The energy transition demands innovative solutions for efficient and sustainable oil and gas production, particularly for heavy and extra-heavy crude. A significant challenge in these operations is the excessive production of water, which increases operational costs and environmental impact. This paper reviews the application of mechanical water control devices to optimize water management in heavy oil fields. By analyzing over 3140 documents, only a final total of 42 previous peer-reviewed articles were considered, where 58% sought to understand and optimize water flow from the reservoir to the well mainly by well simulation; 19% studied the implementation cases in the fields, highlighting the success cases; 16% mentioned CFD and other simulations tools; and 7% are related to these devices. While simulation studies have been widely employed, there is a need for more comprehensive field implementations and data-driven insights. This paper aims to contribute to the advancement of water management techniques, ultimately enhancing the sustainability and profitability of heavy oil production, emphasizing the most significant findings.

The challenge of excess water production in mature heavy oil reservoirs presents significant environmental and economic concerns. This study evaluates the effectiveness of inflow control devices (ICDs) and autonomous inflow control devices (AICDs) for managing water production in heavy oil reservoirs with strong aquifer drives. Our investigation comprises two field implementations and a computational fluid dynamics (CFD) study. In the first field implementation, both ICDs and AICDs achieved substantial water reduction (25% and 32%, respectively) compared to conventional slotted liner completions, with ICDs demonstrating superior oil production performance, extending well life by approximately 30% and doubling accumulated oil. The second field implementation featured rate-controlled production (RCP) devices, showing that two AICD wells together produced 60% more accumulated oil and 40% less water than a single conventional well, effectively relieving surface facility bottlenecks. Full 3D Navier–Stokes simulations for a third field implementation revealed that passive ICDs outperformed AICDs under specific draw-down and spacing conditions, challenging the industry preference for newer technologies. The study’s findings, which include quantifiable reductions in the carbon footprint associated with decreased power consumption, provide valuable insights for operators seeking to optimize water management while minimizing environmental impact, advancing the sustainable oil production practices aligned with UN Sustainable Development Goals 7 (Affordable and Clean Energy), 9 (Industry, Innovation and Infrastructure), and 13 (Climate Action).