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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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16 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Hard Rock Drilling Optimization Software

The main objective of the developed software is to reduce the cost per foot during drilling, in other words, optimize the drilling operational parameters in achieving optimum ROP while avoiding critical operational parameters due to either low ROP, drillstring vibration, accelerated cutter wear, or low MSE. The developed software can also be used for post-well analysis to provide insight and lessons learned for future drilling operations. Several functions are available in the software to help the user perform drilling analysis, optimization, and simulation.

15 GEOTHERMAL ENERGY↗
DOE OSTI2023

The Effects of Plasma Pre-Cracking on Drilling of Hard Rocks: A Single Insert Cutting Experiment

Abstract This paper studies the effects of plasma-induced cracks on rock cutting to support the concept of a plasma-integrated drag bit for accelerated geothermal drilling through hard rocks. For this, a single polycrystalline diamond compact (PDC) drilling technique is used in cutting granite to compare thrust and cutting forces between plasma-treated and untreated rock samples. The cracks are produced using underwater plasma at 80 J per pulse. This energy level does not produce visible damage to the rock. The cutting tests are conducted at a cutting speed of 12.7 m/min and four feed rates of 0.127, 0.201, 0.267, and 0.414 mm/s to represent actual drilling scenarios. The results show a general trend of reduction in both thrust and cutting forces for these feed rates, but the magnitude of reduction highly depends on the feed rate. The maximum force reduction of around 50% is found at the 0.267 mm/s feed rate with statistical significance. Cases with a higher force reduction are also found to have rougher surface topography, which indicates more excessive fracturing and, thus, a cracks-accelerated material removal process. This study provides initial evidence of using underwater plasma to increase the downhole drilling rate of hard rocks.

Engineering↗
DOE OSTI2023

Downhole Sensing and Event-Driven Sensor Fusion for Depth-of-Cut Based Autonomous Fault Response and Drilling Optimization

Achieving robust and efficient drilling is a critical part of reducing the cost of geothermal energy exploration and extraction. Drilling performance is often evaluated using one or more of three key metrics: depth of cut (DOC), rate of penetration (ROP), and mechanical specific energy (MSE). All three of these quantities are related to each other. DOC refers to the depth a bit penetrates into rock during drilling. This is an important quantity for estimating bit behavior. ROP is the simply the DOC multiplied by the rotational rate, and represents how quickly the drill bit is advancing through the ground. ROP is often the parameter used for drilling control and optimization. Finally, MSE provides insight into drilling efficiency and rock type. MSE calculations rely on ROP, drilling force, and drilling torque. Surface-based sensors at the top of the drill are often used to measure all these quantities. However, top-hole measurements can deviate substantially from the behavior at the bit due to lag, vibrations, and friction. Therefore, relying only on top-hole information can lead to suboptimal drilling control. In this work, we describe recent progress towards estimating ROP, DOC, and MSE using down-hole sensing. We assume down-hole measurements of torque, weight-on-bit (WOB). Our hypothesis is that these measurements can provide more rapid and accurate measures of drilling performance. We show how a multi-layer perceptron (MLP) machine learning algorithm can provide rapid and accurate performance when evaluated on experimental data taken from Sandia’s Hard Rock Drilling Facility. In addition, we implement our algorithms on an embedded system intended to emulate a bottom-hole-assembly for sensing and estimation. Our experimental results show that DOC can be estimated accurately and in real-time. These estimates when combined with measurements for rotary speed, torque, and force can provide improved estimates for ROP and MSE. These results have the potential to enable better drilling assessment, improved control, and extended component lifetimes.

15 GEOTHERMAL ENERGY↗
DOE OSTI2022

Real-Time Drilling Optimization System for Improved Overall Rate of Penetration and Reduced Cost Per Foot in Geothermal Drilling

The key to success in geothermal drilling is economic feasibility, and a major cost in the development of geothermal resources is the actual drilling of the wells. In this project, a real-time drilling optimization system for geothermal drilling was developed. The system couples three individual components while drilling. The first component is a drill stem vibration analysis model, the second is Mechanical Specific Energy (MSE) analyses, and the third is a detailed PDC Rate of Penetration (ROP) drill bit model for optimum RPM and WOB combinations. The benefit of the coupled system is that the range of WOB and RPM could be selected to avoid drill stem vibrations. Secondly, MSE is used as an efficiency measure and the detailed PDC drill bit model ensures the drill bit does not endure temperatures that exceed the temperature at which the PDC cutters experience accelerated wear. The new detailed PDC bit model is based on rock/bit interaction that physically tracks the PDC cutter wear flats as the bit drills ahead giving the capability to calculate the temperature being generated underneath the worn cutters to better advise on operational parameters to avoid accelerated cutter wear and failure and to ensure that operational parameters are applied so that overall ROP is maximized. By combining the drill stem vibrations and the detailed PDC bit cutter wear and “safe” non-accelerated cutter wear temperature and optimum ranges of operating parameters, it results in higher ROP and lower cost drilling. Single cutter PDC testing performed in different lithologies at Sandia was utilized to verify the PDC cutter forces and depth of cut for new and worn cutters. Based on single cutter PDC temperature modeling, verification using single cutter data from the testing done by National Oilwell Varco (NOV) was performed. Sandia’s Hard-Rock Drilling Facility (HRDF) was utilized to test different drill bit configurations with different cutter designs and wear status with different induced modes of vibration to obtain the critical bit RPM/WOB ranges resulting in ineffective drilling and low ROP. The collected test data were further used to verify and calibrate the full hole PDC ROP model that was developed based on single cutter interaction data. A full coupled drill stem vibration model was formulated and verified with geothermal field data from the Chocolate Mountain Aerial Gunnery Range (CMAGR). A graphical user interface (GUI) was developed using Tkinter library in the computer programming language Python, which integrates all the developed models in one system. The developed system consists mainly of the PDC ROP model, PDC bit wear model, PDC cutter temperature model, Mechanical Specific Energy (MSE) model, and drillstring vibration model integrated into one system. The developed system can be used for both, post well analysis and real-time optimization using different criteria such as ROP maximization or MSE minimization. The software uses Differential Evolution Algorithm (DEA) to find optimum values for operational parameters based on last foot drilled while avoiding the drillstring vibration and cutter temperature critical operating parameters.

15 GEOTHERMAL ENERGY↗
DOE OSTI2023

RePED 250: A Revolutionary, High-Drilling Rate, High-T Geothermal Drilling System and Companion Power Electronics

Project partner, Tetra has demonstrated developed an electro-crushing technology, a repetitive, pulsed electric drill (RePED), capable of crushing hard rock in tension and at high speeds. In this project, NREL, TPL, and Tetra are upgrading the RePED drilling system for operation in 250 degree C environments, and demonstrating its effectiveness drilling hard rock. The RePED drilling system is being designed to function with most of the elements of a conventional drilling system (e.g., drill pipe, steering tools, measurement-while-drilling (MWD) systems, mud systems), so no specialized rigs or drill pipe are required.

geothermal↗
DOE OSTI2024

RePED 250: A Revolutionary, High Drilling Rate, High-T Geothermal Drilling System and Companion Power Electronics (Final Report)

Geothermal drilling in the United States is drastically slower and more costly than Oil and Gas drilling, primarily due to the additional challenges in geothermal wells: hard rock types and high temperatures. The Repetitive Pulsed Electric Drill (250 degrees C) (RePED-250), developed by Tetra Corporation has the potential to change this with a novel electro-crushing technology. RePED-250 releases pulses of electricity through the rock, which causes it to break in tension, instead of compression like conventional rotary drilling. The tensile strength of hard rocks like granite is only ~5% of their compressive strength, requiring less energy, time, and wear on the bit than conventional drilling. The RePED drill bit has no moving parts, uses drilling mud to remove rock fragments, and standard drill pipe, enabling a direct transition from conventional drilling systems. The objective of this project is to move RePED technology towards commercial readiness for high-temperature geothermal applications. This involves: 1) Creating high-temperature, high power electronic components for the RePED drill capable of operating at the high temperatures of a geothermal well. The target is a 250 degrees C ambient environment. Specifically, capacitors, high voltage switches, and a downhole generator capable of generating the necessary power. 2) Demonstrating RePED's effectiveness drilling through hard rock (granite) and examining its pathway to commercialization and effect on the US geothermal market. Work on this project has led to significant improvement over the state-of-the-art for all the examined electronics, through design, modeling, and testing of these novel components, though some additional development is still needed to deploy these high-temperature parts in a geothermal well. Besides their use in RePED-250, each component has applications in other industries where the stability of electronics at high-temperature is needed. To address the second barrier to commercialization, a 9" hole was drilled through a sample block of granite, demonstrating the tool's effectiveness in hard rock. The team investigated RePED-250's effect on well cost, and the geothermal industry, through various models described in the report.

15 GEOTHERMAL ENERGY↗
DOE OSTI2024

RePED 250: A Revolutionary, High Drilling Rate, High-T Geothermal Drilling System and Companion Power Electronics

Geothermal drilling in the United States is drastically slower and more costly than Oil and Gas (O&G) drilling, primarily due to the additional challenges in geothermal wells: hard rock types and high temperatures. The Repetitive Pulsed Electric Drill (250°C) (RePED-250), developed by Tetra Corporation has the potential to change this with a novel electro-crushing technology. RePED-250 releases pulses of electricity through the rock, which causes it to break in tension, instead of compression like conventional rotary drilling. The tensile strength of hard rocks like granite is only ~5% of their compressive strength, requiring less energy, time, and wear on the bit compared to conventional drilling. The RePED drill bit has no moving parts, uses drilling mud to remove rock fragments, and uses standard drill pipe, enabling a direct transition from conventional drilling systems. The objective of this project is to move RePED technology towards commercial readiness for high-temperature geothermal applications. This involves: 1) Creating high-temperature, high power electronic components for the RePED drill capable of operating at the high temperatures of a geothermal well. The target is a 250°C ambient environment. Specifically, capacitors, high voltage switches, and a downhole generator capable of generating the necessary power. 2) Demonstrating RePED’s effectiveness drilling through hard rock (granite) and examining its pathway to commercialization and effect on the US geothermal market. Work on this project has led to significant improvement over the state-of-the-art for all the examined electronics, through design, modeling, and testing of these novel components, though some additional development is still needed to deploy these high-temperature parts in a geothermal well. Besides their use in RePED-250, each component has applications in other industries where the stability of electronics at high-temperature is needed. To address the second barrier to commercialization, a 9” hole was drilled through a sample block of granite, demonstrating the tool’s effectiveness in hard rock. The team investigated RePED-250’s effect on well cost and the geothermal industry, through various techno-economic models described in the report.

15 GEOTHERMAL ENERGY↗
DOE OSTI2021

Comparison of Rotary and Linear Cutting Methodology in Determining Specific Cutting Energy of Granite

Abstract Single polycrystalline diamond compact (PDC) cutting is a practical technique to understand the rock–tool interactions in drag-bit-type geothermal drilling operations. This paper introduces a rotary cutting method to determine specific cutting energy (SCE) and compares it with the conventional linear cutting method. In this work, granite is selected to represent hard rock formations in geothermal drilling. Cutting tests are conducted on a Computer Numerical Control (CNC) machine with a realistic cutting speed of 12.7 m/min and several chip loads ranging from 0.08 to 0.25 mm. The cutting force is measured using a dynamometer and then converted to specific cutting energy (SCE). The results show that the rotary method produces an inverse relationship between SCE and chip load, whereas the linear method shows the opposite. As a result, the produced SCE by the rotary method tends to be lower than that of the linear method at a higher chip load at and over 0.16 mm. The difference may be attributed to the cutting configuration and associated force components.

Engineering↗
DOE OSTI2023

Sandia and Ditch Witch Technology Commercialization Fund Integral Motor and Percussive Hammer

This report captures the results of development and testing of a integral downhole motor and percussive hammer used for drilling in near-surface hard rock formations. The work was funded through the DOE Office of Technology Transitions Technology Commercialization Fund. It was a collaboration between Sandia National Labs and The Charles Machine Works (aka Ditch Witch). In the collaboration, Sandia developed a pneumatic motor derived from an indexing tool used in other drilling applications, and Ditch Witch developed the bearing pack tied to the output shaft of the motor as well as the angled beacon housing used for directional control.

15 GEOTHERMAL ENERGY↗
DOE OSTI2021

ROP model for PDC bits in Geothermal drilling

Geothermal energy is a renewable source of energy, where heat extraction is preferentially balanced with the reservoir's natural heat recharge rate. The objective of this paper is to present and validate a novel rate of penetration (ROP) model for drilling hard and abrasive formations including granite formations for polycrystalline diamond compact (PDC) bits. The ROP model was developed based on a derived relationship of a threshold weight on cutter (WOC) and its corresponding depth of cut (DOC) for a single cutter. Laboratory data was used to scale the derived single cutter relationship to a full-hole ROP model for PDC bits. The ROP model includes a non-linear correlation for Phase I (inefficient drilling due to low WOB values) and a linear Phase II (efficient drilling) ROP response to WOB. The ROP model was verified using measured drilling parameter data from Utah FORGE well# 58-32 and data from Chocolate Mountains well # 17-8 in Southern California. When compared to oil and gas well drilling, geothermal drilling in granitic formations can be more difficult and complicated due to rock hardness and high temperatures. PDC bits can increase ROP and optimize drilling for these types of hard formations. This paper provides novel insight into the ROP response of PDC bits to drilling operational parameters.

15 GEOTHERMAL ENERGY↗
DOE OSTI2024

RePED 250: Manufacturing and Market Analysis of High-Temperature Alternators

The novel repetitive pulsed electric drill 250 (RePED 250) has the potential to greatly lower the costs and drilling times of geothermal projects. This tool discharges electric pulses through hard rock formations, shattering the rock in tension and allowing it to be quickly removed. One hurdle in bringing this technology to market is the RePED 250 downhole alternator. This component is essential for supplying power to the electronic drilling tool. There are currently no downhole tools on the market that meet the RePED 250 alternator's high temperature and power requirements. This report focuses on the path to commercialization for this novel alternator technology being developed as part of the RePED 250 project. One aim of this work is to identify the geothermal market size for the RePED 250 alternator, as well as other potential markets for this technology outside of geothermal. The geothermal market is very small, with only approximately 13 wells drilled in the United States each year. The worldwide market is several times this size and growing each year. The ability of the RePED 250 technology to drastically reduce the cost of geothermal projects may also lead to an increase in this market size. Technology developed for the high-temperature, high-power RePED 250 alternator can also be used to create high-temperature and high-power motors. These motors and alternators will have potential applications in oil and gas drilling, a $300 billion dollar industry in the United States alone, as well as in more distant industries such as aircraft, weapon systems, space exploration, and electric vehicles. Other aspects of the RePED 250 alternator's path to commercialization are also analyzed, including the supply chain for production materials and potential manufacturing methods. The supply chain and manufacturing practices for low-temperature motors and alternators are well established and require relatively minor changes for the high-temperature and high-power RePED 250 alternator. Sourcing for high-temperature materials has been identified, as well as potential supply chain risks. These most notably include electrical steel and high-temperature samarium cobalt (SmCo) magnets. Overall, these risks are not expected to be significant at the likely manufacturing scale required for the RePED 250.

15 GEOTHERMAL ENERGY↗
DOE OSTI2022

Auto Indexer for Percussive Hammers Final Report

Geothermal energy has been underutilized in the U.S., primarily due to the high cost of drilling in the harsh environments encountered during the development of geothermal resources. Drilling depths can approach 5,000 m with temperatures reaching 170 C. In situ geothermal fluids are up to ten times more saline than seawater and highly corrosive, and hard rock formations often exceed 240 MPa compressive strength. This combination of extreme conditions pushes the limits of most conventional drilling equipment. Furthermore, enhanced geothermal systems are expected to reach depths of 10,000 m and temperatures more than 300 °C. To address these drilling challenges, Sandia developed a proof-of-concept tool called the auto indexer under an annual operating plan task funded by the Geothermal Technologies Program (GTP) of the U.S. Department of Energy Geothermal Technologies Office. The auto indexer is a relatively simple, elastomer-free motor that was shown previously to be compatible with pneumatic hammers in bench-top testing. Pneumatic hammers can improve penetration rates and potentially reduce drilling costs when deployed in appropriate conditions. The current effort, also funded by DOE GTP, increased the technology readiness level of the auto indexer, producing a scaled prototype for drilling larger diameter boreholes using pneumatic hammers. The results presented herein include design details, modeling and simulation results, and testing results, as well as background on percussive hammers and downhole rotation.

15 GEOTHERMAL ENERGY↗
DOE OSTI2022

Experimental Investigation of Drillstring Torsional Vibration Effect on Rate of Penetration with PDC Bits in Hard Rock

Polycrystalline diamond compact (PDC) bits have shown tremendous performance compared to roller cone bits and have gained attraction in deep geothermal drilling applications. While PDC bits can reach a higher rate of penetration compared to other bits, they are more prone to drilling vibrations. The scope of this paper is to quantify the effects of drillstring torsional vibrations on PDC bit performance using a laboratory testing facility. Here, the tests were performed with three drillstring configurations to evaluate the effect of drillstring vibrations. The results showed that rigid testing overestimates the bit rate of penetration by 35% due to torsional vibrations.

15 GEOTHERMAL ENERGY↗
DOE OSTI2023

Utah FORGE: Reports on Northwestern Nevada Well Doublet Drilling and Testing by Fervo Energy

These reports review Fervo Energy's construction of a commercial enhanced geothermal system (EGS). Fervo has qualified full functionality of the system through production testing at commercially relevant operating conditions. The project site is located in a nearfield setting adjacent to an operating geothermal power station in north-central Nevada and is designed to deliver an uplift in high-temperature geothermal flow rates to increase the power capacity at the facility. The project involved drilling a first-of-a-kind EGS horizontal doublet well system consisting of an injection and production well pair within a high-temperature hard-rock geothermal formation. The lithology of the target reservoir is characterized as a mixed metasedimentary and igneous formation, comprised of phyllite, quartzite, diorite, and granodiorite, representative of the geology across the most prospective geothermal areas throughout the western US. This work included a 16-stage plug-and-perforate stimulation treatment which was the first of its kind in a high-temperature mixed metasedimentary and granitic formation in a fully horizontal doublet geothermal well.

15 GEOTHERMAL ENERGY↗
DOE OSTI2026

A ModEx Framework for Watershed Subsurface Investigation With Limited Geophysical Data Using Machine Learning and Hydrologic Modeling

Abstract Subsurface heterogeneity influences watershed hydrology strongly but remains difficult to characterize at catchment scales with sparse and costly field data. Geophysical surveys such as electromagnetic induction (EMI) provide local spatial subsurface images yet scaling them to watershed scales and converting EMI‐derived resistivity into hydraulic properties remains a challenge. We present a Model–Experiment (ModEx) framework that integrates limited EMI data with machine learning (ML) and hydrologic modeling to improve process representation and guide field investigations. Sparse EMI surveys were scaled to the catchment scale using a Random Forest model, and the resulting resistivity fields were combined with nearby borehole constraints to parameterize a hydrologic model. The EMI‐informed hydrological simulations improved predictions of streamflow sustained by subsurface flow and shallow saturation patterns. By combining EMI data and ML with hydrologic modeling, the ModEx framework guides future subsurface surveys, providing a transferable and efficient strategy for data–model integration across diverse watersheds. Plain Language Summary Mapping the underground network of soil and rock that controls water is essential for predicting floods and droughts, but seeing underground is difficult and expensive. We cannot drill everywhere, so scientists use geophysical tools to scan broad areas. There are two key challenges: these geophysical scans are often sparse across the whole watershed, and the geophysical data is hard to translate into water‐related properties. We used artificial intelligence to solve these problems. We taught a computer to find patterns linking the limited geophysical data to the land surface properties. This allowed it to fill in the gaps and create a complete, useful subsurface map for the entire watershed. This new map improves hydrologic simulations, leading to more accurate predictions of water movement in the watershed. It also helps scientists build better models with less data and generates a priority map showing where to measure next, making future investigations more efficient. Key Points Limited EMI scaled with ML improves catchment‐scale subsurface parameterization for hydrologic models The framework integrates hydrologic modeling with limited geophysical data to support subsurface investigation design ModEx framework offers a transferable data–model integration strategy that quantifies and reduces uncertainty guiding watershed studies

Chen, Hang↗
DOE OSTI2021

Multiscale Characterization of the Caney Shale — An Emerging Play in Oklahoma

From a hydrocarbon perspective, the Caney Shale has historically been evaluated as a sealing unit, which resulted in limited studies characterizing the rock properties of the Caney Shale and its suitability for hydraulic fracturing. The objective of our research is to help bridge the current knowledge gap through the integration of multiscale laboratory techniques and to characterize the macro- and microscale rock properties of the Caney Shale. We employed an integrated approach for the characterization of the Caney using 200 ft (61 m) of Caney core from a target well in southern Oklahoma. Core observation and petrographic analysis of thin sections were combined to characterize the general rock types and associated fabrics and textures. Mineralogical composition, pore system architecture, and rock fabric were analyzed using x-ray diffraction (XRD), scanning electron microscopy/energy dispersive x-ray spectroscopy (SEM/EDS), and focused ion beam (FIB)-SEM. In addition, rebound hardness and indentation testing were carried out to determine rock hardness (brittleness) and elasticity, respectively. With the integrated multiscale characterization, three mixed carbonate-siliciclastic rock types were identified — mudstone, calcareous siltstone, and silty carbonate — likely representing a spectrum of deposition from low to relatively high energy environments in the distal portions of a ramp system. Silty carbonate contains mostly interparticle pores. The calcareous siltstones and silty mudstones contain a combination of organic matter pores and interparticle pores. Each of the rock types shows unique mineralogical compositions based on XRD. The mudstone lithofacies has the highest clay content and the least carbonate content. Calcareous siltstones show moderate carbonate and clay content. Silty carbonate indicates the highest carbonate content with the least clay content. In an order of mudstone, calcareous siltstone, and silty carbonate, rebound hardness and Young’s modulus show an increasing trend. As a result of rock-fluid interactions, there are potential scaling reactions during completion and production that could ultimately affect permeability and production rates. Overall, the proposed multiscale integration approach is critical for the geologic characterization of most rocks. However, in shale reservoirs dominated by microporosity and microstructure where engineered fractures are expected to provide permeability at a reservoir scale, successful integration is essential. An optimized, integrated geological characterization of the Caney Shale that is well aligned with the engineering designs in drilling, completing, and producing wellbores will ultimately lead to optimal production while providing safe and environmentally responsible operations.

Wang, Yulun↗