Physically Consistent 2D to 3D Pore Space Synthesis: 1. Dynamic Grain Packing Under Strict Morphology Constraints

Abstract

The 3D digital reconstruction of multi-scale, heterogeneous porous media is traditionally limited by the resolution boundaries and artifacts of X-ray computed tomography (XCT). This paper introduces a physically consistent 2D to 3D pore space synthesis framework that supersedes conventional geometric shuffling with dynamic Newtonian gravitational deposition using a high-performance rigid-body mechanics engine. To honor strict physical contact mechanics, statistical 2D targets, and morphological constraints, we develop a two-stage dynamic packing pipeline that combines realistic 3D grain shapes with a virtual sub-particle insertion engine. The framework is validated against synthetic and natural core benchmarks. First, we show that our stereological integral equation systematically converts size distributions; bypassing this inversion step induces a systematic 50\% deviation in permeability predictions despite identical total porosities, independently altering flow channel topology. Second, temporary virtual spheres serve as architectural placeholders to stabilize large non-equilibrium dissolution voids, ensuring the reconstructed model satisfies target flow metrics within the prescribed tolerance. Finally, when applied to a fine-grained, weakly consolidated sandstone, the workflow exposes and suppresses systematic XCT artifacts, including phantom internal porosity. Ensembles of two-point correlation functions demonstrate that the hydrodynamically and structurally synthesized digital twins quantitatively exhibit closer structural proximity to the uncorrupted rock geometry than the reference XCT dataset itself. This methodology establishes a scalable foundation for high-fidelity multi-phase rock reconstruction, with potential extensions toward complex amorphous cement phases.