The geomechanical and transport properties of rocks are of great importance to geoscience and engineering, as these properties provide responses to external stresses and flow regimes in the subsurface. Typically, experiments conducted on cores from reservoir formations have a degree of uncertainty, due to the heterogeneous characteristics of rock samples. To combat this uncertainty, binder-jet additive manufacturing (3D printing) is an emerging technology to characterize natural porous media in a repeatable fashion. In this study, the 3D printing sandstone analogue involved sand powder and organic binder to mimic silica grains and cement in natural sandstone. The use of compaction rollers and the adjustment of printing parameters allowed one to test how the porosity and strength of 3D-printed samples can replicate the transport and geomechanical properties of natural sandstone. The densities of samples were increased by ~15% and compressive strength by ~65% with the use of the larger roller. This is a promising alternative to experimental testing to calibrate numerical models in geoscience and engineering. The significance of this approach is to allow for customizable porosity, permeability, and strength in rock samples, while preserving scarce natural rock samples.

Natural rocks are highly heterogeneous due to various geological processes that constantly alter their properties. The accumulation, deposition, and cementation of mineral and organic particles continuously modify the spatial characteristics of rock properties. Property variability or anisotropy is commonly observed in most rock types and influences strength, transport, and thermal conductivity behavior. This unpredictability presents a significant challenge for laboratory testing. Binder-jet additive manufacturing (3D printing) has emerged as a valuable technology for characterizing rock properties in geoscience and engineering. This study proposes a novel methodology to evaluate the variability and repeatability of mechanical properties of 3D-printed sandstones during binder-jet additive manufacturing. The mechanical properties were analyzed statistically for samples located in various parts of the 3D printer build volume. The results showed that the 3D-printed sandstones exhibited significant variations in their strength and stiffness properties when measured from samples produced within the same build volume during binder-jet additive manufacturing. The uniaxial compressive strength (UCS) varied from 23 to 38 MPa, with an average value of 29 MPa. Young’s modulus, on the other hand, ranged from 1.5 to 4.05 GPa, with an average value of 2.33 GPa. The variability of the mechanical properties, quantified by the standard deviation, decreased when the entire population of 3D-printed sandstones was divided into smaller samples situated at different elevations of the build platform. These findings offer valuable insights into improving the reliability and predictability of 3D-printed sandstone properties, a critical factor for various applications in fields like petroleum engineering and construction.

Natural rocks can be heterogeneous due to complex diagenetic processes that affect mineralogy and pore architecture. Correlation of geomechanical and transport properties of rocks in three dimensions can lead to large variances in data when tested experimentally. 3D-printing of rock analogues in sand is a promising alternative for experimental testing that can be used to calibrate variables during geotechnical testing. While 3D-printed sand is a homogeneous material, the parameters for creating grain packing and pore infill can be tuned to mimic specific geomechanical and transport properties. Initially, 3D-printed specimens have a low density due to a loose distribution of grains. Herein, we present our efforts at increasing the density through incorporating a roller in the printing process to compact individual layers. We also propose introduction of a more heterogeneous sand mixture that encompasses a wide range of grain-size distributions. Lastly, a discussion between binder saturation (that infills the pore space) of 3D-printed specimens and the axial strength, dimensional control, and porosity is described within. 3D printing of rock analogues is critical in pursuing rigorous destructive tests required for geotechnical and geological engineering because it can provide repeatable, controlled data on rock properties.

Natural rocks are highly heterogeneous due to various geological processes that constantly alter their properties. The accumulation, deposition, and cementation of mineral and organic particles continuously modify the spatial characteristics of rock properties. Property variability or anisotropy is commonly observed in most rock types and influences strength, transport, and thermal conductivity behavior. This unpredictability presents a significant challenge for laboratory testing. Binder-jet additive manufacturing (3D printing) has emerged as a valuable technology for characterizing rock properties in geoscience and engineering. This study proposes a methodology to evaluate the variability and repeatability of mechanical properties of 3D-printed sandstones during binder-jet additive manufacturing. The mechanical properties were analyzed statistically for samples located in various parts of the 3D printer build volume. The results showed that the 3D-printed sandstones exhibited significant variations in their strength and stiffness properties when measured from samples produced within the same build volume during binder-jet additive manufacturing. The Uniaxial Compressive Strength (UCS) varied from 23 to 38 MPa, with an average value of 29 MPa. The Young's modulus, on the other hand, ranged from 1.5 to 4.05 GPa, with an average value of 2.33 GPa. The variability of the mechanical properties, quantified by the standard deviation, decreased when the entire population of 3D-printed sandstones was divided into smaller samples situated at different elevations of the build platform.

Transient hydraulics always characterizes the circulating flow during managed pressure drilling. Therefore, the application of the Godunov scheme to oil-well drilling hydraulics is presented. The numerical model developed describes the treatment process of the initial and boundary conditions from the well geometry and true operational conditions. The well-known finite-volume method and Riemann problem are utilized for building the set of discrete equations. The account of Godunov’s simulation describes the profiles of transient pressure and transient flow rate along the well. For attending the oil-field engineering concerns, the drilling parameters discussed are as follows: choke pressure, pumping pressure, bottom-hole pressure, and circulating flow rate. After the comparison between computed and well data, the results show a small difference of less than 7 and 1 % for pumping and bottom-hole pressures, respectively. The main engineering contribution of this work is the solution and application of the first-order Godunov scheme to analyze the transient hydraulics during actual oil-well drilling and also the analysis and interpretation of the pressure wave behavior traveling along the well. The Godunov scheme has high-potential engineering applications for modeling the transient drilling hydraulics, i.e., controlled flow, underbalanced drilling, and foam cementing, as well.

A new application of the Godunov scheme to describe dynamic oil-well behavior is presented. The numerical model is able to capture discontinuities associated with surface flow-rate variations. The finite volume method and Riemann problems are utilized for building the unsteady discrete solution. Initial and boundary conditions are related to cases of static, steady and transient well condition. Well data used in simulation are taken from true operational conditions and well mechanical configuration. The results of Godunov’s modeling describe the behavior of transient pressure and transient flow rate inside drill pipe and annulus. These profiles are commonly caused by turning on, adjusting mud flow rate and turning off the rig pumps. The evaluated rig indicators are: back pressure, pumping pressure, bottomhole pressure and injected flow rate. Calculated transient profiles are physically consistent and in good agreement with published well data. Therefore, engineering contribution is the application of first-order Godunov method to evaluate the transient hydraulics whereas variations of mud flow rate; also, the analysis and interpretation of the dynamic pressure behavior travelling inside the well. The Godunov scheme has robust engineering applications for modeling the transient drilling hydraulics, e.g., managed pressure drilling, hydraulics of pipe connections, and foam cementing, as well.