Rolf Bracke GZB – International Geothermal Centre, Bochum, Germany

Innovations in Drilling Technologies IEA Geothermal Central and South American Workshop on Geothermal Energy Opportunities and Benefits of Geothermal Direct Use and Innovations in Geothermal Energy Cuernavaca, Morelos, Mexico, 18 & 19 April 2016

Department for Advanced Drilling Technologies (Head: Volker Wittig) 1. BO.REX - 60t Conventional Drilling Rig 2. Coiled Tubing Drilling Evolution Technologies 3. Hyper-Coring System (ICDP - offshore drilling program) 4. High-pressure Water Technologies 5. Thermal Drilling Tooling Developments (Laser & Plasma)

Quelle: BGR

Main areas of drilling technologies are currently being investigated

Percussion DTH hammer drilling

Water Jet drilling

Coiled Tubing drilling

Thermal drilling technologies

Advanced Drilling Technology Research at GZB

Four main areas of drilling technologies are currently being investigated :

Percussion DTH hammer drilling, based on water and especially drill mud including full recirculation of the drilling fluids

Water Jet drilling, based on high pressure liquids / slurries, with /-out abrasives

Coiled Tubing drilling applications, here especially micro hole drilling based on engineered composites, percussion DTH tooling and (abrasive) jetting including directional drilling

Thermal drilling technologies to introduce the new paradigm of drilling Laser supported drilling being the main topic, Plasma drilling techniques are under investigation and evaluation as well as so called Spallation drilling

Advanced Drilling @ GZB

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• hydraulic DTH mud hammer • direct working - with elastomeric recovery • flow through system • possibly dual fluid system

• low differential pressure << 100 bar • adequately high flow rate • high impact energie • low number of moving parts • adjustable frequency

DTH Mud Hammer at GZB in development Coiled Tubing compatible for hard rock

> 160 kW hydraulic power

250 kW Diesel engine @ max. 2.100 RPM

pressure and flow regimes 100 – 1.500 bar up to 8 ½ inch hole size

DTH Hammer Sizes 2“ – 8 1/2“ powered by Triplex Plunger Pump

standard 20 ft ISO container: - pump + engine - 5 m³ water storage tank - various pump heads + tooling

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DTH water hammer drilling + testing: „GeoStar-Project“

expandable shallow geothermal plant very small drilling pad only small surface area required to

install many borehole heat exchangers Accurate, „directional“ drilling with

DTH water hammer

Recirculation and conditioning of drilling fluids for deep drilling with DTH mud hammer systems

complete lamella type

cleaner system

overview recirculation system for

hydraulic DTH water / mud

hammer drilling system

reycling unit with desander desilter,

shaker type cleaner system

sedimentation and mixing

tanks

centrifuge unit if needed for finest

particles

Seismic while drilling data for reservoir and drilling prediction

use of DTH mud hammer high rate of penetration excellent seismic data for

geology analysis and prediction

little borehole deviation & high quality

Full circulation of drilling fluid possible

DTH Seismic while Drilling (cooperation project with OGS / Trieste, Italy)

DTH water hammer makes for very fast drilling and excellent seismic noise source

INTERNATIONALES GEOTHERMIEZENTRUMINTERNATIONAL GEOTHERMAL CENTER

BO.REX Bochum Research & Exploration Drilling Rig 40+20t pull capacity

Four main areas of drilling technologies are currently being investigated :

Percussion DTH hammer drilling, based on water and especially drill mud including full recirculation of the drilling fluids

Water Jet drilling, based on high pressure liquids / slurries, with /-out abrasives

Coiled Tubing drilling applications, here especially micro hole drilling based on engineered composites, percussion DTH tooling and (abrasive) jetting including directional drilling

Thermal drilling technologies to introduce the new paradigm of drilling after the tricone bit had been invented well over 100 years ago Laser supported drilling being the main topic, Plasma drilling techniques are under investigation and evaluation as well as so called Spallation drilling

Advanced Drilling @ GZB

INTERNATIONALES GEOTHERMIEZENTRUMINTERNATIONAL GEOTHERMAL CENTER

Technical options 100 bar 200 bar 800 bar 1.600 bar 1.600 bar abrasive Flow < 2.000 L/min

High pressure water triplex plunger + piston pumps up to 460 kW

GeoJetting Drilling for shallow geothermal systems

Drilling with high- pressure water 800 bar + 100 l/min → ≈ 130 kW hydr. Power

Drilling with high pressure water technique + abrasives 1.500 bar @ 80 l/ min for hard rock geologies Introduction of silicates into the jetstream as working agent @600m/s

The way ahead: Abrasive water jet drilling

Four main areas of drilling technologies are currently being investigated :

Percussion DTH hammer drilling, based on water and especially drill mud including full recirculation of the drilling fluids

Water Jet drilling, based on high pressure liquids / slurries, with /-out abrasives

Coiled Tubing drilling applications, here especially micro hole drilling based on engineered composites, percussion DTH tooling and (abrasive) jetting including directional drilling

Thermal drilling technologies to introduce the new paradigm of drilling after the tricone bit had been invented well over 100 years ago Laser supported drilling being the main topic, Plasma drilling techniques are under investigation and evaluation as well as so called Spallation drilling

Advanced Drilling @ GZB

Coiled Tubing Drilling Evolution • interdisciplinary GZB students project • managed & run mostly by students from

HSBO / RUB / RWTH / TUC / WH / HSOWL

Coil : very light weight but high collapse / burst rating as tubular is composite / fiber reinforced material

excellent spoolability due to high ductility of the Composite materials, no micro cracking issues

Long service life due to enhanced mechanical properties and excellent fatigue life

exact design of composite coil possible based on work load requirements e.g. DTH hammer drilling etc.

Composite type tubing

Coiled tubing Reel

Power Supply

& Pumping system

Coiled Tubing Evolution Demonstrator Drill Rig • DTH hammers with composite coils • Thermal drilling • Microhole jetting • Directional tooling

Injector head with guide arch

• More flexibility larger Ø possible • > 75 % lighter weight in air over steel • excellent spoolability • “earth worm” principle possible • fatigue resistant: >18.000 cycles

without failure • Chemically resistant • low inner surface roughness: less

pressure drop, improved flow

CT Drilling Innovation - new coil materials composites / engineered Plastics

Novel Productivity Enhancement Concept for a Sustainable Utilization of a Geothermal Resource - SURE H2020-LCE-2014-2015 / subcall LCE-2015-1

Helmholtz Zentrum Potsdam Deutsches GeoForschungsZentrum GFZ Germany Technische Universiteit Delft (TUD) The Netherlands International Geothermal Centre (GZB) Germany Íslenskar Orkurannsóknir (ISOR) Iceland Nederlandse Organisatie voor toegepast-natuurwetenschappelijk onderzoek – TNO The Netherlands Well Services b.v. (WS) The Netherlands Imperial College of Science, Technology and Medicine (ICL) United Kingdom Geoterma UAB Lithuania Gamtos tyrimu centras (GTC) Lithuania

Future Research Plan: µ CT-Exploration • depth max. 500 meters • 5 ton injector • Exploration • Temp. Gradient drilling • Mining operations • Special drilling jobs /

foundation works

(Fotos: CSIRO)

Future Research Plan: µ CT-Exploration • depth max. 500 meters • 5 ton injector • Exploration • Temp. Gradient drilling • Mining operations • Special drilling jobs /

foundation works

ECOS-Loop

Gaschromatograph

Online-Detector

Gas-Trap

Conventional MIP-Application

ECOS- online-Application

Data Acquisition

PID/FID

SUGAR

Submarine Gashydrate Reservoir to produce Methane out of Gas Hydrates Exploration - Production – Transport

Financial Support:

mobile SCTDU

Composite Hybrid Riser

Production System

SUGAR B3: Gas Hydrate Production Drilling with Coiled Tubing: Subsea CT Drilling Unit (SCTDU) with surface vessel (of opportunity)

Four main areas of drilling technologies are currently being investigated :

Percussion DTH hammer drilling, based on water and especially drill mud including full recirculation of the drilling fluids

Water Jet drilling, based on high pressure liquids / slurries, with /-out abrasives

Coiled Tubing drilling applications, here especially micro hole drilling based on engineered composites, percussion DTH tooling and (abrasive) jetting including directional drilling

Thermal drilling technologies to introduce the new paradigm of drilling Laser supported drilling being the main topic, Plasma drilling techniques are under investigation and evaluation as well

as so called Spallation drilling

Advanced Drilling @ GZB

Laser Jet Drilling Project: Laboratory tests + results waterjet guided LASER cutting and drilling

Financial Support:

Thermal Drilling: Plasma supported

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