Coupled Modeling of Computational Fluid Dynamics and Granular Mechanics of Sand Production in Multiple Fluid Flow

Sand production is a significant issue in oil and gas fields with poorly consolidated formations, often involving the multiphase flow of reservoir fluids and solid particles. The multiscale mechanisms of sand production, particularly fluid flow and particle movement, remain poorly understood. This study investigates these mechanisms using a coupled computational fluid dynamics and discrete element method (CFD-DEM) modeling approach. Single and multiple fluid flows of water and heavy oil were simulated with increasing fluid injection velocities, leading to different sand production patterns. The simulation results were compared with experimental results from a large cylindrical specimen of weak artificial sandstone under similar loading conditions. The multiphase conditions created various localized flow and deformation patterns that influenced both fluid and solid production, resulting in shorter transient sand production periods. Microstructures and phenomena such as fingering and water coning were observed, associated with a critical flow rate below which oil displacement was uniform and no water breakthrough occurred. Higher fluid injection velocities and fluid viscosities resulted in greater drag forces, leading to progressive damage zones and explaining the occurrence of single or multiple staged sand production events. The evolution of the microscopic granular structure was visualized under the effect of transient sand production.