Experimental Study on Acid Etching and Rough Fracture Conductivity of Carbonate Rocks Using Digital Carving Technology

The success of acid stimulation in tight carbonate reservoirs relies on the formation of non-uniform etching on fracture walls. However, existing research on the influence of the fracture surface morphology on non-uniform etching and fracture conductivity predominantly employed non-replicable tensile fracture surfaces. Previous studies were unable to use identical fracture surfaces to conduct single-factor analysis and clarify the impact of roughness. This study utilized digital engraving technology to fabricate multiple artificial carbonate rock samples with a homogeneous lithology and completely consistent fracture surface morphology. Using the Triangular Prism Method (TPM), the initial fracture roughness of the rock samples was decomposed into large-scale waviness and small-scale unevenness. Through controlled injection parameters, single-factor acid etching experiments were conducted. For the first time, the effects of large-scale waviness and small-scale unevenness on acid etching were investigated, along with the influences of the acid injection rate and injection time. The existence of an optimal injection rate and an optimal injection time was clarified. The results demonstrate that the engraved carbonate samples’ surfaces exhibit good consistency with the original natural fracture surfaces. The acid solution acts to shave the “peaks” and deepen the “valleys” of rough fractures. The large-scale waviness characteristics of the initial rough surfaces determine the overall post-etching morphology, leading to poor surface contact within the fracture. This is the primary reason for the high fluid flow capacity of acid-etched fractures under low closure stresses. However, the small-scale unevenness characteristics of the initial rough surfaces determine the formation and the distribution of small protruding support points on the post-etching surface. This is the primary reason for the retention of high conductivity in acid-etched fractures under high closure stresses. An increase in the acid injection rate or acid injection time does not lead to a linear decrease in linear roughness, surface mismatch, or fracture aperture. A critical acid injection rate or critical acid injection time exists. Optimizing the injection rate or time can achieve an ideal etching morphology—the protrusions formed by punctate etching enable the fractures to maintain a certain level of conductivity even under a high closure stress of 55.2 MPa, while channel etching can increase the conductivity under high closure stress by 20–25%, providing a key direction for optimizing acid etching effects.