Emulsification and interfacial characteristics of different surfactants enhances heavy oil recovery: experimental evaluation and molecular dynamics simulation study

The high viscosity and poor fluidity of heavy oil challenge its extraction, leading to the widespread use of surfactant emulsification to reduce viscosity and enhance recovery. This study evaluated three surfactants—sodium dodecyl sulfate (SDS), sodium oleate (SO), and APG0810—for their suitability and effectiveness in the X reservoir. The solution properties of these surfactants were analyzed and their micro-mechanisms investigated using MD calculations. The effects of surfactant concentration and additives on emulsification and viscosity reduction were elucidated. Ultimately, a system for emulsification and viscosity reduction was selected for physical simulation research. The experimental findings show that SO reduces interfacial tension from 52.4 mN/m to 0.0027 mN/m, transforming lipophilic surfaces into hydrophilic. MD analyses reveal SO’s optimal interfacial properties, with the lowest interfacial energy of −6423.4 kcal/mol, maximum interfacial thickness of 2.56 nm, and minimal diffusion coefficient of 0.4087 Ų/ps at the oil-water interface. These findings align with experimental results, confirming SO’s superior interfacial properties. Combining 0.3% SO with 0.5% n-pentanol results in a 98% viscosity reduction. The emulsion shows excellent stability, with no water separation in the first 30 min and only 8.3% after 2 h. Physical simulation results show that in high(low) permeability core displacement experiments, system flooding and subsequent water flooding can increase recovery rates by 15.39%(36.91%), indicating the system’s potential for enhancing oil recovery in Reservoir X. The findings suggest that the implementation of this system not only boosts the crude oil recovery rate but also carries economic significance in the industry.