Integrated CFD, Thermodynamic and Kinetic Modeling of Calcium Carbonate Scaling in Oil & Gas Completions: A Comparative Study Considering Water/Oil Content Variations

This study simulates two distinct oil and gas completions operating at 131°C and 475 kgf/cm2: one employing three sliding sleeve valves (SSVs) and another utilizing three perforated tubes. A CFD-based methodology was used to determine region-specific water/oil content variations, enabling a comprehensive evaluation of the thermodynamic and kinetic factors affecting calcium carbonate scaling under varying phase compositions. A Multiphysics simulation framework is developed by integrating a CFD model that calculates the water/oil content distribution across production zones, a thermodynamic model to assess supersaturation conditions, and a kinetic model based on a population balance approach to simulate calcium carbonate precipitation. In this framework, the CFD component captures fluid dynamics and local phase behavior, while the thermodynamic analysis identifies potential scaling zones. The kinetic model incorporates nucleation, growth, agglomeration, and transformation processes, enabling precise prediction of scaling behavior under varying operational conditions. Simulation results reveal that the completion with three sliding sleeve valves exhibits nearly 30 times higher crystalline production compared to the perforated tube configuration. This marked difference is attributed to a higher localized pressure drop in the SSV configuration and abrupt water/oil content transitions, both of which promote enhanced scaling conditions. It was also observed that the inferior zone produced more crystalline mass than the intermediate zone for both completions, with the superior zone being the most critical even with lower water content. These findings underscore the significant influence of equipment design and operational variables on scaling risk management, offering guidance for effective mitigation strategies. The novelty of this work lies in its integrated use of kinetic, CFD, and thermodynamic models, combined with an innovative CFD-based water/oil content methodology. This tool offers new insights for evaluating scaling risks and optimizing completion designs in the oil and gas industry.