Wet flame-jet drilling: An alternative technique to access deep heat reservoirs
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1 Wet flame-jet drilling: An alternative technique to access deep heat reservoirs ETH Zürich, Institute of Process Engineering, Switzerland Philipp Rudolf von Rohr Philipp Rudolf von Rohr 7/4/2016 1
2 Outline Introduction Motivation and research on flame-jet drilling Wet lab-scale drilling at 260 bar Flame-jet drilling in the pressure vessel to simulate realistic downhole conditions in a deep well 2-10 km Experimental facility at ETH Main challenges of wet flame-jet drilling Conclusion Source: International Geothermal Association (2013) Philipp Rudolf von Rohr 7/4/2016 2
3 Motivation Facts: A contactless drilling technique reduced wear-out Shallow drilling in the 20 th century for mining purposes Flame-jet drilling market shared by three companies (up to 100 million tons excavated by 37 flame-jet rigs in 1966) Jet Piercing Transactions of the American Institute of Mining, Metallurgical and Petroleum Engineers, 1968, Spallation mechanism However: Deepest well ever drilled by an unassisted flame-jet 332 m In a technical report from Berkley (1990) : Deep Drilling Basic Research VOL. 5 System Evaluation Drilling concept Potential or Limitations Status Flame Jet Drill Inoperable in fluid filled borehole Low potential Summary of systems evaluation (Berkley, 1990) Philipp Rudolf von Rohr 7/4/2016 3
4 Motivation Geothermal plant investment characteristics Drilling costs as a function of depth Sources: Gehringer, 2012 Tester et al., MIT, 2007 Philipp Rudolf von Rohr 7/4/2016 4
5 Spallation Rock Drilling + Reduced drill bit wear and down time + Large penetration rates in crystalline rocks (15.8 m/h reported by Browning in 1981, drillability spallability -1 ) + Mature technology, commercialized during three decades Difficulty to flush the cuttings using air or pressurized gas at depth exceeding 300 m Consequence A water-based drilling fluid is required to drill deeper: Transport of the cuttings Stability of the borehole Our approach Flames in water Philipp Rudolf von Rohr 7/4/2016 5
6 Wet lab-scale drilling at 260 bar 85 mm 600 mm 150 mm High pressure vessel (650 bar at a wall temperature of 500 C) 250 mm Pressure (p), temperature (T), stand-off distance rock to nozzle (SOD) Philipp Rudolf von Rohr 7/4/2016 6
7 Experimental facility pressure vessel kg/h 3000 kg/h l n /min kg/h oxygen compressor fuel pump Process and instrumentation diagram Philipp Rudolf von Rohr 7/4/2016 7
8 Experimental facility Pressure vessel movable probe assembly cooling mantle (CW-2) kg/h oxygen inlet fuel line 3000 kg/h pressure indicator (PI-5) manometer connection kg/h bursting disc l n /min Process and instrumentation diagram Pressure vessel (up to 650 bar at 500 C) Philipp Rudolf von Rohr 7/4/2016 8
9 Experimental facility CW-1,3 Water pump kg/h 2 m 3000 kg/h kg/h l n /min Process and instrumentation diagram Noise and vibration reduction cabinet of the CW-1,3 high pressure water pump Philipp Rudolf von Rohr 7/4/2016 9
10 Experimental facility CW-1,3 Water pump safety valve suction flange discharge side kg/h 37 kw electromotor 3000 kg/h kg/h l n /min Process and instrumentation diagram booster pressure dampener Philipp Rudolf von Rohr 7/4/
11 Experimental facility CW-2 Water pump kg/h 3000 kg/h 2 m kg/h l n /min Process and instrumentation diagram Noise and vibration reduction cabinet of the CW-2 high pressure water pump Philipp Rudolf von Rohr 7/4/
12 Experimental facility CW-2 Water pump safety valve discharge side kg/h 3000 kg/h suction flange 17 kw electromotor kg/h l n /min pressure dampener Process and instrumentation diagram Philipp Rudolf von Rohr 7/4/
13 Experimental facility 3WV-1, Three-way valve kg/h 3000 kg/h kg/h ethanol inlet l n /min Process and instrumentation diagram fuel mixture to fuel pump water inlet Philipp Rudolf von Rohr 7/4/
14 Experimental facility Fuel pump electro motor 8 kw pressure dampener safety valve bursting disc kg/h 3000 kg/h to Coriolis flowmeter kg/h l n /min 1.25 m Triple head, metering, membrane pump fuel inlet Process and instrumentation diagram Philipp Rudolf von Rohr 7/4/
15 Experimental facility Coriolis flow meter FMI-1 to fuel heater kg/h mass flow and density measurement 3000 kg/h kg/h l n /min Coriolis flow meter in the fuel line fuel inlet Process and instrumentation diagram Philipp Rudolf von Rohr 7/4/
16 Experimental facility Fuel heater fuel outlet to pressure vessel kg/h 3000 kg/h 2 m kg/h fuel inlet l n /min Process and instrumentation diagram 4.2 L electrical heater (66 kw) Philipp Rudolf von Rohr 7/4/
17 Experimental facility Oxygen compressor oxygen bundle nitrogen bundle gas boosters kg/h 3000 kg/h inlet of the gas line kg/h l n /min Gas boosters and gas storage bundles Process and instrumentation diagram Philipp Rudolf von Rohr 7/4/
18 Experimental facility Oxygen heater kg/h oxygen to pressure vessel 3000 kg/h 1.6 m kg/h oxygen inlet l n /min Process and instrumentation diagram 0.8 L electrical heater (11 kw) Philipp Rudolf von Rohr 7/4/
19 Wet flame-jet drilling challenges: Forced ignition Challenges of wet flame-jet drilling Auto-ignition Forced ignition Mixture at C Philipp Rudolf von Rohr 7/4/
20 Forced ignition: Sectional view of the burner system oxygen fuel co-annular flow of oxygen fuel injection ports 30 mm 30 mm igniter 26 mm igniter Igniter and fuel injection nozzle Pressure vessel and sectional view of the burner system Philipp Rudolf von Rohr 7/4/
21 Forced ignition: Ignition map at 260 bar Process and instrumentation diagram Ignition map at 260 bar Philipp Rudolf von Rohr 7/4/
22 110 mm Wet flame-jet drilling challenges: Temperature and power control Pression, temperature, SOD Different fuel injection nozzles Philipp Rudolf von Rohr 7/4/
23 Wet flame-jet drilling challenges: Entrainment Influence of entrainment on hydrothermal flame jets: Pression, temperature, SOD Philipp Rudolf von Rohr 7/4/
24 Wet flame-jet drilling challenges: Entrainment Entrainment of surrounding cooling water Pression, temperature, SOD Entrainment depends on density, velocity and enthalpy differences between hot jet and surrounding water Density varies strongly with temperature Velocity varies strongly with nozzle diameter Philipp Rudolf von Rohr 7/4/
25 Wet flame-jet drilling challenges: Entrainment Different nozzle and injection systems Pression, temperature, SOD Entrainment can be minimized by optimizing the nozzle design The injection angle of cooling water is sensitive to the entrainment effect Philipp Rudolf von Rohr 7/4/
26 Conclusions Hot surface ignition with less than 500 W (available down-hole) Downhole flame operation Technical challenges in wet flame-jet drilling Proof of concept Stable and efficient combustion in supercritical water High adiabatic flame temperature and intense heat transfer properties Lab-scale drilling at high pressure in an aqueous environment is feasible Intensive investigations on fluid (heat transfer, combustion) and rock side (thermal fragmentation) are currently ongoing Philipp Rudolf von Rohr 7/4/
27 Thank you for your attention! Questions? Philipp Rudolf von Rohr
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