costs associated with continued demand. For example, operator companies in West Texas face many challenges, including a recent increase from USD 2 to 8 per barrel of freshwater. Also, the transportation of raw water to fracture sites, such as the Bakken shale play, has an environmental impact, with costs of up to USD 5 per barrel, while costs of water disposal range from USD 9 per barrel. This paper aims to investigate produced water as an alternative water-based fluid to several fracture fluids, such as crosslinked, linear gel, and high viscosity friction reducers (HVFRs) to reduce environmental footprints and economic costs. The workflow of this research started with a comprehensive review of extant publications, reports, and case studies to summarize the application of produced water with fracturing fluids in unconventional shale plays, such as the Bakken (North Dakota), Barnett (Texas), Eagle Ford (Texas), Wolfcamp (Texas), Marcellus (Pennsylvania), and Periman Bain (Texas). The critical review begins with explaining the features of produced water, its challenges, and water management options. Furthermore, the different fracturing fluids in a high TDS environment are described using recent lab fluid characterizations of produced water as 10% to 50% of produced water usage at a temperature range between 70 to 210 deg F. Moreover, 2D and 3D pseudo frac simulations are utilized using real field data from the Middle Bakken Formation to construct reliable models to evaluate the feasibility of reused water in shale plays development. The outcomes show that recycling water with high TDS in a high-temperature environment can create a fracture network and proppant transport when high viscosity friction reducers with surfactant (HVFR-PRS) was used. In addition, the result of this critical review is a powerful tool for predicting the future of hydraulic fracturing technology, which might help operator companies reduce costs and develop unconventional wells successfully for a return on their investment. The opportunities and challenges conclusions of water management are provided a survey of future hydraulic fracturing applications in North American shale plays by offering recommendations of environmental and economic impacts. The general guidelines obtained can promote the sustainability of using hydraulic fracturing treatment to produce more oil and gas from unconventional resources without compromising on environmental issues.