An Experimental Study on Oil–Water Emulsification Mechanism During Steam Injection Process in Heavy Oil Thermal Recovery

This article focuses on the oil–water emulsification problem during steam injection in heavy oil thermal recovery. Emulsions were prepared through one-dimensional flow experiments, and key parameters including the inversion point water cut and micro-morphological characteristics (particle size and distribution range) of the emulsions were systematically measured under varied conditions (temperature: 150–360 °C; salinity: 0–7500 mg/L; water cut: 10.07–72.22%). By analyzing the experimental data, the emulsification mechanism and influencing rules were revealed: under the combined conditions of high temperature (150–360 °C), high salinity (up to 7500 mg/L), and low water cut (10.07–19.35%), crude oil and formation water form oil-in-water emulsions under the shear action of porous media. During this process, active substances in crude oil react with inorganic salts in formation water to generate natural surfactants, which reduce the oil–water interfacial tension and enhance emulsion stability, enabling the emulsion to maintain stability even at a high water cut of up to 72.22%, with particle sizes ranging from 1 μm to 350 μm and distribution spans varying from 4 μm to 50 μm. The formation of such emulsions leads to a significant increase in viscosity, adversely affecting oil recovery. In production practice, it is recommended to add chemical agents during the early stage of steam huff and puff development (water cut: 10.07–37.50%). This measure aims to destroy the oil–water liquid film, promote water droplet coalescence (narrowing the particle size distribution span), and facilitate emulsion breaking and phase inversion, thereby effectively mitigating the adverse impacts of oil–water emulsions and improving heavy oil recovery efficiency.