Seawater-resistant emulsified epoxy resin for effective sand control in unconsolidated sandstone oil reservoir

Sand production in oil wells is recognized as a persistent challenge during oilfield development, adversely affecting well productivity and operational stability. Chemical sand control methods, particularly resin-based sand consolidation, are considered a promising solution due to their operational simplicity and effectiveness. However, conventional emulsified resins are known to be highly sensitive to high-salinity environments, which can lead to emulsion destabilization and reduced consolidation strength. To address this limitation, a novel emulsified epoxy resin system was developed in this study using a nonionic emulsifying curing agent-fatty amine poly(epoxy ethyl ether)-by which salinity tolerance is significantly enhanced, supporting dilution water salinity up to 3.8 × 10⁴ mg/L. Through single-factor experiments, an optimal formulation was identified as 16% epoxy resin, 24% emulsified curing agent, 1% coupling agent, and 5.6% stabilizer. The molecular structure of the emulsified resin and the stability of the cured matrix were thoroughly characterized. The effects of curing temperature, time, sand particle size, and stabilizer dosage on compressive strength and permeability were systematically evaluated. It was demonstrated that after being cured at 80 °C for 12 hours, the consolidated cores achieved a compressive strength exceeding 3 MPa with permeability retention above 75%. Furthermore, the consolidated cores were shown to exhibit excellent long-term stability, maintaining their mechanical and flow properties after 30-day immersion in kerosene, 10% HCl, and formation water. This study bridges a critical research gap in high-salinity applications of water-based resin emulsions and provides a robust technical solution for sand control in challenging reservoir environments.