A novel strategy to enhance heavy oil Recovery: Condensation heat transfer calculation and 2-D visualized physical simulation

High carbon emissions and low efficiency in thermal utilization are pivotal challenges in heavy oil development. Addressing the urgent need to enhance heavy oil production, this paper introduces an innovative approach in which aerogel and flue gas serve as supplementary additives in steam thermal recovery. To investigate the mechanisms behind the improved heat transfer and oil recovery facilitated by the combination of aerogel and flue gas, condensation heat transfer experiments and 2-D visual oil displacement experiments were carried out. The condensation heat transfer coefficient, oil displacement performance, and heat utilization efficiency were analyzed and compared. The results showed the porous structure of the aerogel enhances its thermal insulation properties by adsorbing flue gas, thereby reducing the steam-to-cold object condensation heat transfer coefficient by 60.6%. The cementation between aerogel nanoparticles (NPs) retained in the formation and rock particles formed an insulating layer that impedes the upward propagation of steam heat. Combined with efficacy of flue gas foam in improving fluid flow, this promoted the horizontal expansion of the steam chamber, resulting in an 8.2% and 3.4% increase in the steam chamber’s extent compared to using steam and a combination of steam with aerogels, respectively. Moreover, the profile control and thermal insulation impacted following the NPs, lowering the water cut in the produced fluid and enhancing the oil recovery by 7.9%. Upon the application of flue gas, this enhancement in recovery extended to 9.3%.