Polymer Retention Leading to Non-Darcy Flow in Porous Media—Influence of Molecular Weight, Composition and Mechanical Degradation

Polymer flooding is a well-established chemical enhanced oil recovery (EOR) method, primarily aimed at improving sweep efficiency. However, the interplay between polymer properties and porous media, particularly the influence on permeability reduction, remains poorly understood. In this study, we investigate how polymer molecular weight, chemistry, and mechanical pre-shearing influence residual resistance factor (RRF) and in situ rheology in Berea sandstone core floods. Post-polymer brine flow exhibits clear non-Darcy behavior, indicating that permeability becomes rate-dependent after polymer adsorption. Application of a Forchheimer-based approach demonstrates that inertial contributions become significant at reservoir-relevant velocities, suggesting enhanced microscopic inertia dissipation associated with interaction between flowing brine and the stationary adsorbed polymer layer. Applying conventional Darcy-based interpretation systematically overestimates RRF under these conditions. RRF increases with polymer molecular weight for polymers with similar bulk viscosities, suggesting that permeability reduction is primarily controlled by effective hydrodynamic size and pore-scale interactions rather than polymer concentration. Mechanical pre-shearing substantially reduces RRF and the non-linear flow contribution, suggesting that laboratory measurements performed on unsheared solutions may overestimate field-scale injectivity impairment. In contrast, an ATBS-containing polymer exhibits relatively low RRF but high apparent viscosity, indicating that alterations in polymer chemistry may override molecular weight as the main factor. The results demonstrate that polymer–surface interactions can induce rate-dependent permeability at reservoir-relevant velocities, and highlight the need for non-Darcy analysis when interpreting polymer core flood experiments for field application.