Laboratory and Reservoir-Scale Assessment of Thermal–Gas–Chemical Treatment Using Activated Aluminum Alloys at the Karazhanbas Field

Thermal–gas–chemical treatment (TGCT) using activated aluminum alloys is a promising near-wellbore stimulation method for high-viscosity oil reservoirs, combining localized heat generation, hydrogen release, pressure increase, and chemical activation of the treated zone. This study evaluates the potential of TGCT for the Karazhanbas field using laboratory core flooding experiments and reservoir-scale scenario analysis. Experiments were conducted on unconsolidated core models saturated with high-viscosity oil. Treatment with activated aluminum alloy and formation water generated up to 2600 mL of gas but did not increase oil displacement efficiency. In contrast, the system containing activated aluminum alloy, 3 wt.% HCl, and 2 wt.% surfactant intensified the reaction, promoted gas–liquid foam formation, increased electrical resistivity to 5000 Ω·m, and improved oil displacement efficiency from 0.37 to 0.61. The additional oil recovery reached 16.8 mL, corresponding to a relative increase of approximately 65%. Reservoir-scale scenario calculations showed a heterogeneous production response, with maximum oil production rate increases ranging from 0.03 to 3.27 m3/day, depending on well conditions. The results indicate that TGCT efficiency is controlled by the combined thermal, gas, and chemical effects rather than gas generation alone. Field-scale implementation requires the calibration of the treatment radius, effect duration, temperature response, gas saturation, permeability alteration, and well-specific reservoir conditions.