EFFICIENT AND ECONOMIC HYDRAULIC FRACTURE DIAGNOSTICS USING METAMATERIALS AND EDGE AI
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In an effort to decarbonize legacy energy systems, several projects around the world are exploring alternatives to natural gas. Gaseous hydrogen is proposed as a carbon-free fuel to displace natural gas in existing legacy natural gas distribution systems, some of which continue to operate after 100 years (or more) in service. These systems, particularly in older industrial centers, contain cast iron pipe. However, the fracture resistance of most metals is degraded in gaseous hydrogen environments. This study evaluated the fracture resistance of several legacy cast iron pipe materials while exposed to gaseous hydrogen. Measurements were performed in three environments: air, a gas mixture with hydrogen partial pressure of 1 bar and pure hydrogen with a partial pressure of 34 bar. Although cast iron is generally considered a low ductility metal, elastic-plastic fracture methods are needed to assess the fracture resistance of the relatively small specimens that can be extracted from legacy pipe. Hydrogen reduced the fracture resistance of these cast iron materials by 10-40%. In air, the fracture resistance was determined to be as high as 21 MPa m 1/2 , whereas in gaseous hydrogen at pressure of about 1 bar the fracture resistance was as low as 13 MPa m 1/2 . Additional modest degradation of the fracture resistance was assessed at higher partial pressure (as low as 12 MPa m 1/2 ).
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Most porous media, such as geomaterials and biomaterials are highly heterogeneous in nature, and they contain large variations of microscopic pore structures, such as pore sizes, pore distribution, and pore shapes. The oscillation of microscopic structures is a substantial challenge in theoretical characterization and is usually ignored in continuous modeling. However, mechanical behavior of porous media such as deformation and failure, are essentially impacted by the microscopic heterogeneity which needs to be considered in modeling a porous media. Here, this research proposes a numerical modeling framework with a capability to investigate the effect of microscopic heterogeneity on the macroscopic fracture behavior in porous media by using a numerical homogenization technique, combined with the phase-field fracture modeling method. This numerical modeling strategy computes a homogenized elasticity tensor based on microscopic heterogeneous pore structures heterogenous porous domain by solving boundary value problems at microscopic domain. The strain energy and subsequent propagation of macroscopic fractures will be updated using homogenized stiffness information. Using this numerical scheme, the microscopic pore structure’s impact on the fracture behavior through the homogenized elastic tensor will be taken into account. This multiscale technique is benchmarked against classical problems. Finally, the results highlight the importance of the underlying pore structure and reveal that both fracture strength and propagation path can be influenced by the microscopic heterogeneity.
Applications of new technology, such as horizontal drilling and hydraulic fracturing, enabled the United States to significantly increase its production of oil and natural gas during the last decade—the “Shale Gas Revolution.” As natural gas began to dominate the market with abundant supply and low prices, coal production and consumption have declined. Concurrently, the competitiveness of renewable energy and energy storage has climbed sharply, and analysts expect to see continued reductions in fossil fuel use in the coming decades. Many of these changes have been driven by market forces (i.e., low-cost natural gas and renewables), but current and future policy decisions aimed at tackling climate change concerns and reducing greenhouse gas emissions will also shape the future of the energy sector. This transition to low-carbon fuels has created both opportunities for clean energy technologies and challenges for communities traditionally dependent on fossil fuel-related industries. The power sector’s ongoing shift away from coal has left many coal miners and coal-fired power plant employees unemployed and often unprepared for jobs in other industries, including growing clean energy fields. This primer focuses on the declining coal industry, impacts on communities and workers, opportunities to transition workers who have lost their jobs to clean energy and other related sectors (including hydrogen-oriented jobs), recruitment and training strategies, and available programs and actions to make the shift to a low-carbon economy in a fair, just, and equitable manner by engaging the resources of federal and state governments, as well as the private sector.
This work seeks to model the chilled-water injection that occurred at EGS Collab Testbed 2 as part of experiment 3, using the open-source GEOS simulation framework. Modeling of this process, previously conducted using STOMP-GT, confirmed that thermal breakthrough was expected to occur during the chill water injection and may have been masked by strong Joule-Thompsons effects induced by large pressure drops between the fractures and the production wells. Building a GEOS numerical model of this process will allow to include additional physics. In fact, GEOS can model fully coupled thermo-poromechanical processes in fractured porous media and can be employed to model the process of artificially enhancing rock permeability by hydraulically fracturing the rocks. For example, the GEOS model could help understanding the dynamic nature of the EGS collab experiment 3 flow system. Since the limited time and resources do not allow for an extensive study, the focus is on building a baseline model of this process. As such, the main outcomes of this modelling efforts are listed below.
Methods and systems for thermal energy storage and enhanced oil recovery are described herein. In some embodiments, natural gas may be injected down a well which has been previously hydraulically fractured to store thermal energy and to stimulate the well to greater hydrocarbon production.
This study investigates the effect of specimen thickness on fracture toughness and the transition from plane stress to plane strain conditions in Medium-Density Polyethylene (MDPE) using Single Edge Notched Bend (SENB) specimens. Three thickness groups (7.5 mm, 9.0 mm, and 12.1 mm) were tested following ASTM D5045 protocol. Conditional stress intensity factors (KQ) increased from 2.2 MPavm to 2.8 MPavm with increasing thickness, demonstrating significant size dependency. Confocal microscopy revealed a 34% reduction in maximum crack tip opening displacement (CTOD) from 0.478 mm to 0.314 mm as thickness increased, with plastic zone lateral extent decreasing by 32%. This quantitative evidence validates Irwin's theoretical prediction of plastic zone size transition from plane stress r_y˜ (1/2p) (K_I/s_y )^2 to plane strain conditions r_y˜ (1/6p) (K_I/s_y )^2.Scanning electron microscopy confirmed progressive suppression of shear lips and evolution from ductile tearing with extensive polymer chain drawing in thin specimens to localized crazing in thick specimens. Despite all specimens satisfying the ASTM D5045 criterion (B = 2.5(KQ/s_y )^2 ) ,residual shear lips persisted even in the thickest specimens, demonstrating that nominal size requirements alone are insufficient for achieving complete plane strain conditions in highly ductile polymers. The findings emphasize the necessity of integrated analytical and morphological assessment for valid fracture toughness characterization, with critical implications for life assessment and integrity prediction in thick-section polymer components such as natural gas distribution pipelines.
Unconventional oil and gas from shale formations have emerged as some of the fastest growing energy resources in the United States, providing both cleaner energy to consumers and reducing the nation’s reliance on energy imports. To properly harness these important natural resources, the nanopore structure of associated shales must be fully understood, particularly under hydraulic fracturing conditions, where they are exposed to both overburden compressive and hydrostatic fluid pressures. The current study uses small-angle neutron scattering (SANS) to characterize pore structure, including porosity, pore accessibility, and pore size distribution, in the 1–100 nm regime at elevated pressures for mineralogically distinct clay- and carbonate-rich shales from the Permian Basin. Unlike typical porosity measurement techniques, SANS is uniquely capable of characterizing both open and closed porosity, allowing measurement of how pore accessibility changes with pressure and determination of the size range of accessible versus inaccessible pores. The porosity of the clay-rich shale was 7.7%, compared to 0.51% for the carbonate-rich shale. However, only 2.6% of the nanopores in the carbonate-rich shale were inaccessible to water at 8 kPSI (55.1 MPa) compared to 7.8% for the clay-rich shale. Furthermore, our analyses indicated that the closed pores fall within distinct size ranges, likely corresponding with the chemical nature of the pore host material. These results provide valuable insight into the effects of shale petrophysical properties on hydrocarbon extraction from unconventional reservoirs.
Salt formations have been explored for the permanent isolation of spent nuclear fuel based on their high thermal conductivity, self-healing nature, and low hydraulic permeability to brine flow. Vacancy defect concentrations in salt complicate fracture mechanics not driven by dislocation dynamics and can influence the resulting surface structure. Classical molecular dynamic simulations were used to simulate tensile testing of salt crystals (halite) with vacancy defect concentrations of up to 0.5 defects/nm 3 . Increasing defect concentrations resulted in a decrease in ultimate tensile strength and fracture surface energies, driven by increased surface roughness rather than changes in the amount of surface area. Brine–salt surface energies of the fractured surfaces were 0.22 to 0.26 J/m 2 , significantly higher than values reported for atomically flat (100) surfaces at the same brine composition. This change in surface energy increased the brine–salt dihedral angle by ~27°. The dihedral angle threshold for percolation in salt is 60°, and a 27° increase due to rough fracture surfaces identifies a reduction in porosity percolation and a decrease in salt permeability. Therefore, bedded salt and salt domes may be even more stable than those previously predicted from dihedral angle calculations.
Here, using two-dimensional simulations of sheared, brittle solids, we characterize the resulting fragmentation and explore its underlying critical nature. Under quasistatic loading, a power-law distribution of fragment masses emerges after fracture which grows with increasing strain. With increasing strain rate, the maximum size of a grain decreases and a shallower distribution is produced. We propose a scaling theory for distributions based on a fractal scaling of the largest mass with system size in the quasistatic limit or with a correlation length that diverges as a power of rate in the finite-rate limit. Critical exponents are measured using finite-size scaling techniques.
Brittle fracture is difficult to study in situ due to the speed of a growing crack and the often-catastrophic nature of failure in brittle materials. As a result, the influence of microstructural considerations, such as orientation, grain boundary locations, and strain field, on the crack path remains poorly understood. Presented in this study is a method addressing this knowledge gap, which utilizes the double-cleavage drilled compression geometry to achieve quasi-stable fracture in aluminum oxynitride (AlON). Synchrotron X-ray micro-computed tomography is used to characterize the crack shape and length, while high-energy diffraction microscopy provides information on the strains, orientations, and shapes of grains in the microstructure surrounding the crack tip. During testing, the crack grew in discrete and irregular jumps while the fracture toughness falls within reported ranges. The crack in AlON is found to have no greater tendency to crack intergranularly as compared to transgranularly, and grains which are cracked transgranularly do not display a trend in orientation or stress when compared to those around which the crack followed a grain boundary. The high resolution of the crack path and microstructural data provides a path forward for modeling and understanding 3D brittle fracture.
Hydraulic fracturing of low-permeability rocks significantly enhances hydrocarbon production from unconventional reservoirs. However, fluid transport through low-permeability rocks, and the influence of geochemical transformations on pore networks, are poorly constrained. Mineral reactivity during interactions with injected water may alter the physical nature of the rock, which may affect hydrocarbon mobility. To assess alteration to the rock, we previously conducted a hydrothermal experiment that reacted cubed rock samples (1 cm3) with synthetic hydraulic fracturing fluid to simulate physicochemical reactivity during hydraulic fracturing. We analyzed unreacted and reacted rocks by small-angle neutron scattering and high-pressure mercury intrusion to determine how nanoscale (~1-1400 nm) pore networks of unconventional reservoir rocks are influenced by reaction with hydraulic fracturing injectates. We show that fluid-rock interactions have a two-fold influence on hydrocarbon recovery, promoting both hydrocarbon mobilization and transport. Pore-matrix interfaces smooth via removal of clay mineral surface asperities, reducing available surface area for hydrocarbon adsorption by ca. 12-75%. Additionally, hydraulic fracturing fluid-induced dissolution creates new pores with diameters ranging in size from 800-1400 nm, increasing the permeability of the rocks by a factor of 5-10. These two consequences of mineral dissolution act in concert to release hydrocarbons from the host rock and facilitate transport through the rock during unconventional reservoir production.
In this work, to improve the performance of wellbore cement under subsurface environments, graphene nanoplatelets (GNPs) were added in various percentages to Class-H cement slurry. Microstructural characterization of cement slurries cured at 90 °C and 95% RH indicates that GNP modifies the microstructure of hydrated cement by reinforcing pore spaces. As a result, the mechanical properties, such as Young's modulus and axial peak stress, obtained from high temperature triaxial compression tests are significantly improved based on different percentages of added GNPs. Furthermore, the hydrated 1 × 2 inch GNP- Portland cement cores tested under simulated deep wellbore conditions of high-temperature and high pressure (HTHP), appear to have a ductile-like behavior, when compared to a typical brittle nature of Portland cement pastes. From our observations and published data on graphene resistance to fracture, GNP addition to cement is evidently enhancing the flexibility of cement. These improvements would reduce the risks associated with wellbore cement deterioration and a consequent leakage in fossil fuel production, geothermal energy production, CO 2 storage as well as long-term sealing materials in plugging and abandonment of all wellbores at the end of their service life.
This work investigates the rheology and stability of nanoparticle-stabilized CO 2 foams under reservoir conditions (high temperature and high pressure) for fracturing applications. The effects of different parameters on foam apparent viscosity and foam stability were experimentally investigated including the effects of nanoparticle concentration, salinity, foam quality (Γ), shear rate and temperature. The power law model was applied to calculate foam apparent viscosity owing to its pseudo-plastic behavior, and the changes of foam heights over time were used to evaluate foam stability. Results showed that the CO 2 foam apparent viscosity featured a mountain-shaped curve versus Γ, with the peak apparent viscosity obtained at 70% foam quality. The increase of salinity (up to 11%) in the continuous phase improved both foam stability and rheology. Higher nanoparticle concentration could contribute to better foam stability, but there was a threshold concentration, above which the foam apparent viscosity remained stabilized. The CO 2 foam stabilized by nanoparticles displayed a shear-thickening behavior as the experiment flow rate increased from 6 mL/min to 18 mL/min. Further studies showed that as the total flow rate increased, the CO 2 foam became finer-textured with better stability. Elevated temperatures could undermine foam apparent viscosity and long-term stability. The results of this study could provide guidelines as to the design of foam fracturing systems for field applications.
Geogenic Helium-4 ( 4 He) in-situ increases locally in regions of large deformation generated naturally or anthropogenically. This gas release by deformation is a potential geochemical precursor signal for subsurface deformation. To evaluate the applicability of 4 He degassing for correlating deformation in different lithologies, we conducted high force crush tests, up to 97,800 N axial load, to assess the total 4 He released during fragmentation of the rocks. We observed that the highest 4 He released occurred in the sedimentary rocks and that release correlated strongly with lithologic age and U/Th content. Microstructural changes of the pre- and post-test rocks indicate that the degree of grain size reduction relates directly to the total 4 He released during crushing. The range of in-place 4 He was calculated based XRF measurements of uranium and thorium in each lithology, with the results indicating that the majority of the trapped 4 He was not released. However, the 4 He released by deformation depended upon how the each rock deformed during deformation and the degree of grain size reduction. We postulate that 4 He precursor signals can be used to understand subsurface deformation only if geomechanical and geochemical conditions for 4 He enrichment in a lithology are met.