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At least 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Pressure Transducer Measurement Variability in Deep Wells Screened Across the Water Table

Abstract Automated water level measurements collected using vented pressure transducers in deep wells screened across the water table may exhibit a greater response to barometric pressure changes than the true water level. The cause was hypothesized to be disequilibrium in barometric pressure between the wellbores and land surface due to air exchange with the deep vadose zone. In this study, vented and nonvented pressure transducers were installed and operated simultaneously in two deep wells screened across the water table. A vent tube open to the atmosphere at land surface allowed for barometric compensation of the vented transducers. Two nonvented transducers were installed in each well, one submerged in the water and one above the water surface. The difference in readings allowed for barometric compensation. Manual measurements were also collected. It was confirmed that measurements from the vented transducers exhibited greater variability in response to barometric pressure changes than the nonvented transducers and manual measurements. Comparison of the downhole barometric pressure measurements to values from a nearby meteorology station showed the response in the wells to changes in barometric pressure was time‐lagged and attenuated. Thus, the reference pressure from land surface supplied to the vented transducers was not representative of the air pressure within the wells. This caused fluctuations of the transducer readings in response to barometric pressure changes to be greater than the true water level change. This issue can be resolved by the use of nonvented pressure transducers.

McDonald, John P.↗
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 OSTI2021

Investigating Fracture Network Deformation Using Noble Gas Release

We investigate deformation mechanics of fracture networks in unsaturated fractured rocks from subsurface conventional detonation using dynamic noble gas measurements and changes in air permeability. We dynamically measured the noble gas isotopic composition and helium exhalation of downhole gas before and after a large subsurface conventional detonation. These noble gas measurements were combined with measurements of the subsurface permeability field from 64 discrete sampling intervals before and after the detonation and subsurface mapping of fractures in borehole walls before well completion. We saw no observable increase in radiogenic noble gas release from either an isotopic composition or a helium exhalation point of view. Large increases in permeability were observed in 13 of 64 discrete sampling intervals. Of the sampling intervals which saw large increases in flow, only two locations did not have preexisting fractures mapped at the site. Given the lack of noble gas release and a clear increase in permeability, we infer that most of the strain accommodation of the fractured media occurred along previously existing fractures, rather than the creation of new fractures, even for a high strain rate event. These results have significant implications for how we conceptualize the deformation of rocks with fracture networks above the percolation threshold, with application to a variety of geologic and geological engineering problems.

Gardner, W. Payton↗
DOE OSTI2023

DEEPEN Leapfrog Geodata Model Cleaned and Reformatted Exploration Datasets from Newberry Volcano

DEEPEN stands for DE-risking Exploration of geothermal Plays in magmatic ENvironments. As part of the DEEPEN 3D play fairway analysis (PFA) conducted at Newberry Volcano for multiple play types (conventional hydrothermal, superhot EGS, and supercritical), existing geoscientific exploration datasets needed to be acquired, cleaned, reformatted, and assembled in Leapfrog Geothermal. This GDR submission includes all of the cleaned and reformatted (X (m), Y (m), elevation (m), processed data values) datasets used to build the Leapfrog Geodata model. Existing datasets were acquired from the GDR, from AltaRock, and from other sources. This yielded the following datasets: - Digital elevation model produced from LiDAR data by Ramsey and Bard, 2016 - MT surveys from 2006, 2011, 2014, and 2017 (including single inversions) - Gravity surveys from 2006, 2007, and 2011 (including single) - Earthquake catalogs from PNSN, LLNL, and the Newberry EGS Demonstration project - Seismic velocity model from Templeton et al., 2014 - The Frone, 2015 temperature model and a new one produced through extrapolating downhole temperature measurements and the SMU temperature at depth maps. Two versions of the new model are provided: 250 m spacing and 500 m spacing - EarthVision geologic model with alteration from Moser et al., 2016 - Well data from EGS well 55-29, deep geothermal wells, coreholes (GEO N-2 through 5) and several thermal gradient holes - "Newberry Well Data:" Location, simple lithology, directional survey data, and temperature data for the 34 wells and coreholes used in the Newberry PFA Although there are additional 2D datasets available in the area, such as aeromagnetic surveys, these were not included in the analysis. While it may be possible to project these datasets into three dimensions by assuming the surface measurements do not vary with depth, this method is associated with high uncertainty. Preexisting inversions of these data were unavailable, and inverting additional geophysical datasets is outside the scope of this project.

15 GEOTHERMAL ENERGY↗
DOE OSTI2023

Utah FORGE: Well 16A(78)-32/Well16B(78)-32 Circulation Test Data

This dataset encompasses the collected data and associated reports from the low-rate injection circulation test conducted on wells 16A(78)-32 and 16B(78)-32 in July 2023 at Utah FORGE. It includes comprehensive raw circulation data, captured by Pason and Schlumberger (SLB). The dataset details various parameters recorded during circulation testing such as produced fluid, injection pressure, injection rate, produced rate, temperature, downhole pressure difference, bottom hole pressure in the well, and surface treating pressure. Note that the Pason data is presented in Mountain Time, whereas the SLB data is in Pacific Time.

15 GEOTHERMAL ENERGY↗
DOE OSTI2024

Utah FORGE 10-3726: Geothermal Multiset Straddle for High Temperature Applications - 2024 Annual Workshop Presentation

This is a presentation on the Geothermal Multiset Straddle (GMS) for High Temperature Applications by Welltec, presented by Ricardo Vasques. This video slide presentation discusses the development of (1) an annular multiset isolation system; (2) a stimulation straddle isolation system; and (3) a multi open-close flow system, for geothermal environments. This is to enable effective zonal isolation and stimulation with multiset capabilities, to implement downhole controlled EGS in any location, and to extend the productive life of the well. This presentation was featured in the Utah FORGE R&D Annual Workshop on August 15, 2024.

15 GEOTHERMAL ENERGY↗
DOE OSTI2024

Utah FORGE: Neubrex Well 16B(78)-32 DAS Data - April, 2024

This dataset comprises Distributed Acoustic Sensing (DAS) data collected from the Utah FORGE monitoring well 16B(78)-32 (the producer well) during hydraulic fracture stimulation operations conducted in April 2024. The data were acquired continuously over the stimulation period at a temporal sampling rate of 10,000 Hz (10 kS/s) and a spatial resolution of approximately 3.35 feet (1.02109 meters). The measurements were captured using a Neubrex NBX-S4100 Time Gated Digital DAS interrogator unit connected to a single-mode fiber optic cable, which was permanently installed within the casing string. All recorded channels correspond to downhole segments of the fiber optic cable, from a measured depth (MD) of 5,369.35 feet to 10,352.11 feet. The DAS data reflect raw acoustic energy generated by physical processes within and surrounding the well during stimulation activities at wells 16A(78)-32 and 16B(78)-32. These data have potential applications in analyzing cross-well strain, far-field strain rates (including microseismic activity), induced seismicity, and seismic imaging. Metadata embedded in the attributes of the HDF5 files include detailed information on the measured depths of the channels, interrogation parameters, and other acquisition details. The dataset also includes a recording of a seminar held on September 19, 2024, where Neubrex's Chief Operating Officer presented insights into the data collection, analysis, and preliminary findings. The raw data files, stored in HDF5 format, are organized chronologically according to the recording intervals from April 9 to April 24, 2024, with each file corresponding to a 12-second recording interval.

15 GEOTHERMAL ENERGY↗
DOE OSTI2025

Utah FORGE: Well 16B(78)-32 Drill Core Fracture Analysis Images and Data

This dataset contains drilling core data from well 16B(78)-32, including PDF documents with flattened core images annotated by feature type and core interval, as well as spreadsheets detailing feature morphologies by depth, planar feature measurements, and planar feature orientations rotated to in situ conditions. Core was recovered from three intervals, one per stimulation stage, in the crystalline rocks affected by the stimulation of well 16A(78)-32. Seven core runs were conducted, yielding 135.8 feet of recovered core. Features in the core were categorized into planar fractures, semi-planar fractures, unbroken mineralized fractures, rough fractures, curviplanar fractures, concave-convex surfaces, and planar compositional features such as mylonite or dike-like structures. Planar features were measured while the core was positioned horizontally, with the core axis aligned to a downhole azimuth of 42 degrees. Planar core measurements from stimulations 2 and 3 that could be confidently correlated with FMI data were rotated to in situ orientations. This was done by rotating the planes along vertical and horizontal axes to match the azimuth and inclination data recorded in the directional survey of well 16B(78)-32, as well as applying an axial rotation to resemble the fracture orientations observed in the FMI log at corresponding depths. Coherent sets of planar fracture measurements were made by aligning the core within each 3-foot section of the dissected core barrel, and between adjacent 3-foot sections within a core run by matching rock fabrics, saw cuts and/or tool marks. Where coherent fracture measurements could not be made within a core run, data sets are denoted by a subscript (i.e. 2-Ta and 2-Tb both come from tangent core run number 2).

15 GEOTHERMAL ENERGY↗
DOE OSTI2021

Microseismic at HFTS2: A Story of Three Stimulated Wells

A microseismic data set was acquired at Hydraulic Fracturing Test Site 2 (HFTS2) in the Delaware Basin (Texas, USA) by the HFTS2 consortium as a part of data-collection program designed to help maximize the efficiency of hydraulic fracturing, understand the impacts of nearby depleted zones, and increase the production of hydrocarbons. Advanced methods of microseismic monitoring applied at HFTS2 include 1) native synchronization of five monitor arrays, 2) real-time location of microseismic events, 3) joint event hypocenter/ velocity-model inversion that locates microseismic events simultaneously with constructing azimuthally anisotropic velocity models, 4) high-resolution reservoir imaging, utilizing microseismic events as downhole sources. HFTS2 microseismic data set illustrated the influence of geologic complexity, variations in treatment designs, and the presence of parent wells on the efficiency of hydraulic fracturing. Three Wolfcamp wells, Boxwood 1H, 2H, and 4H, were stimulated sequentially, exhibiting very different patterns of microseismicity. When the Boxwood 1H well is stimulated, its toe stages quickly reacted to the presence of depleted Bitterroot section to the east of the Boxwood pad, extending microseismic events over 3,000 ft to the east. This behavior changes dramatically after the treatment passes the Bitterroot section at the toe, and the heel stages in 1H showed tight microseismic grouping around the stimulated well, indicative of treatment of virgin reservoir rock. The Boxwood 2H demonstrates this same pattern of behavior between the toe and heel stages of the well, suggesting that the depleted Bitterroot section remains easier to refracture than adjacent non-depleted rock. Microseismic activity associated with Boxwood 4H treatment is distinctly different from those in Boxwood wells 1H and 2H. The events generated during stimulation of 4H are hardly influenced by the depleted Bitterroot section and fill the space between the previously stimulated 1H and 2H wells. Altogether, microseismic patterns suggest that treatment fluids tend to find the weakest passages through geologic formations, and the relative well positions and treatment sequence have a significant impact on fracture geometry, as indicated by microseismic event locations.

58 GEOSCIENCES↗
DOE OSTI2024

Integrating Experiments and Well Logs to Predict Caney Shale Static Mechanical Properties During Production with Supervised Machine Learning

Caney shale is one of the emerging oil reservoirs in Oklahoma. Understanding the impact of effective stress on its mechanical properties is critical for predicting hydraulic fracture geometry and overall hydrocarbon production. The objective of our study is to evaluate the impact of effective stress on the dynamic Young’s modulus using ultrasonic velocity measurements for Caney shale samples. A triaxial cell was utilized to measure ultrasonic (P-wave and S-wave) velocities for ten downhole Caney shale samples under various effective stresses to indirectly assess the impact of pore pressure change. The dynamic Young’s moduli estimated from these measurements were integrated with available conventional well logs (excluding sonic logs) and triaxial test results from Benge et al. (2021) to predict the static Young’s modulus using Random Forest (RF) and Extreme Gradient Boosting (XGBoost) models. The results showed that the estimated dynamic Young’s moduli from ultrasonic measurements were higher than the corresponding static Young’s modulus of cores from the same vertical well at similar depths. With increasing effective stress, the dynamic Young’s modulus increased for all samples. The estimated dynamic-to-static correction factor tended to be higher in zones of high neutron porosity (PHIN) and low density compared to other zones. Finally, SHapley Additive exPlanations (SHAP) for RF and XGBoost models identified depth, gamma ray (GR), and PHIN as key features for predicting the static Young’s modulus. This study enhances our understanding of the dynamic and static Young’s moduli for the Caney shale interval, as a function of effective stress and conventional well logs. The findings from this study can improve predictions of production throughout the well's lifespan by offering insights into the mechanical property degradation resulting from pore pressure depletion.

Kholy, Sherif M.↗
DOE OSTI2021

Illinois State Geological Survey (ISGS), Illinois Basin - Decatur Project (IBDP) Seismic Data, July 7, 2021. Midwest Geological Sequestration Consortium (MGSC) Phase III Data Sets. DOE Cooperative Agreement No. DE-FC26-05NT42588.

Seismic data from the IBDP, included primarily under folders: Active_Seismic_Data and Passive_Seismic_Events_Monitoring. The data included under IBDP_Located_Microseismic_Event_Data are a subset of microseismic (Passive Seismic Events Monitoring) data acquired throughout the project from pre-injection to shut-in. These data represent the “located” microseismic events and the two datasets, located in folders Downhole_Geophone_Data and Surface_Seismometer_Data, are correlated.

3D Seismic,Carbon Sequestration,Decatur,Illinois B↗
DOE OSTI2022

Rock Physics-Based Data Assimilation of Integrated Continuous Active-Source Seismic and Pressure Monitoring Data during Geological Carbon Storage

Summary There has been substantial controversy concerning the role of geological carbon storage (GCS) in sequestering anthropogenic carbon emissions to mitigate climate change and global warming. Arguments center on the inability to monitor a geological storage site precisely and continuously, especially highlighting the associated costs and spatiotemporal trade-offs when using conventional subsurface monitoring techniques (well logs, core samples, chemical tracers, and 4D seismics). Active surveillance of GCS sites is essential for managing and mitigating potential leaks but is also required by regulation. With the goal of enhancing the monitoring capability at GCS sites, we present a rock physics-based joint data assimilation model to study a popular GCS site at Cranfield, Mississippi, USA. Synthetic continuous active-source seismic monitoring (CASSM) data (in the form of Vp and Qp measurements) and wellbore pressure monitoring data are assimilated with an ensemble of reservoir realizations to monitor gas saturation and reservoir pressure changes over a period of 100 years. Synthetic seismic attributes are generated using rock physics models (RPMs) and wellbore pressure monitoring data are extracted from the ground truth. Two assimilation methods, ensemble Kalman filter (EnKF) and ensemble Kalman smoother (EnKS), are tested in an observation system simulation experiment (OSSE) environment to assess the prediction accuracy of the individual and composite observation systems. The joint monitoring system achieves more accurate estimates of gas saturation and pressure, across the time span from start of injection to end of forecast, as compared to a single type of monitoring tool and irrespective of data assimilation algorithm choice. These results indicate that jointly assimilated data from two types of sensors (in this case, crosswell seismic and downhole pressure) may lead to a more risk-reducing monitoring design. One would expect that more data, vis-à-vis inclusion of a new sensor type, will improve the accuracy of any GCS monitoring system. However, from a practical standpoint, one important question is whether such a gain in accuracy is worth the additional cost associated with the new sensor. This paper focuses on quantifying the gain in accuracy, such that a practitioner can answer this question.

Engineering↗
DOE OSTI2021

Development and Field Testing Novel Natural Gas Surface Process Equipment for Replacement of Water as Primary Hydraulic Fracturing Fluid (Final Report)

Southwest Research Institute® (SwRI ® ), Schlumberger Technology Corporation (SLB), and Chevron Corporation ® (Chevron) developed a novel, optimized, and lightweight process for natural gas (NG) to replace water as a low-cost fracturing medium with a low environmental impact. Hydraulic fracturing is used to increase oil and NG production by injecting high-pressure fluid, primarily water, into a rock formation, which fractures the rock and releases trapped oil and NG. This method was developed to increase yield and make feasible production areas that would not otherwise be viable for large-scale oil and NG extraction using traditional drilling technologies. Since the fracturing fluid is composed of approximately 90% water, one of the principal drawbacks to hydraulic fracturing is its excessive water use and associated large environmental footprint. According to recent data collected at fracture sites within the United States, fracturing applications in North America can consume as much as 9 million gallons of water per well. During the fracturing process, some of the fracturing fluid is permanently lost and the portion that is recovered is contaminated by both fracturing chemicals and dissolved solids from the formation. The recovered water or flow-back represents a significant environmental challenge, as it must be treated before it can be reintroduced into the natural water system. Although there is some recycling for future fracturing, the majority of the flow-back water is hauled from the well site to a treatment facility or to an injection well for permanent underground disposal. To mitigate these issues, an optimized, lightweight and modular surface process using NG to replace a majority of the water was developed as a cost-effective and environmentally clean fracturing fluid. Using NG will result in significantly less consumption since the gas that is injected as a fracturing fluid will be mixed with the formation gas and extracted as if it were from the formation itself. This process will minimize the collection, waste, and treatment of large amounts of water and will reduce the environmental impact of transporting and storing the fracturing fluid. There are two major steps involved in utilizing NG as the primary fracturing medium: (1) increasing the supply pressure of NG to wellhead pressures suitable for fracturing and (2) mixing the required chemicals and proppant needed for the fracturing process at these elevated pressures. The second step (NG-proppant mixing at elevated pressures) still requires demonstration; but very similar processes have been demonstrated in the field with other gases such as nitrogen (N 2 ) and carbon dioxide (CO 2 ). However, the first step (a compact, on-site unit for generating high-pressure NG at costs feasible for fracturing) has not been developed and is currently not commercially available. Due to the inherent compressibility of NG, more energy is required to compress the gas than what is required to pump water (or other incompressible liquids) to the very high pressure required for downhole injection. This project aimed to develop a novel, hybrid method to overcome this challenge. The project accomplishments and findings are discussed in this report. Ultimately, the research and development efforts described herein demonstrate that fracturing with NG foam is a feasible alternative to using water.

02 PETROLEUM↗
DOE OSTI2021

Fiber optic system for direct detection of CO 2 leakage in carbon storage wells (Abbreviated Final Report)

The feasibility study focused on the development of new fiber for distributed chemical sensing that will allow direct detection of CO2 leakages in the environment. This is particularly important for monitoring well integrity for carbon capture and storage (CSS), which can provide early warning for an incoming well failure and potential CO2 leaking through it. We proposed Raman or IR interrogation within gas-filled Holey Fibers (HoFs) interleaved with Fiber Bragg Grating (FBG) sections, so that the location and concentration of the gases would be provided simultaneously. The methodology would overcome current roadblocks to using fiber optics for CO2 (and other gases) detection in wells with direct in-situ measurements of concentration along with other important parameters such as temperature and pressure. We were able to assess commercially available IR/Raman hollow core fiber and demonstrated detection of CO2 through them in our controlled environment setups at various pressure conditions. We have also established the ability of drilling precisely with fs-lases side holes to enable penetration of CO2 into the hollow core fiber and reduce diffusion rates. Open joint collars were also explored with double functionality: to obtain splice to solid core fiber critical for field deployment and create gas ingress locations. Both diffusion-only and pressurized fiber system have been constructed following COMSOL based semi-hybrid optical /fluidodynamics models. FBGs have been identified and procured and characterized. Along the work we leveraged internal modeling/design, photonics/laser characterization, optical fiber fabrication, and AM lab capabilities to design, develop and test in-house components or assemblies. Our results indicate the potential of HoF for CO2 downhole direct detection.

25 ENERGY STORAGE↗
DOE OSTI2021

Evaluation of Microhole Drilling Technology for Geothermal Exploration, Assessment, And Monitoring

One of the greatest barriers to geothermal energy expansion is the high cost of drilling during exploration, assessment, and monitoring. Microhole drilling technology—small-diameter 2–4 in. (~5.1–10.2 cm) boreholes—is one potential low-cost alternative for monitoring and evaluating bores. However, delivering high weight-on-bit (WOB), high torque rotational horsepower to a conventional drill bit does not scale down to the hole sizes needed to realize the cost savings. Coiled tube drilling technology is one solution, but these systems are limited by the torque resistance of the coil system, helical buckling in compression, and most of all, WOB management. The evaluation presented herein will: (i) evaluate the technical and economic feasibility of low WOB technologies (specifically, a percussive hammer and a laser-mechanical system), (ii) develop downhole rotational solutions for low WOB drilling, (iii) provide specifications for a low WOB microhole drilling system, (iv) implement WOB control for low WOB drilling, and (v) evaluate and test low WOB drilling technologies.

15 GEOTHERMAL ENERGY↗
DOE OSTI2021

Intelligent Monitoring System for Real-time Geologic Storage, Optimization, and Reservoir Management

The objective of the subtask was to develop a near-real-time monitoring system for seismic data at the Decatur, IL, geologic carbon sequestration (GCS) site and specifically include fiber-optic cable derived distributed acoustic signal (DAS) data in the process. Owing to the large volumes of data, we opted to utilize existing deep borehole conventional seismic sensors for detection and pull DAS and shallow borehole seismic data once a detection has been made. Unfortunately, the horizontal fiber-optic cables did not yield microseismic signals for use in locating events near the GCS site. Various stacking and filtering approaches were tested without any coherent detection becoming apparent. We attribute the insensitivity to local microseismic events to a lack of coupling in downhole, vertical cable and the non-ideal alignment of the horizontal fiber-optic cable to the vertically polarized seismic energy. Despite the inability to detect and utilize the DAS data from the fiber-optic cables, we developed a general processing framework that enables easy adaptation for future deployment of fiber-optic cables with better suited alignment at Decatur or elsewhere.

Kaven, J. Ole↗
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

Ultra-fast and Thick Boriding of Geothermal Casing to Enhance Reliability

Harnessing the heat that is continuously generated underneath the Earth’s crust (geothermal) is a clean and renewable source of energy. Geothermal energy can be used to heat and cool buildings, including greenhouses, and to generate electrical power. Compared to other renewable energy sources such as solar and wind, geothermal energy is more reliable because it is available all the time and versatile in its many forms of application and deployment. Nonetheless, the deployment and extensive use of geothermal energy still lags behind other renewable sources due to some technical, but mainly economic challenges. Upfront costs of geothermal power well development are relatively high. Some of this high cost is attributed to the use of expensive construction materials to ensure adequate performance during operation. For example, Inconel 625, super duplex 2507, and titanium alloy materials are used in downhole casings, piping, and other components exposed to brine solution to withstand harsh operating environments (high temperature and corrosive environments). Relatively low-cost carbon steel can be used in many of these components in geothermal power plants; however, they are susceptible to excessive corrosion, thereby limiting their useful lifespan. Ultra-fast boriding (UFB) surface treatment of carbon steel may drastically increase its corrosion resistance thereby providing a cost-effective material solution in geothermal applications. Scientists at Argonne National Laboratory (ANL) recently developed a technique to accelerate the boriding process using a high-temperature electrochemical process to produce relatively thick boride layers on various metal and alloy materials in minutes rather than the several hours it takes through the typical pack boriding process; hence, the process is designated UFB. The process uses molten borax salt at 900– 1000°C in an electrochemical cell in which the material to be borided is the cathode and a graphite plate is the anode. Continuous and durable boride layers with thicknesses of 100–300 µm have been produced on a variety of metals and alloys in one hour. Such a surface layer can indeed be a cost-effective pathway to prevent corrosion of casing materials in contact with the chemically aggressive and corrosive geothermal brine fluids.

15 GEOTHERMAL ENERGY↗