Foam-Templated Polymer Gels for Mitigating Sediment Entrainment in Salt Caverns: A Robust Strategy for Safe CCUS Operations

As critical infrastructure for carbon capture, utilization, and storage (CCUS) and large-scale energy storage, subsurface salt caverns are seriously challenged by fluid-induced sediment mobilization during the supplementary debrining. Conventional bulk resin consolidation often causes severe viscous fingering, uneven consolidation, and pore clogging under hypersaline conditions. Here, we develop a foam-templated hybrid polymer gel co-stabilized by silica nanoparticles, polyvinyl alcohol, and the zwitterionic surfactant. The key novelty is the use of foam as a transient transport template that redistributes the resin phase and promotes selective cementation at grain-contact points instead of indiscriminate pore filling. This nano-reinforced gel system remained stable under hypersaline conditions (24% NaCl), and temperatures ranging from 20–80 °C. Micro-CT analysis showed that this selective templating preserved an interconnected pore network with a porosity above 45% and a CT-derived permeability of approximately 1.18 D, while reducing binder consumption by 55.6% relative to bulk resin injection. Crucially, a 1:200 geometrically scaled, velocity-matched pilot model demonstrated that this gel strategy limited sediment entrainment below 0.5% and reduced fluid discharge by 45.9%. These results establish a material-efficient consolidation strategy that combines sediment stabilization with permeability preservation, providing a promising solution for safer supplementary debrining in salt-cavern CCUS and energy-storage operations.