Experiments on Rock-Bit Interaction During a Combined Thermo-Mechanical Drilling Method

Abstract

The development of deep geothermal systems to boost global electricity production relies on finding cost-effective solutions to enhance the drilling performance in hard rock formations. Conventional drilling methods, based on mechanical removal of the rock material, are characterized by high drill bit wear rates and low rates of penetration (ROP) in hard rocks, resulting in high drilling costs, which account for more than 60% of the overall costs for a geothermal project. Therefore, alternative drilling technologies are investigated worldwide with the aim of improving the drilling capabilities and therewith enhancing the exploitation of deep geothermal resources. In this work, a promising drilling method, where conventional rotary drilling is thermally assisted by a flame-jet, is evaluated. Here, the thermal weakening of the rock material, performed by flame-jets, facilitates the subsequent mechanical removal performed by conventional cutters. The flame moves on the rock surface and thermally treats the material by inducing high thermal gradients and high temperatures, therewith reducing the mechanical properties of the rock. This would result in reduced forces on the drill bits, leading to lower bit wear rates and improved rates of penetration and therefore significantly decreasing the drilling costs, especially for deep-drilling projects. In this work, the feasibility of the proposed drilling method is assessed by comparing the rock-bit interaction in sandstone and granite under baseline and thermally treated conditions. Rock abrasivity, tool penetration and cutting forces are investigated to quantify the rock-bit interaction in granite and sandstone under baseline conditions and after the thermal treatment. The results highlights the dominant mechanisms regulating the rock removal. The removal performance of the tool in the granite material are found to be greatly enhanced by the thermal treatment both in terms of volume removed from the sample and worn volume at the tool’s tip. On the other hand, the sandstone material, after a thermal treatment, yields significantly lower wearing of the cutting tool. Thus, this results allow to draw important conclusions regarding the achievable drilling performances during the combined thermo-mechanical drilling method towards its application in the field.