1. Introduction
As human demand for energy has increased, conventional oil and gas resources have been unable to meet people’s demands. Shale oil is an unconventional energy resource with substantial reserves, and the exploration and development of shale oil and gas have garnered significant attention. In a broad sense, shale oil refers to oil and gas resources in organic-rich shale and adjacent non-source rock interlayers. Zou et al. [
1] believe that shale oil constitutes mature oil contained within organic-rich shale formations characterized by nano-scale pore sizes. Organic-rich shale develops a laminar structure, and micrometer and nanometer pores and micro-fractures are the main storage space. Jiang et al. [
2] believe that shale oil refers to the liquid hydrocarbons in a free, dissolved, or adsorbed state in the effective source rock shale, which is the residual retention and accumulation after hydrocarbon generation and shale expulsion. Shale oil flows little or not far from the source rock. Shale oil is characterized by low porosity and low permeability, tight reservoirs, and strong heterogeneity, which often result in a difficult transformation of shale oil during the production process, low oil rate per well, rapid decline of oil rate, and low or no natural production. The production of shale oil depends on the combination of horizontal drilling technology and hydraulic fracturing technology. Horizontal drilling in shale oil reservoirs increases the contact area between the reservoir and the wellbore, thereby increasing productivity and the recovery ratio. Hydraulic fracturing is a method of fracturing rock by injecting fluids at high pressure to increase the flow of reservoir fluid.
During fracturing, shale oil develops complex fracture networks. The hydraulic fractures formed during fracturing intertwined with the original fractures in the shale, and the original fractures are extended to different degrees. Evaluating the conductivity of fractures is very important for the shale oil flowback process. Palmer and Mansoor [
3] incorporated pore compressibility and permeability as functions of effective stress and matrix shrinkage into a single equation, resulting in a widely adopted theoretical permeability model. Schutjens et al. [
4] proposed the relationship between the degree of compaction and the decrease in porosity based on the linear pore elasticity theory of small strain. He proposed that the decrease in permeability of sandstone near the elastic range is primarily dependent on the increase in average effective stress. Legrand et al. [
5] studied the production mechanism of tight oil in Yemen, and the crude oil flow mainly depended on matrix microfractures and fracture channels. The crude oil flows through the matrix microfractures into the fracture channel and is then produced. Lu [
6] established an elastic–plastic deformation model of self-supporting fractures after hydraulic fracturing in deep shale and studied the flow capacity and characteristics of self-supporting fractures. Furthermore, the interaction between fracturing fluid and reservoir rocks and minerals [
7] during the fracturing process leads to alterations in rock wettability, which can significantly impact post-fracturing productivity. The perforation and fracturing operations generate a substantial amount of heat energy, causing an increase in the surrounding wellbore temperature that adversely affects wellbore stability. Wellbore stability and formation thermal conductivity [
8] also play a role in influencing productivity to some extent. However, this paper does not focus on chemical or thermal reactions; instead, it primarily investigates the influence of fracture networks and production strategies on shale oil flowback.
A mathematical model is a method used to study the flowback after fracturing. Fang et al. [
9] developed a shale gas productivity prediction model for multi-stage fractured horizontal wells, which considers the flow of fracture networks, shale matrix compressibility, gas slip, Knudsen diffusion, and surface diffusion. The semi-analytic model is solved using Laplace integral transformation and the point source method. The research results of Du [
10] provide a new perspective for understanding the flow law of shale gas reservoirs with dual media. His non-Darcy flow model takes into account a multitude of complex factors, including adsorption, desorption, and slippage effects, and has a higher degree of accuracy and reliability than the traditional Darcy flow model. Furthermore, his model can be solved by Laplace spatial solutions under different boundary conditions and has been verified by drawing well–test curves. Andersen [
11] developed a shale gas productivity prediction model that considers the compressibility of the shale matrix and solves it using a semi-analytical method. This enables the spatial distribution of pressure, adsorption, porosity, and apparent permeability to be determined at a given time. Gao et al. [
12] developed a mathematical model for the nonlinear flow of shale gas, taking into account the random distribution of non-uniform equivalent porosity and permeability. They proposed a semi-analytical method and an explicit iterative scheme based on the Boltzmann transform and local homogenization approximation. Ren et al. [
13] constructed an unstable flow mathematical model of stagewise fractured horizontal wells in low permeability reservoirs. They solved this model by combining perturbation transform, Laplace transform, and the superposition principle with a semi-analytical method. However, when the mathematical model is used to describe the flow in the shale, the flow mechanism is limited. For the mathematical model of a simple mechanism, it can be solved quickly and has great application value. However, for a complex mechanism, it is often impossible to solve. When a discrete crack is used, the calculation is large, and the time is long. When the equivalent fracture zoning model is employed, the fundamental characteristics of the fracture network cannot be reflected. Furthermore, the fracture distribution is challenging to characterize, the difference in liquid production between the fractures cannot be considered, the yield is evenly divided, and the irregular reconstruction area is difficult to address.
The fracture network structure of a fractured reservoir is complex, and the reservoir contains multi-phase fluids such as oil, water, and gas. The mechanism of flowback stage after fracturing is very complicated. The numerical simulation method can accurately simulate the fracture distribution and multi-phase fluid flow of stage-fractured horizontal Wells, which provides an effective way to study the flowback mechanism and production prediction after fracturing. Clarkson [
14] established a shale gas production model considering adsorption and slippage effects, which is highly applicable to shale reservoirs without fractures. Takuto Sakai et al. [
15] developed a new type of reservoir simulator to predict the flow behavior of shale gas/oil, which can simulate three-dimensional and three-phase flow behavior. The simulator can reproduce the flow of fluid between induced hydraulic fractures and natural fractures. Fan et al. [
16] established a multi-stage fractured horizontal well composite model considering SRV based on the characteristics of low porosity and low permeability in tight oil gas reservoirs and used the finite element method to solve the model. The fluid flow around the hydraulic fracture is divided into five flow states, and the larger the SRV, the shorter the time to reach quasi-steady flow. Zhao et al. [
17] used CMG software to build a single-well productivity model of shale oil fracturing. The fluid model adopted a component model to study and explore the effects of compaction, gas phase non-Darcy effect, and nanoporous fluid phase state on productivity. Through the inversion of reservoir parameters through a historical fitting, the final recovery ratio is predicted. The model does not take into account the stress sensitivity of opened beddings and the threshold pressure gradient in the matrix.
A suitable flowback strategy can enhance the production of shale oil wells. The application of measures such as soaking and controlled pressure flowback has been demonstrated to be an effective means of increasing shale oil production in practice. In a study by LaFollette [
18], multiple linear regression and an enhanced tree model were employed to analyze a range of reservoir quality indicators, well structure, completion, stimulation measures, and production parameters in the Barnett shale gas and Middle Bakken oil areas. The study concluded that the quality of the reservoir is a principal determinant of tight oil production. Wang et al. [
19] developed a dual-medium two-phase flow model of shale reservoirs, which considers the flow mechanism of shale reservoir fluids. The flow behavior throughout the entire cycle of drilling and production is simulated, and the impact of flowback performance, including soaking time and pressure drop rate, on shale oil production is studied. Zhu [
20] conducted a comprehensive investigation into the nine factors that influence shale oil production capacity, utilizing layer system analysis and the entropy weight method. Furthermore, from the perspective of enhancing the energy efficiency of fracturing fluids, he put forth an efficacious system for shale oil production, comprising post-fractured soaking and the regulation of the decline in pressure during the flowback phase. Nevertheless, a transparent system for controlling the rate of pressure decrease and an optimization method for shale oil reservoirs have yet to be established. Karantinos et al. [
21] proposed a coupling model between the wellbore and the reservoir. This model employs the black oil model in the reservoir and multi-phase flow analysis in the wellbore. The model permits the choke size to be altered at different times, and it is possible to study the influence of a choke size management strategy on shale production. This approach is anticipated to assist operators in selecting the optimal choke size, enhancing well performance and efficiency, and reducing the risk of wellbore or completion failure. Bagci et al. [
22] developed a methodology for selecting the optimal choke size following fracturing. The impact of optimized choke size and flowback time on proppant production was demonstrated. The production of proppant was found to decrease with an increase in choke size and flowback period. The results demonstrate that the optimal choke size is contingent upon pressure drop, fluid volume, wellhead pressure, and fracture geometry parameters. Liu [
23] employed the EDFM to construct a discrete fracture model, considered the fracture network formed by real reservoir fracturing and the migration of proppant, proposed three choke systems, studied the changes in fracture conductivity and production under different choke systems, and concluded that radical choke systems lead to a rapid reduction in bottomhole flow pressure and proppant production, thereby reducing fracture conductivity and resulting in a lower recovery ratio. Nevertheless, this model does not sufficiently consider the law within the shale matrix. In general, a realistic choke management analysis is lacking in unconventional reservoirs. At present, scholars have conducted extensive research on mathematical models of multi-phase fluid flow in shale reservoirs, but there is relatively little research on models for flowback period in shale oil reservoirs. Furthermore, numerous scholars have studied the flowback period of shale gas reservoirs [
24] and coalbed methane reservoirs, but almost no research on the optimization and modeling for the flowback stage in shale oil reservoirs has been conducted.
In this paper, based on a case of a shale oil reservoir in Gulong, Daqing, extensive research has been conducted on the flowback performance attributes and factors influencing shale oil reservoirs. The production system for shale oil is reasonably optimized. First, the analysis focuses on the reservoir and fluid properties of the Gulong shale reservoir, and the effect of opened bedding by hydraulic fracturing on flowback is considered. A numerical model of multi-phase flowback of the Gulong shale reservoir was established based on the flow mechanism, including PTPG and stress sensitivity effects. This model was utilized to study the influence of geological parameters, flowback modes, and other factors on the shale oil flowback performance. Second, the effects of different factors (PTPG, matrix permeability, opened bedding permeability, stress sensitivity, fracturing fluid distribution) on the flowback performance of the Gulong shale reservoir were studied. Subsequently, a summary of production data from Daqing Gulong shale oil wells is presented, with nine representative wells selected for analysis. Furthermore, three modes of shale oil flowback are distinguished: the fast–slow mode, the slow–fast–slow mode, and the fast–slow–fast mode. A numerical model is employed to examine the impact of various flowback modes on the flowback performance of shale reservoirs. Finally, the model was optimized from the perspective of the total oil and recovery ratio. The study is of great significance for understanding the flowback performance and for the beneficial development of Gulong shale; scholars seldom focus on shale oil flowback optimization. This article uses numerical simulation methods to optimize the flowback strategy based on typical flowback BHP data. Compared with existing flowback optimization methods, this method can not only guide the flowback strategy of shale oil reservoirs (oil breakthrough time, which is a unique indicator for shale oil development, and recovery rate) but also clarify the pressure propagation range during the flowback and production process.
5. Optimization of Flowback Modes
A reasonable flowback strategy is a crucial factor in the efficient production of shale oil. In the context of oilfield operations, the flowback strategies of shale oil wells are frequently modified through the replacement of different-sized chokes. The study of choke size on shale oil flowback performance is limited to the regulation of the shale oil rate. The varying pipe resistance under different choke sizes leads to different pressure fields, which, in turn, affects the shale oil rate. It is commonly accepted that casing pressure and flowing bottom hole pressure exert a significant influence on oil rate. The bottom hole flow pressure exerts a direct influence on the inflow performance relationship; however, it is typically not feasible to measure this parameter directly in the field. In this chapter, we establish the relationship between the choke size and the casing pressure, and the relationship between the casing pressure and the bottom hole flow pressure (BHP). This allows us to indirectly obtain the link between the choke size and the BHP, which is necessary to achieve a thorough study of the shale oil flowback strategies.
5.1. Flowback Modes for Shale Oil Wells
A selection of oil wells within the Gulong block were subjected to analysis. The study on the parameters of choke size, casing pressure, and BHP revealed that the decreasing rates of casing pressure and BHP vary with choke sizes. Consequently, three shale oil flowback modes are distinguished by the rate of decline in BHP [
34], as shown in
Figure 18.
As shown in
Figure 18a, the fast–slow mode is distinguished by a rapid increase in the choke size during the initial phase, which is then maintained at a constant level. The rate of decline in casing and bottom hole flow pressure is initially rapid, followed by a slower rate of decline. As shown in
Figure 18b, the fast–slow–fast mode is defined by a rapid increase in choke size during the initial phase, followed by a medium choke size in the intermediate stage and a large choke size in the late stage. The rate of decrease in casing and bottom hole flow pressure is initially rapid, then gradual, and finally rapid again. As shown in
Figure 18c, the slow–fast–slow mode is characterized by a gradual increase in the size of the choke throughout the stage. The rate of decline in casing pressure and BHP is initially slow, followed by a period of accelerated decline, and then a subsequent slowdown.
The BHP exerts a direct influence on the inflow performance relationship (IPR). If the BHP is excessive, the production pressure differential will be insufficient, resulting in a reduction in the oil rate. Meanwhile, the bigger production pressure results in a series of problems such as crude oil degassing and reservoir stress sensitivity [
35]. Conversely, if the BHP is insufficient, the production pressure differential will increase. Consequently, the method of controlling BHP is employed to categorize the three flowback modes.
5.2. Optimization Method of Flowback Modes
In this paper, we employed a constructed numerical model to optimize three distinct flowback modes. Due to the inability to directly simulate the oil choke as a variable, we employed the BHP as a control variable and conducted simulations with variable BHP. This implies that control was achieved by modifying the lower limit of the BHP daily. During the simulation, the reservoir and fluid properties parameters were maintained at their original values, and a 1000-day production simulation was conducted. The objective of this study was to evaluate the three different flowback modes based on the total oil. By analyzing and comparing the simulation results, it is possible to determine the ultimate oil production and use this as a criterion for selecting the preferred flowback mode. The optimization process facilitates a more comprehensive understanding of the most suitable flowback strategy, which, in turn, leads to enhanced oil production and improved production efficiency. The parameters in the numerical model are from
Table 2, most of which are oilfield test parameters or experimental results. PVT and other parameters are from
Section 3.3.
5.3. The Impact of Different Flowback Modes
5.3.1. The Impact on Oil Break-through Time
The oil rate curves of the three flowback modes exhibit distinct characteristics, with the primary difference being the oil breakthrough time. The order of oil breakthrough time from shortest to longest is as follows: fast–slow–fast mode, fast–slow mode, slow–fast–slow mode. The oil breakthrough times for the aforementioned flowback modes are 29, 63, and 75 days, respectively. The analysis indicates that the oil breakthrough time is primarily influenced by the BHP at the outset of the flowback period. A more rapid decline in pressure during the initial stages of the flowback period results in a greater pressure gradient within the matrix, which, in turn, leads to a shorter oil breakthrough time.
5.3.2. The Impact on Flowback Performance
As shown in
Figure 19, the decline rate of bottom hole pressure (BHP) during the initial stages of production directly affects the rate of oil increase during that period. Consequently, the decline rate of BHP in the late stage determines the rate of oil decrease during that phase.
In the slow–fast–slow mode, the decline rate of BHP is relatively modest during the initial stages. Furthermore, there is a prolonged period during which no oil is produced. Upon transitioning to the fast stage, the BHP undergoes a pronounced decrease. Consequently, the rate of oil increase is rapid. The time required to reach the production peak is the shortest, and the oil rate peak is the largest. The period of stabilized production is shorter, and the decrease in oil rate is faster after the period of stabilized production.
In the fast–slow mode, the rate of decrease in BHP is considerable during the initial stages. Concomitantly, the oil rate increases at a rapid pace. Subsequently, as the process enters the slow stage, the oil rate increases at a gradual pace, eventually reaching a point of decline. The slower rate of oil decrease is primarily attributable to the elevated BHP at the onset of the slow stage. Furthermore, the bottom hole flow pressure can continue to decrease in the subsequent slow stage, and the oil supply area can be further expanded. The period of stabilized production is lengthy, yet the stable oil rate is the lowest.
The fast–slow–fast mode is characterized by a significant decrease in BHP in the early stages, which facilitates the breakthrough of oil. Subsequently, the oil rate increases at a gradual pace as the well transitions into the slow stage. Upon re-entry into the fast stage, a notable increase in oil rate is observed. The period of stabilized production is relatively brief, yet the stabilized oil rate is high.
A comparison of the water-cut rate curves presented in
Figure 20 reveals notable discrepancies in the water-cut rate during the medium stage. At the outset of the flowback process, the water-cut rate of the slow–fast–slow mode exhibited the most rapid decline, while the water-cut rate of the fast–slow–fast mode exhibited the slowest decline. As the development time progresses, the disparity in water-cut rate between the three modes gradually diminishes. As production progresses, the water-cut rate of the fast–slow mode gradually becomes the largest, although the difference between the rates remains minimal.
Figure 21 indicates that various flowback modes exert a considerable influence on the gas–oil ratio. Given the sensitivity of the dissolved gas–oil ratio to pressure changes, particularly below the bubble point pressure, fluctuations in BHP have a notable impact on the gas–oil ratio. During the initial production phase, the gas–oil ratio of the fast–slow mode exhibits an initial increase, and the time required to maintain a low gas–oil ratio is longer. In the slow phase (200th day), the gas–oil ratio exhibits a rapid increase to a higher level. In the fast–slow–fast mode, the production process commences with a low gas–oil ratio until the fast phase (200th day), at which point the gas–oil ratio rises rapidly to a higher level. In the slow–fast–slow mode, the gas–oil ratio rises rapidly in the fast phase (150th day) and remains at a high level. However, after the 300th day, the gas–oil ratio decreases at a faster rate than in the other two modes. In conclusion, the choice of production system model will have a significant impact on the gas–oil ratio. According to the characteristics of these models, a suitable system model can be selected to control the gas–oil ratio to achieve more efficient production.
5.4. Optimization Results and Discussion
As shown in
Figure 19, the initial production discrepancy between the three flowback modes is considerable. As shown in
Figure 22, the total oil differences between the three flowback modes are the greatest in the initial stages. Over time, the discrepancy in total oil between the three modes diminishes gradually. The fast–slow mode exhibited the greatest total oil on the 1000th day.
As shown in
Figure 23, the three flowback modes were optimized using the total oil and recovery ratio on the 1000th day. The total oil produced by the three flowback modes, namely, fast–slow, slow–fast–slow, and fast–slow–fast, was 9.6211 m
3, 9.4783 m
3, and 9.4331 m
3, respectively. The corresponding recovery ratio of oil was 1.2231%, 1.2050%, and 1.1992%, respectively. From the perspective of the most significant total oil production and the highest recovery ratio, the results of the three flowback modes are as follows: the fast–slow mode is the most optimal, the slow–fast–slow mode is the second most optimal, and the fast–slow–fast mode is the least optimal.
A correlation has been identified between choke size, casing pressure, and BHP, which allows for the derivation of the optimal choke mode among the three modes. The most optimal choke mode is characterized by a rapid increase in choke size in the initial stage, followed by a maintenance of a medium choke size.
In the case of shale, due to its extremely low permeability and significant PTPG in the matrix, the movable oil in shale reservoirs is primarily distributed within the volume containing fractures. Furthermore, within the volume containing fractures, only the oil near the fractures exhibits a superior mobility effect. As oil is recovered near the fractures, the rate of shale oil production begins to decline. The primary focus of production is on the expansion of the oil supply area and the high recovery of crude oil in the vicinity of the fractures.
There is a relationship between oil rate and pressure spread range: the larger the pressure spread range, the higher the oil production. As shown in
Figure 24,
Figure 25 and
Figure 26, the production performance of the three models was evaluated based on the 300th-day and 1000th-day pressure distribution maps. Upon analysis of the pressure distribution maps on the 300th day, it was observed that the pressure spread range exhibited considerable variation across the three production modes, ranging from large to small in the following order: slow–fast–slow, fast–slow, and fast–slow–fast. Conversely, on the 1000th day, the pressure spread range exhibited minimal variation, with the three modes displaying a similar pattern of large to small in the following order: fast–slow, slow–fast–slow, and fast–slow–fast. The range of pressure spread is consistent with the result of oil production.
In slow–fast–slow mode, the initial pressure spread range is the largest, the crude oil production range is the largest, and the initial daily oil rate and total oil are the largest. However, the rapid reduction of BHP leads to the rapid closure of the opened bedding, which, in turn, increases the flow resistance of the opened bedding. A large amount of crude oil degasses, and the oil rate fluctuation is large, which is not conducive to the later crude oil recovery. In the latter stages of production, the pressure spread range is to some extent affected. The late pressure spread range is relatively narrow, the oil supply range is similarly limited, and the oil rate is similarly low.
In fast–slow–fast mode, the initial pressure spread range is the smallest, the crude oil supply range is similarly limited, and the oil rate and total oil are similarly low in the early stages. The initial production is low, which makes the oil rate more stable. In the latter stages of production, a precipitous decline in BHP results in the abrupt closure of previously opened bedding. The pressure spread range is narrow, the oil production range is limited, and the oil rate in the latter stages is minimal.
In the fast–slow mode, the initial pressure spread range is situated between the fast–slow mode and the slow–fast–slow mode. The initial oil rate is lower than that observed in the slow–fast mode, and the degasser phenomenon is less pronounced in the reservoir. The period of stable oil rate is the longest. In the subsequent production phase, the pressure drop spread range is the greatest, during which the oil supply area within the matrix expands effectively and the oil recovery area is also high. In the fast–slow mode, the BHP drops more rapidly in the initial stages. Furthermore, the fracturing fluid can be recovered with minimal delay following the fracturing process. The well proceeded rapidly to the production stage. The oil recovery ratio of the matrix in the vicinity of the fracture is high, and the oil recovery period is prolonged. The stable choke size is conducive to a stable oil rate and the longest stable oil rate period. Consequently, the fast–slow mode has the highest total oil yield.
6. Conclusions
In this paper, an orthogonal fracture grid model suitable for fractured shale oil reservoirs with numerous beddings is established. Additionally, the potential three-phase flow phenomenon of oil, gas, and water during production, as well as PTPG and stress sensitivity, is taken into consideration and solved using numerical simulation methods. Furthermore, the proposed model has been verified through production data from a production well in the Gulong block.
The numerical model established in this paper is utilized to investigate the impact of geological factors, such as PTPG and matrix permeability, and engineering factors, such as the stress sensitivity of opened bedding, the permeability of opened bedding, and the distribution of fracturing fluid within the matrix, on shale oil flowback performance. The findings indicate that the geological factors and engineering factors have a great impact on the shale oil production peak and decline rate. In addition, geological factors and fracturing fluid distribution have an obvious influence on the peak production time, and the PTPG has a significant effect on oil breakthrough time.
According to field data from Daqing Gulong shale oil wells, three types of BHP flowback modes are categorized, and each corresponds to a choke flowback mode. Using the numerical model established in this paper, three types of flowback modes are analyzed and optimized. The results demonstrate that the fast–slow mode has the highest total oil production and oil recovery ratio in 1000 days. The flowback strategy of this well has been optimized, which gradually increases the chock size in the initial stage and then maintains a medium chock size, bringing the most oil production. The optimization method for flowback in this article can be utilized in other production wells in the Gulong block. Meanwhile, for shale oil reservoirs with highly developed beddings, the model and optimization method can also bring higher production and economic benefits.