Sustainable dewatering of unconventional gas wells using engineered multiphase flow dynamics.

• Demonstrated capability of three-phase foam flow in dewatering unconventional wells. • Examined flow regimes of foam flows in vertical tubing and annulus. • Examined the effect of pressure on dynamic and static foam flow characteristics. • Tested the effect of salt and particles on foam stability. This paper aims to investigate and demonstrate, for the first time, the feasibility of using an artificial lift system, referred to as foam assisted gas lift (FAGL) for dewatering unconventional gas wells to depressurise coal and allow gas to be produced. More specifically, this paper investigates the capability of a three-phase foam flow to lift gas, liquid and solid particulates to the surface to optimise gas production by minimising the flowing bottom-hole pressure (FBHP) and minimising downtime, operational costs and production losses caused by downhole pump failures. A laboratory set-up of a 9 m vertical tubing with 80 mm (3.1 in) ID and a 7 m annulus with a casing inner diameter of 170 mm (6.69 in) and tubing outer diameter of 70 mm (2.76 in) are used to investigate the foam flow behaviour in both geometries for a wide range of gas and water flowrates, 40–6500 L/min and 10–80 L/min, respectively. The 80 mm tubing is pressurised up to 6 bar, allowing examining the foam flow characteristics and foam stability at different depths of a gas well, by changing the operating pressure. Foam flow regimes in the tubing and the annulus, which are key in determining the FBHP are characterised by analysing differential pressure signals, collected at 100 Hz frequency. The addition of foamer (sodium dodecylbenzene sulfonate) significantly advanced the transition from churn to the annular flow regime, resulting in a lower required gas flow rate to obtain the least attainable FBHP. A model is developed to evaluate the FBHP of the FAGL, compared against the measured FBHP in 36 gas wells in Australia, equipped with down-hole pumps for dewatering. Our results indicate that FAGL is capable of maintaining a low FBHP for a wide range of gas and water flow rates. The effective particle lifting capacity of foam flow is also demonstrated. Further, the positive impact of water salinity (0.1 M NaCl) in the presence of particles (15–25 g/l) on foam integrity is presented. [ABSTRACT FROM AUTHOR]