Design of water nozzle shape and structure optimization for eccentric injection mandrel in water injection wells

Abstract

AbstractInjection mandrel is one of the key components to control the water injection rate of each layer in the layered injection process in the oilfield. The imbalance between the layers can be changed by an optimized injection mandrel to control the appropriate injection rate. This study introduces an approach to optimize water injection in oilfields, focusing on a new eccentric injection mandrel with adjustable flat nozzles. Firstly, computational fluid dynamics (CFD) simulations were carried out using FLUENT software to model and analyze the flow characteristics of the injection mandrel. The simulation results were validated through experimental comparisons, demonstrating excellent consistency. Secondly, the nozzle shapes were identified and optimized. The semicircle nozzle demonstrating superior regulation performance due to its smallest differential pressure and a robust linear relationship between flow rate and opening degree. Finally, orthogonal tests are designed for three influencing factors of the eccentric injection mandrel: number of injection holes, injection hole diameter, and nozzle shape. The simulation results show that the number of injection holes is 36, the diameter of injection holes is 3.2 mm, and the eccentric injection mandrel has relatively better performance. After optimization, the differential pressure between the inlet and outlet is reduced by 57.14%, and the average shear stress on the fluid is reduced by 3.88%. This innovative methodology, employing CFD simulations and orthogonal tests, offers precise water injection rate control, reducing water wastage, and optimizing energy consumption in water injection systems.