A new technology is transforming the study of oil extraction processes in Brazil. By utilizing microfluidic devices and 3D printing, researchers are creating laboratory simulations that replicate, on a reduced scale, the complex conditions of oil reservoirs. The project, funded by Petrobras, is conducted within the Center for Energy and Petroleum Studies (CEPETRO) at the University of Campinas (Unicamp), under the technical coordination of the Institute of Chemistry (IQ/Unicamp) and the startup Polaris, based in Unicamp's Science and Technology Park, with support from Inova Unicamp.

The major innovation lies in the miniaturization of tests, allowing rapid and representative laboratory simulations of the interaction and partitioning processes of organic acids in multiphase systems of water, oil, rock, and CO₂. While conventional reservoir simulation methods require large volumes of oil, water, and rock samples, the new technology enables these tests to be conducted with volumes hundreds of times smaller. "Our goal is to understand how the presence of CO₂ and the chemical composition of reservoirs influence the distribution of organic acids, as well as to investigate the impact of these processes on well productivity," says Leandro Wang Hantao, the research coordinator.

Economic Advantages

With the microfluidic device technology developed by Polaris, operational costs for simulating fluid-rock interactions under reservoir conditions are significantly reduced. Unlike conventional tests that require large sample volumes, microfluidics allows the use of minimal amounts of fluids.

Additionally, the technology demands less energy to maintain experimental conditions, making the process more efficient, economical, and sustainable. The innovative approach uses devices that operate with microliters of samples and can be rapidly produced from specific resins developed by the startup. "Our approach significantly reduces the consumption of reagents and materials, as well as minimizes waste generation during experiments," explains Reverson Fernandes Quero, CEO of Polaris. "This results in substantial savings, enabling studies to be conducted more swiftly and with less environmental impact."

Precise Replication

A key differentiator of the project is the ability to accurately reproduce the physical and chemical characteristics of oil reservoir rocks. The 3D-printed devices by Polaris can simulate properties such as porosity and permeability found in real geological formations. "We can create devices that mimic the characteristics of specific rocks, such as the mineralogical composition present in reservoirs, allowing laboratory tests to closely approximate actual reservoir conditions," Quero explains.

This detailed simulation capability not only contributes to a better understanding of oil extraction processes but also offers an agile alternative for testing different CO₂ and water injection conditions. "Before implementing any field intervention, we can test in the laboratory how changes in fluid composition, such as reinjection water, impact oil exploration," adds Hantao.

Pioneering Technology

The technology being developed in the project is the first of its kind in Brazil and stands out globally for creating customized resins to simulate reservoirs on a microscale.

"Commercially available resins and chips cannot meet the specificities of our projects, which involve severe conditions of pressure, temperature, and exposure to solvents during experiments. Therefore, we saw the opportunity to develop customized materials capable of withstanding these challenges and ensuring the necessary precision in our tests," Quero explains. "We developed microfluidic devices made with special resins that not only withstand these conditions but are tailored for each application, something unique in the world."

Synergy Between Macro and Micro

Another important differentiator of the project is the collaboration among researchers. In addition to Professor Leandro Wang Hantao, who coordinates the chemical and chromatographic analyses, and Polaris, which develops the microfluidic devices, the project also includes Professor Paulo de Tarso Vieira e Rosa, the project's vice-coordinator (IQ/Unicamp) and a specialist in supercritical technologies, who conducts macro-scale experiments.

Together, they aim to compare the results of miniaturized devices with tests on larger samples, identifying how phenomena observed on a micro scale can be applied to optimize large-scale processes. "The synergy between macro and micro approaches allows us to explore details of oil production phenomena that were previously invisible to traditional methods," Hantao emphasizes.

Impacts and Market Potential

With a duration of two years, the project aims to improve the analysis of interaction and partitioning processes of organic acids in multiphase systems (water/oil/rock/CO₂), studying how variables such as CO₂ concentration, alkalinity, and temperature affect oil production. In addition to generating scientific advancements, this technology has the potential to optimize extraction operations and reduce operational costs, directly benefiting the energy industry. "We are facing a technology that can revolutionize our understanding of the phenomena occurring in oil studies, reducing costs and environmental impact, while bringing significant gains both for research and practical application in the sector," the researchers conclude.

About CEPETRO: The Center for Energy and Petroleum Studies (CEPETRO) is a research center at the University of Campinas (Unicamp), with over 35 years of history, focused on oil, gas, renewable energies, and energy transition. Currently housed in five buildings with more than 5,000 square meters of space, it has its own laboratories and more than 350 researchers. In addition to conducting research and development (R&D) projects, CEPETRO provides technical services and consulting, trains highly qualified human resources, and promotes knowledge dissemination. Its R&D projects are funded by companies, foundations, and government research funding agencies. CEPETRO is one of the largest recipients of funds through the R&D clause of the National Agency of Petroleum, Natural Gas, and Biofuels (ANP).