Enhancing filter cake removal by engineering parameter optimization for clean development of fossil hydrogen energy: A numerical simulation

Abstract

Long-term zonal isolation is crucial for the development of fossil hydrogen energy, while efficient filter cake removal is the basis for successful zonal isolation. However, enhanced filter cake removal usually relies on adding chemicals into preflush fluid, which are potential pollutants to the environment. In this study, engineering parameter optimization is used to realize enhanced filter cake removal. Firstly, filter cake removal was identified as multiple-phase fluid flow, and a new three-fluid numerical model was established accordingly. The effects of five engineering parameters on the removal efficiency were simulated and the results showed that borehole enlargement and casing eccentricity reduced removal efficiency. The critical borehole deviation angle and casing rotation speed for optimal removal efficiency were 45° and 40 rpm, respectively, while the removal efficiency monotonously increased with flushing velocity. After all engineering parameters were optimized, the maximum removal efficiency was as high as 89.34%, which was comparable to that achieved by using potentially polluting chemicals. The borehole enlargement rate was identified as the most sensitive parameter, followed by casing eccentricity, flushing velocity, borehole deviation angle, and casing rotation speed subsequently. Two empirical models to predict removal efficiency were developed for convenient field application. Briefly, the complex removal behaviors of the filter cake are better understood for reducing the risks of failed zonal isolation and avoiding chemical overuse, which potentially contributes to the cleaner and more environment-friendly production of fossil hydrogen energy.