Abstract
Nano-silica is widely used to enhance gel properties, but its size, concentrations, and aggregation behaviors all matter. The influencing rules of these factors remain unclear especially in harsh reservoir conditions. This study presented a comprehensive investigation into the gelation, rheological, and plugging properties of phenolic polymer gels reinforced by modified nano-silica (GSNP) of different sizes and concentrations in harsh reservoir conditions. Specifically, the nano-silica was modified with a highly soluble silane, and gel properties were evaluated through rheological, differential scanning calorimetry (DSC), and sandpack flooding tests. The results showed that the incorporation of GSNP prolonged the gelation time, enhanced gel strength, and improved stability, allowing the gelation solution to enter deeper into the formation while maintaining long-time effectiveness. The optimal gel system was obtained with 0.4 wt.% GSNP-30, under which condition the storage modulus increased by approximately 14 times, and the content of non-freezable bound water more than doubled. This system exhibited plugging efficiency exceeding 80% in formations with permeabilities ranging from 1000 to 6000 millidarcy and enhanced the oil recovery factor by over 25%. The reinforcement mechanisms were attributed to the adsorption of GSNP onto polymer chains and its role in filling the gel matrix, which enhanced polymer hydrophilicity, suppressed polymer aggregation/curling, prevented ion penetration, and promoted the formation of a more uniform gel network. Careful optimization of nanoparticle size and concentration was essential to avoid the detrimental effects due to nanoparticle overfilling and aggregation. The novelty of this study lies in the practicable formulation of thermal and salt-tolerant gel systems with facile modified nano-silica of varying sizes and the systematic study of size and concentration effects. These findings offer practical guidance for tailoring nanoparticle parameters to cater for high-temperature and high-salinity reservoir conditions.