Synthesis and Migration-Plugging Performance of a Novel High-Temperature Resistant Epoxy-Based Profile Control Agent for Heavy Oil Steam Flooding

Severe steam channeling in heterogeneous heavy oil reservoirs severely restricts thermal recovery efficiency, as conventional conformance control materials cannot simultaneously achieve long-term high-temperature resistance and deep reservoir penetration. This work develops a high-temperature-resistant epoxy-based liquid microsphere system for deep profile control in heavy oil steam flooding. A triple thermal-stabilization strategy is constructed: imide chain extension to enhance backbone rigidity, benzoxazine-phthalonitrile grafting to form dense triazine crosslinked networks, and KH-550-functionalized nano-silica for synergistic reinforcement. FT-IR and 1H NMR verify the successful incorporation of rigid imide and triazine structures. TGA confirms the optimal formulation exhibits less than 5% mass loss at 350 °C. Multi-segment sand-packed tube tests demonstrate favorable deep migration capacity with inter-stage pressure ratios below 4 across 5000–15,000 × 10−3 μm2 permeability, and the cured network retains over 95% plugging efficiency after 350 °C steam scouring. Dual-tube heterogeneous flooding delivers 12.05% incremental oil recovery, outperforming rigid inorganic particles. This system provides a high-performance candidate for deep steam channeling mitigation in heavy oil thermal recovery.