Surfactant-Polymer (SP) flooding has gained recognition as an effective enhanced oil recovery (EOR) method, particularly in heterogeneous reservoirs where conventional methods often fall short. Despite its laboratory-scale success, the transition of SP flooding to field applications presents notable challenges due to geological complexity and scale-dependent behaviors. This study conducts a thorough evaluation of SP flooding performance through advanced numerical simulations, aiming to bridge the gap between coreflood experiments and actual reservoir conditions. By upscaling a calibrated coreflood model to a 3D heterogeneous reservoir, we observed a 14.83% increase in oil recovery, resulting in a total recovery factor of 48.96%. This study indicates that while slug size had a relatively minor effect, the injection sequence WF-SPF-PF-PWF produced the most favorable results. In heterogeneous systems, optimal recovery with minimal chemical loss was achieved by increasing polymer concentration and slug size, while reducing surfactant concentration and extending the surfactant slug. Sensitivity and uncertainty analyses revealed that residual oil saturation (Sor) reduction and chemical adsorption were critical drivers of SP flooding success, with projected recoveries ranging from 100.69 to 125.85 million STB. These results underscore the necessity for tailored flood designs, accurate parameter calibration, and robust uncertainty analysis to ensure effective implementation of SP flooding in complex reservoir environments.
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