Deep earth drilling is a key technique to extract oil, gas, and geothermal heat from the earth. Many complex energy focusing methods have been explored as an alternative approach to reach these resources but most of them require high energy. However, by utilizing short time span liquid plasma discharges, energy focusing can be achieved within traditional drilling systems. These discharges induce a rapid expansion process and a resulting shockwave. It is believed that this focused energy will lower the required cutting force to progress through the rock. Lowering the required cutting force will allow for lower drill bit wear, quicker rate of penetration, and an overall cost savings of the project. Plasma breakdown characteristics at drilling relevant pressures, ranging from 1 to 350 atm, were studied. A resistance–capacitance circuit with an air gapped spark switch was utilized to generate pulsed plasma between the pressurized electrodes. It was found that the required breakdown voltage increases as the pressure increases. It was also found that a plasma channel formation and an associated breakdown may or may not occur between the electrodes at different pressures due to variation in required breakdown voltages. Breakdown time-lag in the dielectric medium (tap water, 780 μS cm−1) increased as the pressure was increased, which indicated a higher voltage drop at higher pressures (>100 atm). The plasma generated cavitation bubble with an associated shockwave occurred as pressures were increased. However, the bubble radius and the bubble duration decreased as the pressure was increased. The plasma generated shockwave speeds fall within the expected speed of sound in water. Finally, preliminary rock cracking tests were performed on granite at high pressures (340 and 272 atm) and it was found that plasma is able to create cracks in the rock.
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 80J 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.
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