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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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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Rheological investigation of effect of high temperature on geothermal drilling fluids additives and lost circulation materials

High temperatures (HT) and the corrosive environment make the design of a geothermal drilling fluid a highly complex task. The presence of HT exacerbates the problems due to thermal degradation. Geothermal aquifers usually combine high-temperature and complex chemistry, making them highly corrosive. Although geothermal drilling fluids are exposed to thermal degradation, research of the effect on mud rheological properties in temperatures near or above 149°C (300°F) is limited. In this study, a High Pressure-High Temperature (HPHT) rheology setup was used to measure drilling fluids' properties up to 204.4°C (400°F). Rheological behavior of viscosity, density, lost circulation, and alkalinity control additives were analyzed at HT. It was found experimentally that Bentonite alone is thermally stable at HT. In contrast, Caustic Soda showed a tendency to gelate at temperatures above 93.3°C (200°F), adversely affecting mud rheology. Alkalinity control materials to replace Caustic Soda were evaluated. Among them, Lime presented the best thermal stability at 204.4°C with a range of variation of 0.0024 Pa.s (2.4 cP) on apparent viscosity after three consecutive tests. Besides, it was tested 11 different lost circulation materials (LCM) for understanding their rheological behavior at HT. Further, it was found that HT has less impact on fine granular materials rheological behavior with an average increase of 17.7% compared with the baseline. In contrast, flaky, fibrous, and coarse granular materials presented a more apparent impact in WBM rheology with a deviation of 166% compared with the baseline.

15 GEOTHERMAL ENERGY↗
DOE OSTI2021

Data of High-Temperature Dynamic LCM Testing Setup

Data from high temperature dynamic sealing tests for various fracture widths, at various temperatures (degrees F), with 5 wt.% bentonite-based mud containing various material fiber contents, at 100 to 400 psi differential pressure. Data from pressure test and evaluation of the dynamic lost circulation materials (LCM) testing unit to reflect the condition of open and sealed fracture using fracture width of 1000 microns at 120 degrees F. Links to two papers based on the data - "Loss circulation prevention in geothermal drilling by shape memory polymer" which was published in Geothermics 89 (2021) 101943) as well as "Evaluating sealability of blended smart polymer and fiber additive for geothermal drilling with the effect of fracture opening size", published in the Journal of Petroleum Science and Engineering 206 (2021) 108998.

15 GEOTHERMAL ENERGY↗
DOE OSTI2023

Utah FORGE: Well 16B(78)-32 Drilling Data

This drilling data for Utah FORGE well 16B(78)-32 include a well survey, core summary, mud and mud temperature logs, daily reports of the drilling process, and additional data from the Pason oil and gas company. Well 16B(78)-32 serves as the production well for reservoir creation, fluid circulation, and demonstration of heat extraction for the FORGE project. It has been drilled as a doublet approximately 300 feet parallel to and above the injection well 16A(78)-32. The proposed total depth was 10,658 feet, which was exceeded. Spudding began on April 26th, 2023. As of June 20th, 2023, the total depth measured 10,947 feet and the vertical depth measured 8,357 feet. Drilling included the trial use of insulated drill pipe (IDP) from Eavor Technologies, which was considered a success. IDP restricts counter-current heat transfer between drilling fluid inside the drill string and hotter returning fluid in the annulus, thereby ensuring the bottomhole assembly (BHA) remains submerged in cool fluid. Eavor rented 350 joints of IDP to FORGE which were run in two consecutive BHAs at the well. The results of this trial are included here.

15 GEOTHERMAL ENERGY↗
DOE OSTI2021

Evaluating sealability of blended smart polymer and fiber additive for geothermal drilling with the effect of fracture opening size

Geothermal formations often contain extensive fracture networks. These fracture networks contribute to the significant loss of drilling fluids during geothermal drilling. Multiple loss circulation materials (LCM) such as fiber, granules, and pills have been proposed to tackle this problem but with only limited success. Recent advances in materials science have led to the development of thermoset shape memory polymers (SMP) to address the lost circulation problem. In this paper, we evaluate a thermoset SMP performance in sealing near wellbore fractures of different sizes in geothermal wells. The SMP performance was assessed using granite disks and cylindrical granite cores having fracture sizes of 1000 μm and 3000 μm. A static filtration test was performed using cedar fiber, CaCO 3 , and SMP. Results showed cedar fiber performed better than the CaCO 3 ., reducing fluid loss by 89% and improving sealing pressure by 200 psi. A novel dynamic testing unit that allows for high-temperature testing under flowing conditions was used in this study. The analysis showed that 3% by weight SMP and fiber blends could bridge and plug the 1000 μm fracture. For a larger fracture of 3000 μm width, there was a need to increase the weight concentration of the SMP to 6% to plug the fracture opening effectively. We showed the influence of key parameters such as the type of LCM, concentration, and particle size distribution in optimizing the performance of drilling fluid loss treatment.

02 PETROLEUM↗
DOE OSTI2021

Expanding thermite reactions for downhole applications

Methods and apparatus for forming platforms and flow control features in underground wells is described, using modified thermite reactions to form a ceramic plug in place. The reactive package is engineered to expand laterally, filling the well, and may be used to form a ceramic bridge plug, porous ceramic screen sections, or mitigate lost circulation of drilling fluids. These objectives are achieved through the design of the reactive package and through use of carefully chosen reaction additives that control the molten product rheology, solidification temperature, and pore generations and sustainment.

Lowry, William Edward↗
NASA NTRS1995

SSME Main Combustion Chamber (MCC) hot oil dewaxing

In an attempt to comply with the changing environmental regulations, a process was developed for the replacement of perchloroethylene in the dewaxing of the Space Shuttle Main Engine (SSME) Main Combustion Chamber (MCC) and other associated hardware filled with the Rigidax (R) casting compound. Rigidax (R) is a hard blue-dyed, calcium carbonate filled thermoplastic casting compound (melting point 77 C) that is melted and poured into hardware cavities to prevent contamination during material removal processes, i.e. machining, grinding, drilling, and deburring. Additionally, it serves as a maskant for designated areas during electroforming processes. Laboratory testing was conducted to evaluate seven alternate fluids for the replacement of perchloroethylene in the dewaxing process. Based upon successful laboratory results, a mineral oil was selected for testing on actual hardware. The final process developed involves simultaneous immersion and flushing of the MCC channels using a distinct eight stage process. A nonvolatile hydrocarbon analysis of a solvent flush sample is performed to determine the hardware cleanliness for comparison to the previous perchloroethylene dewaxing process.

Akpati, Anthony U.↗
NASA NTRS1994

SSME Main Combustion Chamber (MCC) 'Hot Oil' Dewaxing

In an attempt to comply with the changing environmental regulations, a process was developed for the replacement of perchloroethylene in the dewaxing of the Space Shuttle Main Engine (SSME) Main Combustion Chamber (MCC) and other associated hardware filled with the Rigidax(registered mark) casting compound. Rigidax(registered mark) is a hard blue-dyed, calcium carbonate filled thermoplastic casting compound (melting point 77 C) that is melted and poured into hardware cavities to prevent contamination during material removal processes, i.e. machining, grinding, drilling, and deburring. Additionally, it serves as a maskant for designated areas during electroforming processes. Laboratory testing was conducted to evaluate seven alternate fluids for the replacement of perchloroethylene in the dewaxing process. Based upon successful laboratory results, a mineral oil was selected for testing on actual hardware. The final process developed involves simultaneous immersion and flushing of the MCC channels using a distinct eight stage process. A nonvolatile hydrocarbon analysis of a solvent flush sample is performed to determine the hardware cleanliness for comparison to the previous perchloroethylene dewaxing process.

Akpati, Anthony U.↗
DOE OSTI2021

CO2 Electrolyzer to Produce Formic Acid Using Flue Gas at Industry Relevant Current Density

The electrochemical conversion of carbon dioxide (CO2) into valuable fuels and feedstocks has gained great attention recently due to the global urgency to mitigate the rapid climate change. A wide variety of chemicals can be obtained through the electrochemical CO2 reduction reaction (CO2RR). Among all the chemicals generated through CO2RR, formic acid has attracted great interest because of its wide applications in silage preservation in agriculture, as an antibacterial agent in animal food additives, as a chemical additive in leather and tanning processing, as a chemical component in textile dyeing and finishing, as a reagent in pharmaceutical and chemical synthesis, and as deicing agents and a component in drilling fluids. Recently, the use of formic acid as a feedstock for biorefineries has also attracted increasing interest.

Yang, Hongzhou↗
DOE OSTI2022

Integration of Large-Scale Electrical Imaging into Geological Framework Development and Refinement

Geologic framework models (GFMs) are critical to the construction of reliable simulation models of groundwater flow and contaminant transport. To support GFM development, direct information (e.g., core samples, fluid samples, hydraulic testing) tends to be sparse and separated by large distances relative to the spatial scales of aquifer heterogeneity. There are additional challenges associated with highly contaminated legacy waste sites, where drilling is particularly costly, and invasive sampling requires specialized handling and disposal of hazardous materials. At these sites in particular, non-invasive geophysical imaging can play an important role in filling spatial gaps between boreholes and reducing characterization costs by optimizing and minimizing the number of necessary boreholes. Here this paper presents a case study demonstrating the use of large-scale (> 30 km 2 ) electrical mapping to identify hydrostratigraphy and potential paleochannels at the Hanford Site, located in Washington State, USA. In two field campaigns, over 36 line-kilometers of electrical resistivity tomography (ERT) data were collected along 14 transects. ERT surveys were sited and performed to image critical aspects (e.g., paleochannels, stratigraphic contacts) of the subsurface, demonstrating a general workflow for integrating ERT with GFM development. Inconsistencies between the GFM and ERT were catalogued to provide a basis for future site characterization using complementary geophysical methods and (or) direct sampling.

58 GEOSCIENCES↗
DOE OSTI2021

Experimental study on rheological and settling properties of shape memory polymer for fracture sealing in geothermal formations

This article studies the rheology and annular flow of a smart lost circulation material (LCM) at 160 °C, using a high-temperature flow loop. The smart LCM is a shape memory polymer (SMP) that activates at high temperatures, and its particle size increases to seal fractures in geothermal formations. SMP was mixed with the base fluid in two different concentrations, 1.0 and 3.0 wt%, to study rheology, wellbore hydraulics, activation process, and settling behavior under different testing conditions. The results of this study showed that the SMP could be activated at high temperatures. An increase of 80–100% in the particle size was observed at 160 °C. The mud samples showed a high shear-thinning behavior at the two concentrations with a Power-law flow index (n) ranging between 0.025 and 0.101. No additional frictional pressure losses were observed when SMP was added to the base fluid. SMP particles showed an excellent suspension at 1.0 wt% while, at 3.0 wt%, a bed was formed at a low flow rate and without pipe rotation. Increasing the drill pipe rotational speed or flow rate effectively removed the bed and homogeneously dispersed the SMP particles, ensuring a better sealing efficiency. SMP particle dispersion in inclined wells was better than in horizontal wells. Moreover, the findings of this study help optimize the lost circulation treatment by considering a wide range of operating parameters that can further be extended to different systems and geometries.

02 PETROLEUM↗
NASA NTRS2012

The Mojave Subsurface Bio-Geochemistry Explorer (MOSBE)

The MOSBE Team has developed a terrestrial field campaign to explore two subsurface biological habitats under the Mojave Desert. This field campaign will not only help us understand terrestrial desert biology, but also will develop methodologies and strategies for potential future Mars missions that would seek to explore the Martian subsurface. We have proposed to the ASTEP program to integrate a suite of field demonstrated instruments with a 20 m subsurface drill as a coherent unit, the Mojave Subsurface Bio-geochemistry Explorer. The ATK Space Modular Planetary Drill System (MPDS) requires no drilling fluid, which allows aseptic sampling, can penetrate lithic ground up to 20 meters of depth, and utilizes less than 100 Watts throughout the entire depth. The drill has been developed and demonstrated in field testing to a depth of 10 meters in Arizona, December 2002. In addition to caching a continuous core throughout the drilling depth, it also generates and caches cuttings and fines that are strata-graphically correlated with the core. As a core segment is brought to the surface, it will be analyzed for texture and structure by a color microscopic imager and for relevant chemistry and mineralogy with a UV fluorescence/Raman spectrometer. Organic and soluble ionic species will be identified through two instruments -- a microcapillary electrophoresis, and an ion trap mass spectrometer that have been developed under PIDDP, ASTID and MIDP funding.

robotic subsurface drilling↗
DOE OSTI2022

Chemical and Reactive Transport Processes Associated with Hydraulic Fracturing of Unconventional Oil/Gas Shales

Hydraulic fracturing of unconventional oil/gas shales has changed the energy landscape of the U.S.. Recovery of hydrocarbons from tight, hydraulically fractured shales is a highly inefficient process, with estimated recoveries of < 25% for natural gas and < 5% for oil. This review focuses on the complex chemical interactions of additives in hydraulic fracturing fluid (HFF) with minerals and organic matter in oil/gas shales. These interactions are intended to increase hydrocarbon recovery by increasing porosities and permeabilities of tight shales. However, fluid-shale interactions result in the dissolution of shale minerals and the release and transport of chemical components. They also result in mineral precipitation in the shale matrix, which can reduce permeability, porosity, and hydrocarbon recovery. Competition between mineral dissolution and mineral precipitation processes influences the amounts of oil and gas recovered. We review the temporal/spatial origins and distribution of unconventional oil/gas shales from mudstones and shales, followed by discussion of their global and U.S. distributions and compositional differences from different U.S. sedimentary basins. We discuss the major types of chemical additives in HFF with their intended purposes, including drilling muds. Fracture distribution, porosity, permeability, and the identity and molecular-level speciation of minerals and organic matter in oil/gas shales throughout the hydraulic fracturing process are discussed. Also discussed are analysis methods used in characterizing oil/gas shales before and after hydraulic fracturing, including permeametry and porosimetry measurements, X-ray diffraction/Rietveld refinement, X-ray computed tomography, scanning/transmission electron microscopy, and laboratory- and synchrotron-based imaging/spectroscopic methods. Reactive transport and spatial scaling are discussed in some detail in order to relate fundamental molecular-scale processes to fluid transport. Furthermore, our review concludes with a discussion of potential environmental impacts of hydraulic fracturing and important knowledge gaps that must be bridged to achieve improved mechanistic understanding of fluid transport in oil/gas shales.

04 OIL SHALES AND TAR SANDS↗
NASA NTRS2015

Deployable Emergency Shutoff Device Blocks High-Velocity Fluid Flows

NASA's Marshall Space Flight Center has developed a device and method for blocking the flow of fluid from an open pipe. Motivated by the sea-bed oil-drilling catastrophe in the Gulf of Mexico in 2010, NASA innovators designed the device to plug, control, and meter the flow of gases and liquids. Anchored with friction fittings, spikes, or explosively activated fasteners, the device is well-suited for harsh environments and high fluid velocities and pressures. With the addition of instrumentation, it can also be used as a variable area flow metering valve that can be set based upon flow conditions. With robotic additions, this patent-pending innovation can be configured to crawl into a pipe then anchor and activate itself to block or control fluid flow.

Nabors, Sammy A.↗
DOE OSTI2022

Lost Circulation Materials in Geothermal Drilling: Thermal Degradation, Viscosity, Compression, and Flow Loop Tests

This dataset provides a set of experimental data on the performance of lost circulation materials (LCMs) used in geothermal drilling operations. It includes results from four distinct tests: thermal degradation, viscosity measurements, compression tests, and high-temperature flow loop experiments. The materials tested, such as cedar fiber, cotton seed hulls, magma fiber, microcellulose, and sawdust, were analyzed under a range of conditions to assess their effectiveness in mitigating fluid losses in geothermal wells. Data on thermal degradation explores mass loss, water loss, and gas release for each material when subjected to temperatures between 90C and 250C. Viscosity measurements capture the behavior of LCM mixtures under different temperatures, while compression tests investigate the structural integrity of both undegraded and thermally degraded materials. The high-temperature flow loop experiments simulate geothermal well conditions, analyzing how different materials and mixtures affect fluid flow and sealing performance in a fractured reservoir environment. In addition to the experimental data, the dataset includes photos documenting the materials, schematics of test setups, and several published manuscripts that provide detailed insights into the experimental methods and findings.

15 GEOTHERMAL ENERGY↗
NASA NTRS2000

Modeling and Design of an Electro-Rheological Fluid Based Haptic System for Tele-Operation of Space Robots

For many years, the robotic community sought to develop robots that can eventually operate autonomously and eliminate the need for human operators. However, there is an increasing realization that there are some tasks that human can perform significantly better but, due to associated hazards, distance, physical limitations and other causes, only robot can be employed to perform these tasks. Remotely performing these types of tasks requires operating robots as human surrogates. While current "hand master" haptic systems are able to reproduce the feeling of rigid objects, they present great difficulties in emulating the feeling of remote/virtual stiffness. In addition, they tend to be heavy, cumbersome and usually they only allow limited operator workspace. In this paper a novel haptic interface is presented to enable human-operators to "feel" and intuitively mirror the stiffness/forces at remote/virtual sites enabling control of robots as human-surrogates. This haptic interface is intended to provide human operators intuitive feeling of the stiffness and forces at remote or virtual sites in support of space robots performing dexterous manipulation tasks (such as operating a wrench or a drill). Remote applications are referred to the control of actual robots whereas virtual applications are referred to simulated operations. The developed haptic interface will be applicable to IVA operated robotic EVA tasks to enhance human performance, extend crew capability and assure crew safety. The electrically controlled stiffness is obtained using constrained ElectroRheological Fluids (ERF), which changes its viscosity under electrical stimulation. Forces applied at the robot end-effector due to a compliant environment will be reflected to the user using this ERF device where a change in the system viscosity will occur proportionally to the force to be transmitted. In this paper, we will present the results of our modeling, simulation, and initial testing of such an electrorheological fluid (ERF) based haptic device.

Mavroidis, Constantinos↗
DOE OSTI2022

Numerical Simulations in Support of a Long-Term Test of Gas Production from Hydrate Accumulations on the Alaska North Slope: Reservoir Response to Interruptions of Production (Shut-Ins)

In this work, we investigate by means of numerical simulation a planned year-long field test of depressurization-induced production from a permafrost-associated hydrate reservoir on the Alaska North Slope at the site of the recently drilled Hydrate-01 Stratigraphic Test Well. The main objective of this study is to assess quantitatively the impact of temporary interruptions (well shut-ins) on the expected fluid production performance from the B1 Sand of the stratigraphic Unit B during controlled depressurization over different time scales, as well as on other relevant aspects of the system response that have the potential to significantly affect the design of the field test. We consider eight different cases of depressurization, including (a) rapid depressurization over a 60-day period to a terminal bottomhole pressure P W of 2.8 MPa and (b) a slower depressurization rate to a final P W of 0.6 MPa at the end of the year-long production test, in addition to (c) a multi-step depressurization regime and (d) a quasi-linear continuous depressurization strategy. The results of the study indicate that shut-ins obviously reduce gas release and production during and immediately after their occurrence, but their longer-term effects are strongly dependent on the depressurization regime and on the time of observation, covering the entire range of potential outcomes. Shut-ins (a) have a universally strong negative effect when quasi-linear depressurization is involved regardless of the length of the production period, and (b) have a strong positive effect in multi-step depressurization schemes that becomes apparent earlier for large initial pressure drops, but (c) can also appear to have practically no effect for slow stepwise depressurization at the end of the year-long production test. Shut-ins lead to a rapid reformation of hydrates, even to the point of disappearance of a free gas phase in the reservoir. Rapid depressurization regimes lead to early maximum rates of hydrate dissociation and gas production, while the maximum rates occur at the end of the production test for the cases of slower depressurization. Shut-ins do not appear to have a significant impact on water production, as the cessation of production is followed by higher rates production when depressurization resumes. Similarly, (a) the fraction of produced CH 4 originating from exsolution from the water, (b) the water-to-gas ratio, and (c) the rate of replenishment of produced water by boundary inflows do not appear significantly affected by shut-ins, the effects of which seem to be temporary in the majority of the cases. The study confirmed the superiority of multi-step depressurization methods as the most effective strategies for hydrate dissociation and gas production and showed that two observation wells (located at distances of 30 and 50 m from the production well) are appropriately positioned and both able to capture the P, T, and S G behavior during the fluid production and shut-ins in any of the eight cases we investigated.

03 NATURAL GAS↗