Jared Potter -- Hydrogen plasma drill


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Jared POTTER  
  Hydrothermal
Spallation Drill

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Potter
Drilling  
599 Seaport Boulevard  
Redwood City, CA 94063  
http://www.potterdrilling.com

 


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[http://www.potterdrilling.com/geothermal-energy/egs/Technology
Explained](http://www.potterdrilling.com/geothermal-energy/egs/Technology%20Explained)  
   
 Potter Drillings
technology drills boreholes using a process called spallation. The
process starts by applying a high-intensity fluid stream to a rock
surface to expand the crystalline grains within the rock. When the
grains expand, micro-fractures occur in the rock and small
particles called spalls are ejected. The process is accelerated by
several factors including inherent stress in the rock formation.  
  
Potter Drilling is not the first company to develop spallation
drilling technology. Air spallation drilling was used commercially
from 1947 through 1961 for ore mining and was adapted to
geothermal drilling by the Department of Energy in the 1970s. Air
spallation demonstrated impressive drilling performance, producing
8 inch to 12 inch boreholes to depths of 1,100 feet at rates
faster than 50 feet per hour in solid granite.  
  
Potter Drillings technology differs from prior air based
techniques in that it uses hot fluid rather than air to spall
rock. Because spallation occurs in a water filled borehole, Potter
Drillings technology can be used to drill to depths required for
universal EGS (12,000 to 30,000 feet).  
  
Fluid-based hydrothermal spallation has the following advantages:  
  
Greater wellbore stability: Fluid-filled boreholes are more stable
and require fewer casing intervals.  
Increased buoyancy for spalls: Fluid can be used to carry spalls
to the surface from extreme depths.  
More heat flux and faster rates of penetration: Fluid heat
transfer surpasses the impressive performance demonstrated in
air-based spallation technologies.  
Drilling rates up to 5X conventional rates  
Non-contact technology virtually eliminates wear on the drill head  
Fewer casing intervals are required, so smaller, less expensive
casing is used to achieve equivalent bottom hole diameters  
Potential to use neutrally buoyant, composite drill strings  
Ideally suited for directional and extended-reach drilling  
  
Hydrothermal spallation was invented and patented by cofounder Bob
Potter and Jefferson Tester of MIT. The patent is owned by MIT and
licensed exclusively to Potter Drilling.  
  
 


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<http://www.greentechgazette.com/index.php/geothermal-energy/hydrogen-rocket-bores-through-granite-for-deep-geothermal-wells/>  
June 16th, 2009  
  

Hydrogen Rocket Bores Through Granite for Deep
Geothermal Wells

  
A scientist named Jared Potter has created a couple of prototypes
for deep drilling for geothermal energy. Right now, companies are
using diamond drill bits for grinding through granite and other
compact rocks in order to tap into geothermal energy far below the
Earths surface.  
  
The first prototype is called a Flame Jet Drill and it works by
using hydrogen heated to 3200 degrees F and drills through granite
three times as fast as a traditional drill, with no breakage of
drill bits. The superheated hydrogen does not melt the rock into
magma as one would imagine but rather causes the granite to
fragment and the outcome is a perfectly round hole.  
  
The second prototype that Potter is working on is for deep water
drilling for geothermal energy. The Hydrothermal drill superheats
hydrogen to 7200 degrees F, which in turns heats a jet of water
that serves to drill through granite and other hard rock.  
  
Deep drilling for geothermal energy has long been a dream with
many scientists with limited success. With Jared Potters
prototypes soon to be commercialized the dream may turn into
reality more quickly that previously imagined.  
  


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WO
2010042720  
METHODS AND APPARATUS FOR
THERMAL DRILLING

  
2010-04-15  
Inventor(s):     WIDEMAN THOMAS W [US]; POTTER
JARED M [US]; POTTER ROBERT M [US]; DREESEN DONALD [US] +
(WIDEMAN, THOMAS, W, ; POTTER, JARED, M, ; POTTER, ROBERT, M, ;
DREESEN, DONALD)  
Applicant(s):     POTTER DRILLING INC [US]; WIDEMAN
THOMAS W [US]; POTTER JARED M [US]; POTTER ROBERT M [US]; DREESEN
DONALD [US] + (POTTER DRILLING, INC, ; WIDEMAN, THOMAS, W, ;
POTTER, JARED, M, ; POTTER, ROBERT, M, ; DREESEN, DONALD)  
Classification:      - international:   
 E21B43/114; E21B7/14; E21B7/18; E21B43/11; E21B7/14;
E21B7/18 - European:     E21B43/114; E21B7/14;
E21B7/18  
  
Abstract -- Methods and
apparatus for spalling a geological formation, for example to
thermally drill a wellhole, are provided. Such methods may include
providing a housing comprising a reaction chamber and a catalyst
element held within the reaction chamber, providing at least one
jet nozzle, contacting one or more unreacted fluids or solids with
the catalyst element, wherein the unreacted fluid or solid is
adapted to react over the catalyst element, thus generating a
reacted fluid, and emitting the reacted fluid through the at least
one nozzle, wherein the at least one nozzle is directed to an
excavation site within or on the geological rock formation,
thereby creating spalls and/or a reacted rock region.   
  
RELATED APPLICATIONS  
  
[0001] This application claims priority to U.S.S.N 61/103,859,
filed October 8, 2008; U.S.S.N. 61/140,477 filed December 23,
2008; U.S.S.N. 61/140,489, filed December 23, 2008; U.S.S.N.
61/140,512, filed December 23, 2008; and U.S.S.N. 61/236,958,
filed August 26, 2009, each of which is hereby incorporated by
reference in its entirety.  
  
FIELD  
  
[0002] In various embodiments, this disclosure relates to methods
and apparatus for conducting processes capable of spalling or
penetrating a material such as rock. For example, the disclosed
methods may be used for preparing boreholes for geothermal energy
systems.  
  
BACKGROUND  
  
[0003] Drilling very deep boreholes or enhancing existing wells in
hard rock far below the earth's surface, e.g. 10,000 feet deep or
more, is inherently incompatible with traditional mechanical or
contact drilling or rock removal technologies. Low rates of
penetration, extreme bit and drill string wear, and excessive time
spent "tripping" to replace damaged or worn bits and drill string
make conventional rotary and coiled tubing drilling economically
non-viable for many deep, hard rock applications.  
  
[0004] Several non-contact techniques have been developed for hard
rock drilling but may be effective only in shallow and/or air
filled boreholes. Most notably, air or flame jet spallation
drilling uses a hot gas or flame directed against a rock surface
to cause spalling and removal of the rock. This technique,
however, is only feasible in shallow, air-filled boreholes. To
drill deeper, a borehole must be filled with water or "mud" to
provide mechanical stability. In this environment, flames are not
viable in part because of the difficulty in generating or
maintaining the required flame under the high pressure water
column. For example, the high pressures at the bottom of deep,
fluid-filled boreholes make behavior of the flames extremely
unstable and difficult to maintain. Further, initiating combustion
under these conditions is extremely challenging and typically
requires an energy source to be provided at the bottom of the
borehole. However, using an energy source such as a spark or glow
plug would require, e.g., a power cable to be run from the
surface, which is not feasible in deep applications. Other energy
sources such as flame holders are inherently unstable, especially
at such depths.  
  
[0005] Further, most combustion reactions produce very high
temperature flames, typically 1800-3000<0>C or more. Such
temperatures can destroy drilling components and require careful
addition of cooling water to maintain a temperature that can be
withstood by downhole tools. In addition, such high temperatures
can melt rock (e.g., into an amorphous glass) so that the rock is
then unspallable. Even a momentary interruption in cooling water
can transform rock so that it can no longer be spalled and/or
destroy downhole components, even if a cooler temperature is
recovered. Small changes in the stand-off distance, or distance
from the combustion to the rock surface, can result in dramatic
changes in the nature of the high temperature flame impingement,
which may result in a temperature too low for spallation, or
temperatures high enough to soften or melt the rock. Such tight
tolerances for stand-off distances are difficult to control at the
bottom of a deep borehole.  
  
[0006] Further, flame-based combustion systems require multiple
conduits for fuel, oxidant and cooling or circulating water. Other
approaches to spallation drilling such as the use of electrical
heating require sufficient power down hole. In deep drilling
operations, multiple conduits or supply of sufficient power
through cables from the surface or through transformation of
energy by hydraulic flow may not be feasible, or may be simply
impossible.  
  
[0007] Combustion systems that require the use of gaseous
oxidants, such as air or oxygen, are also unsuitable for deep
fluid filled borehole conditions, in part because the pressures
required to pump these gases against a hydrostatic column of a
fluid filled borehole are sometimes impossible to achieve, and
even if possible, have associated safety risks.  
  
[0008] While thermal spallation has promised to provide a solution
to deep, hard-rock drilling, no methods have been able to
adequately or feasibly provide the heat required for viable
spallation drilling deep into a water filled borehole. If the
challenge of drilling deep boreholes in hard rock is not solved,
EGS may not become the much needed clean alternative to meeting
our current and future global energy needs.   
  
SUMMARY  
  
[0009] The present disclosure relates, at least in part, to a
method of reducing near wellbore impedance, or reducing the
restriction to fluid flow in the immediate vicinity (e.g. 1 inch
to about 3 feet) of an existing borehole wall) by providing a
spallation system to e.g. increase the diameter of a section of an
existing borehole or well, for example a geothermal well.  
  
[0010] For example, one aspect of the invention includes a method
for spalling a geological rock formation. The method includes
providing a housing comprising a reaction chamber and a catalyst
element held within the reaction chamber, providing at least one
jet nozzle, contacting one or more unreacted fluids or solids with
the catalyst element, wherein the catalyst element facilitates the
reaction of the unreacted fluid, thus generating a reacted fluid,
and emitting the reacted fluid through the at least one nozzle.
The at least one nozzle may be directed to an excavation site
within or on the geological rock formation, thereby creating
spalls and/or a reacted rock region.  
  
[0011] In one embodiment, the unreacted fluid or solid is at a
temperature of about 350 <0>C or less. In one embodiment,
the reacted fluid is about 500 <0>C to about 1100 <0>C
when formed. The contacting may occur at a pressure of about 1 to
about 200 MPa. The unreacted fluid may be substantially a liquid.  
  
[0012] One embodiment further includes introducing a flow of water
or drilling mud into the excavation site. One embodiment further
includes heating the unreacted fluid or solid. The reacted fluid
may interact with a heat exchanger disposed in a position capable
of heating the unreacted fluid or solid.  
  
[0013] In one embodiment, the method is capable of producing an
about 1 inch diameter borehole in said geological formation at
about 0.5 inches per minute of reacted fluid flow. In one
embodiment, the method is capable of producing an about 8 inch
diameter borehole in said geological formation at a rate of
penetration of about 20 feet per hour or more. The flow of water
or drilling mud may at least partially form an ascending fluid
stream. The ascending fluid stream may at least partially remove
the spall.  
  
[0014] In one embodiment, the catalyst element may include a
transition metal, such as a transition metal chosen from:
platinum, lead, silver, palladium, nickel, cobalt, copper,
chromium, manganese,   
iridium, gold, ruthenium and rhodium, or mixtures or oxides or
salts thereof. The transition metal may be disposed on a support.
The catalyst element may be disposed on spheres, grains, pellets,
or other appropriately configured elements comprising alumina. The
catalyst element may have at least about 10 m<2>/g surface
area of catalyst. The catalyst element may be heated.  
  
[0015] In one embodiment, the unreacted fluid includes an aqueous
solution. The unreacted fluid may be a miscible fluid mixture or a
non-miscible fluid mixture. The unreacted fluid or solid may
include an oxidant. The unreacted solid may include an
encapsulated oxidant.  
  
[0016] In one embodiment, the unreacted fluid or solid includes a
fuel. The fuel may be a carbonaceous fuel. The fuel may include
hydrocarbons. The fuel may be a liquid fuel at room temperature.
The fuel may be a hydrocarbon gas, such as methane, ethane,
propane, butane (e.g. natural gas (NG) and/or liquefied natural
gas (LNG)) at room temperature. In one embodiment, the fuel is
gasoline, diesel, kerosene, biodiesel, or alcohol. In one
embodiment, the fuel includes an alcohol, an alkyl, alkenyl,
alkynyl, an alkoxyalkyl, or combinations thereof. In one
embodiment, the fuel is an alcohol fuel. In one embodiment, the
unreacted fluid may include an alcohol fuel chosen from methanol,
ethanol, propanol, or butanol.  
  
[0017] In one embodiment, the oxidant may be chosen from oxygen,
peroxide, permanganate and combinations thereof. In one
embodiment, the oxidant may be hydrogen peroxide or metal
peroxide. In one embodiment, the unreacted fluid may include
hydrogen peroxide or metal peroxide. The unreacted fluid may
include an aqueous solution comprising about 2% to about 35% by
weight hydrogen peroxide. The unreacted fluid may include about
10% to about 20% by weight methanol or ethanol. The unreacted
fluid may include an aqueous solution including about 10% to about
20% by weight hydrogen peroxide and about 10% to about 20% by
weight methanol or ethanol. In one embodiment, the unreacted fluid
may have a density similar to water.  
  
[0018] The method may further include transporting the unreacted
fluid to the housing through at least one conduit. The fuel and
oxidant may be transported to the housing through separate
conduits, or through the same conduit.  
  
[0019] Another aspect of the invention includes a method for
flamelessly penetrating or reacting rock. The methods includes
contacting a composition comprising an oxidant with a catalyst to
flamelessly form a reacted fluid, and directing said reacted fluid
to said rock, thereby effecting penetration of the rock and/or
forming a reacted rock region.  
  
[0020] In one embodiment, the contacting step occurs in the
presence of a fuel. In one embodiment, the composition includes an
alcohol fuel, such as ethanol or methanol. The oxidant may include
oxygen or hydrogen peroxide.  
  
[0021] In one embodiment, the method further includes drilling the
reacted rock region with a drill bit. The contacting may occur at
about 5,000 ft to about 40,000 ft below a surface of the earth.  
  
[0022] Another aspect of the invention includes a method for
producing a reacted fluid flow capable of spallation of rock. The
method includes contacting an unreacted fluid with a catalyst
element in the presence of an oxidant thereby generating a reacted
fluid, and emitting the reacted fluid through a nozzle, thereby
producing the reacted fluid flow capable of spalling rock.  
  
[0023] In one embodiment, the reacted fluid is at a temperature of
about 500 <0>C to about 900 <0>C. In one embodiment,
the reacted fluid produces a heat flux of about 0.1 to about 10
MW/m<2> when said reacted fluid is in contact with the rock.
The unreacted fluid may be substantially a liquid. The reacted
fluid may be substantially a gas or a supercritical fluid. The
unreacted fluid may include a fuel. The unreacted fluid may
further include an aqueous solution. The unreacted fluid may be a
miscible fluid mixture. The unreacted fluid may include an
alcohol, such as an alcohol chosen from methanol, ethanol,
propanol or butanol. In one embodiment, the oxidant may be oxygen.
In one embodiment, the oxidant may be a peroxide. In one
embodiment, the oxidant is hydrogen peroxide. In one embodiment,
the unreacted fluid comprises the oxidant. In one embodiment, the
catalyst comprises a transition metal, such as a transition metal
chosen from silver, lead, gold, platinum, palladium, or nickel.
The reacted fluid may include water.  
  
[0024] Another aspect of the invention includes an apparatus for
excavating a borehole in a geological formation. The apparatus
includes a housing, a reaction chamber within the housing, a
catalyst element held within the reaction chamber, and at least
one jet nozzle in fluid communication with the reaction chamber.
[0025] In one embodiment, the apparatus further includes at least
one conduit in fluid communication with the reaction chamber and
adapted to transport an aqueous solution to the reaction chamber.
In one embodiment, the apparatus further includes a heat exchanger
positioned above the reaction chamber, wherein the heat exchanger
is adapted to transfer heat between the aqueous solution being
transported within the at least one conduit and a fluid passing
around the heat exchanger. In one embodiment, the catalyst element
may include a metal catalyst bed. The catalyst element may include
a transition metal.  
  
[0026] In one embodiment, the apparatus may further include a
single jet nozzle, or a plurality of jet nozzles. The at least one
jet nozzle may be directed substantially along an elongate axis of
the apparatus. At least one of the plurality of jet nozzles may be
directed at an acute angle to an elongate axis of the apparatus.
The at least one jet nozzle may have a diameter ranging from
approximately 0.01 inches to approximately two inches. The single
jet nozzle may be a center jet nozzle or a non-rotating peripheral
gap ring nozzle.  
  
[0027] These and other objects, along with advantages and features
of the present invention herein disclosed, will become more
apparent through reference to the following description, the
accompanying drawings, and the claims. Furthermore, it is to be
understood that the features of the various embodiments described
herein are not mutually exclusive and can exist in various
combinations and permutations.  
  
BRIEF DESCRIPTION OF THE DRAWINGS  
  
[0028] In the drawings, like reference characters generally refer
to the same parts throughout the different views. Also, the
drawings are not necessarily to scale, emphasis instead generally
being placed upon illustrating the principles of the invention. In
the following description, various embodiments of the present
invention are described with reference to the following drawings,
in which:  
  
[0029] FIGS. 1A-1E are
schematic views of a spallation process, in accordance with one
embodiment of the invention;  
  

![](fig1.jpg)

  
[0030] FIG. 2A is a
schematic top view of a drill head for a thermal spallation
system, in accordance with one embodiment of the invention;  
  

![](fig2.jpg)

  
[0031] FIG. 2B is a
sectional side view the drill head of FIG. 2A; [0032] FIG. 2C is a
schematic bottom view of the drill head of FIG. 2A; [0033] FIG. 2D
is an end view of the drill head of FIG. 2A positioned against a
rock interface;  
  
[0034] FIG. 2E is a side
view of the drill head of FIG. 2A positioned against a rock
interface;  
  

![](fig2a.jpg)

  
[0035] FIG. 3A is a
schematic side view of a thermal- abrasive reaming system, in
accordance with one embodiment of the invention;  
  

![](fig3.jpg)

  
[0036] FIG. 3B is a
schematic sectional side view of the nozzle and reamer of the
thermal spallation-abrasive reaming system of FIG. 3A;  
  
[0037] FIG. 4A is a
schematic side view of a composite thermal spallation and tricone
roller bit drill system, in accordance with one embodiment of the
invention;  
  

![](fig4.jpg)

  
[0038] FIG. 4B is a
sectional side view of the nozzle and tricone drill bit for the
thermal spallation and tricone roller bit drill system of FIG. 4A;  
  
[0039] FIG. 4C is an end
view of the nozzle and tricone drill bit of FIG. 4B ;  
  
[0040] FIG. 5 is a
schematic sectional perspective view of a spallation system and
PDC drag drill bit, in accordance with one embodiment of the
invention;  
  

![](fig5.jpg)

  
[0041] FIG. 6A is a
schematic sectional side view of a thermal spallation system and a
milling/abrasive drill bit, along with an induction type heater
system, in accordance with one embodiment of the invention;  
  

![](fig6.jpg)

  
[0042] FIG. 6B is an end
view of the thermal spallation system and a milling/abrasive drill
bit of FIG. 6A;  
  
[0043] FIG. 7A is a
schematic side view of a spallation system and hammer drill bit,
in accordance with one embodiment of the invention;  
  

![](fig7.jpg)

  
[0044] FIG. 7B is an end
view of the spallation system and hammer bit of FIG. 7A;  
  
[0045] FIG. 8 is a
graphical representation of thermal effects on the strength of
plagioclase feldspar, in accordance with one embodiment of the
invention;  
  

![](fig8.jpg)

  
[0046] FIG. 9 is a
graphical representation of differential stress vs. strain on
natural quartz crystals at various temperatures both dry and water
saturated, in accordance with one embodiment of the invention;   
  

![](fig9.jpg)

  
[0047] FIG. 10 is a
graphical representation of an experimentally determined melting
curve for water saturated granite mixture vs. pressure, in
accordance with one embodiment of the invention;  
  

![](fig10.jpg)

  
[0048] FIG. 11 is a
sectional side view of the convergent radial flow reactor;  
  

![](fig11.jpg)

  
[0049] FIG. 12A and 12B
are schematics of convergent and divergent radial flow reactors;  
  

![](fig12.jpg)

  
[0050] FIG. 13 A, 13B, and 13C
show views of a rock core confinement system for laboratory
drilling demonstrations;  
  

![](fig13.jpg)

  
[0051] FIG. 14 is an
image of a cross section of a 24" x 24" x 36" Sierra White Granite
block after being drilled, in accordance with one embodiment of
the invention;  
  

![](fig14.jpg)

  
[0052] FIG. 15 shows a
graph of wear rates of PDC and TSP cutters against hard granite as
a function of temperature;  
  

![](fig15.jpg)

  
[0053] FIG. 16 shows a
graph of the relative shear strength as a function of the ultimate
temperature for two example granites;  
  

![](fig16.jpg)

  
[0054] FIG. 17 is an
image of a 4" diameter, 6" long, rock core with a drill head
therein, in accordance with one embodiment of the invention;  
  

![](fig17.jpg)

  
[0055] FIG. 18 is an
image of a 4" diameter, 6" long rock core where an initial
predrilled borehole (represented by the dotted line) is opened,
increasing the borehole diameter and producing a thermally
affected zone, in accordance with one embodiment of the invention;  
  

![](fig18.jpg)

  
[0056] FIG. 19 A-D show
schematic views of a fracture intersecting a wellbore: (A) with
high near wellbore impedance; (B) globally opened; (C) to reduce
the near wellbore impedance; and (D) with the fracture
preferentially opened to produce to reduce near wellbore
impedance;  
  

![](fig19.jpg)

  
[0057] FIG. 20 is an
image of a slabbed Granodiorite sample subjected to spallation
drilling followed by a dye penetrant which indicates a zone of
microfracturing and several distinct linear fracture zones
emanating perpendicular to the borehole region, in accordance with
one embodiment of the invention; and  
  

![](fig20.jpg)

  
[0058] FIG. 21 shows a
graph of spalled particle size distribution for an example thermal
spallation drilling system. DESCRIPTION  
  

![](fig21.jpg)

  
[0059] The present disclosure relates, at least in part, to
methods and systems for use in spallation, fracturing, loosening,
or excavation of material such as rock, for example, methods of
making or excavating boreholes, and/or enlarging existing
boreholes. Such methods include using a disclosed working fluid or
reacted fluid, e.g. a working fluid capable of producing a heat
flux of about 0.1 to about 50 MW/m<2> when in contact with
rock.  
  
Methods  
  
[0060] For example, provided herein are systems and methods that
may be capable of creating 20 feet of an e.g., 8 inch borehole in
about hour, or 20 feet of a 4 inch borehole in about an hour or
less, or about a 0.2 inches of ~1 inch borehole in about 4
minutes. Also provided herein are systems or methods for opening a
length of existing borehole, e.g. with an original diameter of
that may be as small as 4 inches, to a final diameter of about 36
inches or more, which in some embodiments may be accomplished in
12-24 hours, or days. Contemplated systems and methods may be used
to create boreholes, shafts, caverns or tunnels in a target
material such as crystalline rock material, silicate rock, basalt,
granite, sandstone, limestone, peridotite, or any other rocky
material. Disclosed systems and methods may also be used for
producing multilaterals from an existing borehole, which in turn
may be opened. In certain embodiments, disclosed systems and
methods may be used, for example, to create vertical boreholes,
horizontal boreholes, deviated boreholes, angled boreholes, larger
diameter boreholes, curved boreholes, or any combination thereof.
Also provided herein are systems and methods that may spall rock
at a rate of about 100 ft<3>/hour or more, which may be
useful for example for the creation of tunnels, caverns,
mineshafts, and the like.  
  
[0061] For example, also provided herein are methods to reduce
existing wellbore impedance and/or improve production of existing
wells (e.g. EGS wells). Such methods may include, for example,
increasing the diameter of at least portions (e.g. a working,
producing, or production zone or portion - one or more sections
that are typically significantly downhole, may be uncased, or
cased with slotted or perforated casing, and where substantially
most of the energy output or fluid production occurs, for example,
in an EGS well) of an existing wellbore.  
  
[0062] The systems and methods disclosed herein may include
sensors such as gyroscopes, magnetometers, and/or inclinometers,
for monitoring the orientation of the drilling systems. Systems
and methods may also include at least one of temperature and/or
pressure sensors, flow sensors, natural rock gamma ray sensors,
resistivity/conductivity sensors and rock and/or pore space
density sensors, to identify rock properties and hydrologic
conditions that may influence the desired trajectory, for example,
of the borehole/drill hole. For example, sensors may be provided
to selectively monitor flow entry points and/or temperature
changes of fluids that will influence the target which influences
desired direction of drilling or hole opening. In one embodiment,
the methods and systems described herein provide for deep borehole
drilling, for example from approximately 1,000 feet to about
50,000 feet, or 5,000 feet to about 50,000 feet, or about 10,000
feet to approximately 50,000 feet below the surface, or more. In
other embodiments, methods and systems described herein provide
for hole openings in e.g. production zones of a wellbore. One or
more wellbore diameters may be increased by about 0.1 to 10 feet
or more. In other embodiments, for example, substantially
perpendicular holes relative to a production zone of an existing
well can be formed that may be about 1 to about 1,000 feet or more
in length. Also contemplated herein are the formation of
parallel/collinear slots, multilaterals (similar to branching of a
tree) or horizontal deviations, which may be used to increase
production from e.g. a single, substantially vertical wellbore.
These multilaterals may be further hole opened.  
  
[0063] For example, provided herein are systems and/or methods
that may be configured for drilling boreholes in hard rock for
geothermal, enhanced or engineered geothermal systems (EGS),
and/or oil and gas applications, natural gas production or
enhanced oil recovery or unconventional oil production, using a
disclosed working fluid to spall rock. However, the systems and
methods described herein may also be used for other applications
such as, but not limited to, exploratory boreholes, test
boreholes, boreholes for scientific study or resource assessment,
quarrying, ground source heat pumps, water wells, resource mining
(conventional or solution mining), combined HDR (hot dry rock)
solution mining, gas or liquefied natural gas (LNG) applications,
CO2 sequestration capture or storage, storage of water or other
resources, nuclear waste disposal, thermal or supercritical
oxidations of wastes, downhole chemical processing and/or tunnel
or cavern creation (new or in conjunction with an existing well).  
  
[0064] For example, methods are provided herein for increasing the
diameter along a section of an existing geothermal well or
borehole, for example, methods are provided for creating
substantially axial (i.e. substantially parallel/collinear with
the wellbore) slots along the length of a working portion or
production zone of an existing borehole, methods of perforating an
existing borehole (e.g. creating holes substantially perpendicular
to the wellbore); methods for creating radial branches off of
and/or stemming from an existing borehole (e.g. intersecting a
production zone); and/or methods of creating one, two, or a
plurality of substantially axial slots along a length of an
existing borehole, wherein the methods include using a disclosed
working fluid. The axial slots or radial branches may be oriented,
in some embodiments, so as to intersect the greatest number of
fractures or to be facing the injection well. Also contemplated
herein are methods for substantially expanding the diameter of a
wellbore along a given length, or for removing a portion of
material by spallation, whereby the spallation induces further
fracturing, collapse or break-out of the rock wall.  
  
[0065] Methods contemplated herein also include hydrothermal
reactions, explosions or detonations, which take place in the
wellbore or fractures for only a finite period. For example, an
unreacted fluid may be pumped into the wellbore and/or allowed to
penetrate the fractures. A reaction may then be initiated by e.g.
a catalyst "pill" sent down the drill string or by exposing a
sample of catalyst in a downhole tool, initiating a hydrothermal
reaction and causing spallation in fractures and macrofracturing
in wellbore.  
  
[0066] Alternatively, the wellbore may be cooled by traditional
means of circulating fluids. An unreacted fluid which has a Self
Accelerating Decomposition Temperature (SADT) - a temperature at
which reaction runs away and propagates - that is below the
formation temperature may then be injected into the wellbore and
fractures. As the formation is allowed to recover from the cooling
treatment, the reaction may initiate, with or without the use of a
catalyst.  
  
[0067] In some embodiments, two or more components of the
unreacted fluid, e.g. fuel and oxidant may be delivered through
the conduit in "slugs" so that there is no chance of a premature
reaction in the conduit. Once the desired mixture of e.g. fuel and
oxidant have been created in the wellbore, the reaction can be
initiated by e.g. a catalyst pill, exposing a catalyst in the
tool, auto-initiated, or by allowing the wellbore to warm. Since
high concentrations of e.g. fuel and oxidant can be delivered by
this "slug" flow, it may be possible to produce an unreacted fluid
mixture e.g. above the detonation limits which allows for
propagation of the reaction and Shockwave throughout the producing
zone and/or fractures, creating spallation and fracturing. [0068]
In general, as discussed herein, "spallation" refers to the
breaking away of surface fragments of a material, e.g. rock
"spall" refers to the fragments of material formed by a process of
spallation. A thermal spallation process can refer to a spallation
process that uses a working fluid other than air, such as working
fluid that includes water (e.g., hydrothermal spallation resulting
from the creation of high temperature water from hydrothermal
oxidation reaction as disclosed herein), water or oil based
drilling muds, supercritical fluids, and the like.  
  
[0069] Disclosed herein, in an embodiment, is a spallation method
that may use a means, for example, a hydrothermal means, a
flameless means and/or a self-energized means, e.g., a means that
does not use a separate energy source to initiate or generate a
chemical reaction to produce a heated, working fluid and/or a
means that does not include a flame. For example, a flameless
chemical means may include a reaction such as a hydrothermal
oxidation reaction, or a reaction that includes a physical change
in the reacting fluids, e.g., a phase change and/or solvation. An
exemplary hydrothermal oxidation reaction is the catalyzed
reaction of aqueous methanol and aqueous peroxide. It is
understood by a person skilled in the art that a flameless
hydrothermal reaction refers to an exothermic reaction that
produces heat but does not produce a flame. A flameless reacted
fluid is the product of a flameless hydrothermal reaction. For
example, a contemplated hydrothermal oxidation reaction may
produce visible light through diffuse ionization, but does not
produce light from a flame, as does combustion. In some
embodiments, contemplated reactions are aqueous and flameless.
Such reactions are substantially stable in the presence of water
or increased temperature or pressure. Contemplated reactions are
distributed through water so the reacted temperature may be
produced at a desired temperature (e.g., below the limits of tool
construction or at a desired jet temperature) without e.g.
requiring mixing of cooling water. In some embodiments,
contemplated fuel and/or oxidant may be delivered to the drill
head down a single conduit at e.g., near pressure balance with the
fluid in the borehole.  
  
[0070] Such means may allow the application of a working fluid to
a surface zone of a target material such as a hard and/or
crystalline rock with substantially high heat flux. Provided
herein, for example, are means to form a working fluid for e.g.
borehole creation or borehole enlargement which may produce a heat
transfer capability of about 0.1 to about 20 MW/m<2>, or
about 1.0 to about 30 MW/m<2>, about 0.5 MW/m<2> to
about 8 MW/m<2>, about 0.1 MW/m<2> to about 8
MW/m<2>, or about 2 MW/m<2> to about 7 MW/m<2>,
when in contact with the material. For example, provided herein
are means to form a working fluid may produce a heat flux of about
0.1 to about 10 MW/m<2>, or about 1.0 to about 10
MWVm<2>, about 0.5 MW/m<2> to about 8 MW/m<2>,
or about 1 to about 8MW/m<2> or about 2 MW/m<2> to
about 7 MW/m<2>, when in contact with the material.  
  
[0071] In an alternative embodiment, provided herein are means for
producing a working fluid having a heat flux of about 0.01 to
about 10 kW/m<2> when in contact with material. Such a heat
flux may be used to form e.g., caverns, tunnels and mineshafts, or
for enlarging the diameter of an existing borehole, for example,
using a lower heat flux process.  
  
[0072] In some embodiments, the disclosed methods, means, and
apparatus are capable of achieving and/or maintaining ( in for
example, a reaction chamber) or directing a reacted fluid towards
e.g. a rock surface at a temperature that is not substantially
higher than a certain desired temperature (for example not
substantially higher that the desired working fluid or the limits
of materials of construction of the system and/or apparatus), e.g.
to achieve and/or maintain a reacted fluid temperature between
about 500 <0>C (or about 500 <0>C above the ambient
rock temperature), and about 900 <0>C, or about the
temperature of rock fusion and/or brittle ductile transition. In
some embodiments, maintaining such a reacted fluid temperature may
be more advantageous as compared to known techniques such as air
spallation and/or flame spallation, which can use high combustion
temperatures that can induce melting or fusing of rock or can
damage downhole hardware. For example, FIG. 8 depicts brittle
ductile measurements on feldspar samples under no loading and with
overburden pressure applied to the material. It will be
appreciated that the temperature that induces melting or fusing of
rock, or the brittle/ductile transition may vary with the type
and/or nature of rock. For example, FIG. 9 depicts the
relationship between differential stress and strain on natural
quartz crystals for variations in temperatures and water content,
while FIG. 10 shows how the melting curve for water saturated
granite is affected by pressure. Furthermore, it can be
appreciated that using a heat source which exceeds this
temperature may lead to undesirable transformation of the rock,
such as melting or softening. For example, if it occurred, such
undesired melting or softening may impede further spallation.  
  
[0073] In some embodiments, such a temperature and/or heat flux is
necessary for the spallation of rock by e.g. creating enough heat
flux to remove spalls while e.g. substantially maintaining a
temperature that does not e.g. degrade materials of construction
and/or fuse or soften rock, minerals or grain boundaries which may
make rock substantially more difficult to spall. For example,
applying a working fluid having substantially high heat flux when
in contact with rock may cause grains within the rock to expand
and thereby produce microfractures within the rock. The growth of
such microfractures may result in a fractured region that spalls,
buckles and/or separates from the surface of the rock or material.
When such spall is ejected from the rock surface, it exposes fresh
material below the spall, and the spall process may continue. An
exemplary spallation process is shown in FIG.l. Such spallation
processes may be easier when, for example, pre-existing stress in
rock, e.g. lithostatic loading or deviatoric (non-uniform)
loading, is present.  
  
[0074] In the thermal spallation process of FIG. 1, a rock 1 has
an exposed surface 3 which contains, near the surface, a small
flaw 2 in the mineral structure. Heat is applied to the rock
surface 3 by a high temperature source, such as a supersonic flame
jet or hydrothermal jet. The rock 1 may be subjected to the
natural stress found in the ground which acts on the grain in all
directions, but is typically lowest in a direction perpendicular
to the exposed mineral surface. As the mineral starts to expand
from the applied heat, stresses parallel to the exposed surface
increase, so the flaw 2 starts to grow 5 to relieve the stress.
The flaw may expand to a size 6 where the grain or portion of the
grain 7 is separated from the rock 1, thereby leaving a void 8 and
a fresh surface for further heat transfer and spallation.  
  
[0075] In some embodiments, the heat flux and/or temperature of
the working fluid may be adjusted to produce or facilitate rock
removal processes such as macrofracturing, dissolution, partial
melting, softening, change in crystalline phase,
decrystallization, or the like. For example, removal of large
volumes of rock such as in the creation of caverns, mine shafts or
tunnels, or larger hole opening processes, such as reducing near
wellbore impedance, may require lower heat fluxes.  
  
[0076] Substantially high heat fluxes may produce small spalls,
which in turn may improve lift (and removal) from the borehole.
For example, spalls produced by methods disclosed herein are, in
some embodiments, approximately less than or about 0.1mm to about
2.0 mm thick and may have diameters less than or about 1-20 times,
or about 1 to about 5 times, their thickness. In some embodiments,
spalls may be produced that are less than or about 0.1mm to about
2.0mm in all dimensions. In some embodiments, spalls as large as
10 mm may be formed; these spalls have significant thermal damage
and microfracturing which may cause them to be broken down further
in the flow streams or by mechanical forces in the wellbore during
drilling.  
  
[0077] In some embodiments, such as hole opening using lower heat
fluxes, created spalls may be on the order of inches to several
feet; these spalls may be left in place, allowed to fall into an
existing cavern or "rat hole"( existing below the production
zone), or may be reduced and/or removed by a secondary process
such as mechanical drilling. Non-removal of such formed spalls may
be advantageous, e.g. smaller conduits may be needed to transport
fluids to and from the bottom of the hole. Substantial non-removal
of spalls may be particularly advantageous if larger spalls are
generated by lower heat fluxes. In other embodiments, any rock
that is removed may intentionally makes the hole less stable,
resulting in break-out or cave-ins, further expanding the diameter
without requiring the complete spallation of all of the loosened
material.  
  
[0078] In some embodiments, seismic or acoustic monitoring of the
fracturing or the sound in the section of the borehole may provide
information as to the size and extent of spalling and the size or
shape of the resulting borehole. In other embodiments, the methods
and apparatus disclosed herein also provide for an additional down
hole fluid, which may improve buoyancy or lift of cuttings (for
example, improved buoyancy in aerated foams, liquid water or
drilling mud as compared to air used in flame jet spallation) and
may, in some embodiments, assist in transport of particles to the
surface of the wellbore where they can be separated from e.g.,
water using standard oilfield (or geothermal) drilling
technologies such as, but not limited to, shaker screens, mud
pits, and hydro-cyclone de-sanders, and de-silters. In some
embodiments, the methods of spallation disclosed herein produce
substantially smaller cuttings or spall in comparison to
conventional rotary drill cuttings. In another embodiment, the
methods of spallation disclosed herein provide for substantial
control over the size of spalls formed, by e.g. controlling heat
flux and/or temperature e.g. of a heated or reacted fluid.  
  
[0079] In another embodiment, application of a high heat flux
(e.g. using a reacted or working fluid) on the surface of the
target material may result in a thermally affected zone or reacted
rock region. For example, a thermally- affected zone having
reduced mechanical strength (due to e.g. microfracturing,
macrofracturing, softening, and/or annealing), which may extend as
much as about <1>A inch or more below the rock surface, may
be created by a disclosed reacted or working fluid inducing e.g. a
substantially high heat flux. Provided herein is a method for
penetrating or reacting rock, e.g. a method for forming a reacted
rock region, which may be suitable for penetration using
conventional mechanical rock drills. (For example, such reacted
rock region may be easier to drill using mechanical rock drills as
compared to a rock region that has not been reacted). Such a
method may therefore further include mechanically drilling,
reaming, or otherwise removing the reacted rock, as described
below. For example, removing the reacted rock may increase the
diameter or improve the shape of the well.  
  
[0080] Near wellbore impedance may occur where fractures intersect
a wellbore, as shown, e.g., in FIG. 19A. In one embodiment, a
method of fracture enlargement is provided, e.g. to reduce
wellbore impedance, by using a provided working fluid in a
wellbore. Pressure in an existing well may be controlled, in some
embodiments, by e.g., "shutting in the well", "zonal isolation" or
by "packing off the length of the borehole being treated such that
the working fluid is forced into or near fractures (e.g.
identified fractures or fractures along an isolated zone),
inducing spallation or geomechanical changes at the surface of the
fracture, enlarging the fracture, and thereby resulting in an
improvement in the flow of fluids through the fracture, as shown,
e.g., in FIG. 19D. In other embodiments, the pressure in an
existing well may be controlled to prevent flow of the fluid into
the fractures, by either maintaining neutrally or "underbalanced"
conditions. In other embodiments, the pressure may be varied or
cycled; this may assist in blowing produced spalls or fractured
rock out of the fractures or away from the borehole wall. Pressure
or flow may also be cycled to allow for the measurement of flow
and temperature from the borehole to determine how effective the
treatment has been, or if additional treatment is necessary. In
other embodiments, the wellbore may be expanded more globally, by
removing the rock in and around the fracture, also leading to a
reduction in wellbore impedance, as shown, e.g., in FIGS. 2OB and
2OC. In other embodiments, the walls of the borehole can be
spalled to create features such as slots or perforations that may
be designed to better intersect the existing fractures or to
weaken the walls of the wellbore in that location so as to induce
further collapse and expansion of the wellbore, leading to a
further reduction in impedance. In some embodiments, the reacted
fluid may comprise other chemicals which may assist in the process
of reducing wellbore impedance, e.g. chemicals which increase or
decrease the solubility of certain minerals. Incorporation of
these chemicals either from the unreacted fluid or from a separate
stream, may be used to prevent minerals from being dissolved by
the high temperature fluid jet and/or or being redeposited in the
cooler fractures, or may be used to facilitate dissolution of the
minerals in either the spalls or along the fracture walls. These
chemicals may include alcohols e.g. methanol, or bases e.g.
hydroxides, or combinations of the two, such as alcoxides.
Alternatively, these chemicals may include acids, such as HCl, HF
or the like.  
  
[0081] The disclosed methods and apparatuses of e.g., spalling
rock, can be applied to any formation of rock, for example, can be
applied to a subterranean formation in which the hydrostatic head
of fluid in the borehole produces a pressure at the bottom of the
borehole that does not exceed the fracture pressure of the
formation. In some embodiments, during operation of the disclosed
methods, the pressure of a borehole may be maintained below the
formation's fracture pressure or above the pressure of exposed
permeable formations to prevent inflow. For example, a drilling
mud may be used to vary the hydrostatic pressure in the borehole
or to create partial isolation of the working zone.  
  
[0082] The methods described herein may further include monitoring
properties (e.g. size, shape, temperature and/or chemical
composition) of the formed spalls and/or may include adjusting or
monitoring e.g. a working fluid temperature and/or heat flux, to
e.g., optimize rate of penetration or maintain a pre-determined or
desired range of spall sizes. Such measurements may be performed
by e.g., an optical measurement, seismic measurement, an acoustic
measurement, a chemical measurement, and/or a mechanical
measurement. For example, fluid flow and temperature sensors
coupled with computational models may be used to determine heat
flux at e.g. the bottom of the borehole. In some embodiments,
chemistry of the returning fluid (e.g. fuel, oxidant or combustion
products) may be monitored to e.g. adjust the downhole reaction
conditions or as an indicator of system, e.g., combustion or
oxidation catalyst efficiency. For example, CO, CO2, formaldehyde,
formic acid, NOx , oxygen, fuel (e.g. alkanes, methanol or
ethanol), or oxidant may be detected in returning fluids as e.g.
indicators of condition of a catalyst used for oxidation
reactions. In another embodiment, fluid chemistry (e.g. pH,
dissolved minerals, suspended minerals, and agglomerates) may be
monitored in the returning fluid, which may allow for adjusting
additives in the working or cooling-lift fluid to reduce or
enhance solid or mineral precipitation, agglomeration,
dissolution. Downhole monitoring of temperature, heat flux,
stand-off, and/or borehole geometry by e.g. temperature sensors,
flow sensors, acoustic monitors, or calipers may allow for
optimization of the drilling conditions. In other embodiments,
standard oilfield and geothermal drilling methods and equipment
for the measurement of the formation, orientation, and borehole
conditions, e.g. measurement while drilling (MWD) or logging while
drilling (LWD) systems may be used, as well as directional
drilling and drilling with casing or casing while drilling
technologies.  
  
[0083] For example, in a disclosed method for hole opening of
existing wellbores, a drill string deploying the heating system
(e.g. the catalyst or combustion chamber for producing the reacted
fluid) may also contain instrumentation to help identify and
locate the areas of the working portions to be treated. Once the
instrumentation identifies the regions or fractures, a drill
string can then be pulled up the wellbore to align the jets or
nozzles with the areas to be treated. A packer or heat shield may
be used to separate the instrumentation from the heat of the
spallation process and to isolate the zone of the borehole to be
treated.  
  
Working Fluids and Apparatus  
  
[0084] In some embodiments, the working fluid includes a
substantially aqueous fluid, e.g. water. Other exemplary fluids
include oil or water based drilling mud. The fluids may be
selected for optimum heat capacity and/or heat transfer
properties. In alternate embodiments, a working fluid may include
a gas such as neon or nitrogen. Contemplated working fluids may
include by appropriate additives, e.g. viscosifiers, thermal
stabilizers, density modifying additives such as barite, and those
common in oil, gas and/or geothermal drilling.  
  
[0085] The working fluid may be directed through one or more
nozzles, for example, a nozzle disposed in a drilling system. Such
nozzles may be adapted to direct the fluid substantially along an
elongate central axis, for example, in a pulsing (e.g. cyclically
pulsing) flow or a substantially continuous flow. For example, in
some embodiments, a single, centrally located, non-rotating
thermal spallation system may have a reduced number of moving
parts and reduced mechanical complexity that may result in a
substantially simplified and/or cost effective system. Minimizing
the moving parts within a thermal spallation system, may allow
stronger and more robust materials to be used in construction of
the system, and therefore the resulting structure may be better
adapted to withstand the high pressures, temperatures, and
mechanical wear and impact that is generated at the bottom of a
borehole during operation. In another embodiment, a combination of
centrally located and peripheral nozzles can be used to optimize
heat flux across the surface of the rock, drilling rates, spall
size or borehole geometry.  
  
[0086] For example, such as in hole opening applications provided
herein, the shape of the openings may be controlled to make
features in the walls of existing boreholes such as channels,
perforations, slots, or multilaterals (multiple branches drilled
out from the existing wellbore). For example, the shape of the
openings may be controlled by controlling spall size, or may be
controlled by the orientation of the nozzles. For example, an
apparatus with at least one substantially perpendicular nozzle may
be slowly run along the length of a production zone of an existing
borehole, creating a slot. Alternatively, a single substantially
perpendicular jet may sit on one position in the existing borehole
creating a perforation. An apparatus with multiple perpendicular
jets (within the same or different apparatus) or if the tool or
apparatus is rotated, a series of holes or parallel slots can be
created. The pressure from the surface pumps and/or reaction may
be used to move the nozzle e.g., towards the rock face to maintain
a small stand-off. A ring or peripheral gap nozzle can create
disc-like openings if stationary (as shown, e.g., in FIG. 19B), or
open the diameter along the length of the wellbore if translated.
A less directed or more even heat flux may be applied to open the
hole more evenly in all areas, or in the areas of greatest
existing stress. In an embodiment, methods of reducing wellbore
impedance are provided that include the use of less focused or
directed jets, jets substantially axial with the wellbore or with
greater stand-off distances or lower heat fluxes, to produce more
global spalling of the area of a production zone. In some
embodiments, "packers" or plugs (e.g., cement or ceramic plugs)
may be used to isolate the areas of a production zone to be
treated.  
  
[0087] Also provided herein are apparatuses for spalling rock,
such as an apparatus that includes a fluid heating means adapted
to heat a fluid to a temperature greater than about 500<0>C
above the ambient temperature of a surrounding material and less
than about the temperature of the brittle-ductile transition
temperature of the material; and at least one nozzle adapted to
direct the heated fluid onto a target location on the surface of
the material, wherein the fluid produces a heat flux of about 0.1
to about 20 MW/m<2> at an interface between the fluid and
the target location, and thereby creating spalls of the material.
The nozzles of the disclosed apparatuses and systems may include a
high temperature resistant material, e.g. a ceramic or ceramic
composites, metal-ceramic composites, stainless steels, austenitic
steels and superalloys such as Hastelloy, Inconel, Waspaloy, Rene
alloys (e.g. Rene 41, Rene 80, Rene 95), Haynes alloys, Incoloy,
MP98T, TMS alloys, and CMSX single crystal alloys, metal carbides,
metal nitrides, alumina, silicon nitride, and the like. The
materials may also be coated to improve their performance,
oxidative and chemical stabilities, and/or wear resistance.
Chemical Heating  
  
[0088] For example, a disclosed spallation system or apparatus
that is capable of producing a fluid for use in the disclosed
methods and apparatuses may include at least one jet nozzle, and a
housing including a reaction chamber and, optionally, a catalyst
element held within the reaction chamber. In operation, unreacted
fluids or solids can be contacted with the catalyst element within
the housing, resulting in the unreacted fluid or solid reacting,
with the catalyst element and generating a reacted fluid. This
reacted fluid may then be emitted through the at least one jet
nozzle and directed to an excavation site within the geological
rock formation, thereby creating spalls and/or a reacted rock
region. In some embodiments, contemplated unreacted fluid or
solids react in the presence of a catalyst substantially
self-energized, e.g., does not require an additional energy or
heat source such as e.g., a spark, flame holder, flame, or glow
plug to initiate or maintain the reaction and produce the reacted
fluid.  
  
[0089] For example, one or more unreacted fluids or solids (e.g.
one or two unreacted fluids (e.g. liquids) (which may be the same
or different), or one unreacted fluid and one unreacted solid, or
one or two unreacted solids (which may be the same or different),
may be contacted with the catalyst element, thereby forming or
generating a reacted or working fluid. Such reacted fluid may be
emitted through at least one nozzle (e.g. one center nozzle, a
ring or peripheral gap nozzle, or a plurality of nozzles), where
the at least one nozzle is directed to an excavation site (e.g.
bottom hole or against the borehole wall) within or on the
geological rock formation. The directed reacted fluid may create
spalls which may or may not then be transported to the top of the
hole and/or may create a reacted rock region e.g., down hole. It
will be recognized by one skilled in the art that discrete spots
on the catalyst may, at times, exceed the final temperature of the
working fluid due to localized heating on the catalytic surface,
but the reaction is self-energizing and does not require an
additional heat source to be provided by e.g. a power cable from
the surface or an unstable flame holder.  
  
[0090] The unreacted fluid may, in one embodiment have a density
similar to water. This may be advantageous, for example, in
minimizing any pressure differences between the unreacted fluid
and the fluids in the wellbore. For example, if the density of the
unreacted fluid is slightly greater than the fluids in the
wellbore, any required pumping pressures for the unreacted fluid
may be reduced. [0091] Contacting unreacted fluids or solids with
the catalyst may occur at a pressure of for example, about 1 to
about 200 MPa or 1 to about 400 MPa. The unreacted fluid or solid
may be at a temperature of about 20 <0>C to about 350
<0>C. In some embodiments, at least one of the unreacted
fluids is substantially liquid.  
  
[0092] Contemplated catalysts include catalysts comprising
transition metals and/or noble metals, e.g. lead, iron, silver,
platinum, palladium, nickel, cobalt, copper, iridium, gold,
samarium, cerium, vanadium, manganese, chromium, ruthenium, zinc,
and/or rhodium, and or mixtures and/or alloys or salts thereof,
and/or complexes, e.g. carbonyl complexes thereof. Contemplated
catalysts include oxides and/or nitrides of e.g. metals. The
catalyst may, in one embodiment, include lanthanum, zirconium,
aluminum or cerium (e.g. lanthanum cerium manganese hexaaluminate,
Zr-Al-oxides and Ce-oxides) or other mixed metal oxide catalysts.
The catalyst may include promoters (e.g. cerium and/or palladium).  
  
[0093] In some embodiments, the catalyst may be provided on a
non-reactive support, and/or on a substantially porous support, or
a support with channels (eg. a honeycomb structure). Such supports
may include alumina, sol-gels such as sol-gel derived alumina,
aerogels, carbon supports, solid oxides, solid nitrides,
oxidatively stable carbides, silica, magnesium and/or oxides
thereof, titanium zirconium, and/or zeolites, metals, ceramics,
intermetallics, corrosion resistant metals (e.g. iron chromium
alloys), or alloy or composites thereof, or other materials
commonly used in catalytic supports. The supports can be but are
not limited to powdered, granular, or fixed bed. In some
embodiments, the catalyst or catalytic bed may further include
inhibitors that inhibit e.g. plating or poisoning on the surface
of the catalyst or catalytic support. In other embodiments, the
catalyst may include cation salts and/or promoters such as ionic
promoters or tin, nickel, silver, gold, cerium, platinum,
manganese oxides, or salts. A contemplated catalyst may include
other components such as boron, phosphorus, silica, selenium or
tellurium. Catalysts or their supports may be comprised of
nanoparticles.  
  
[0094] In other embodiments, the catalyst may be configured as a
bed over which (or through which) the unreacted fluid is flowed.
In some embodiments, the catalyst bed may be sized and shaped to
fit within an appropriate drill head housing, or the catalyst bed
may be disposed in a different housing separate from the nozzle.
In one embodiment, the catalyst bed may be substantially
cylindrical, less than approximately three inches in diameter and
two feet in length. In an alternative embodiment larger or smaller
catalyst beds may be used. For example, in one alternative
embodiment a catalyst bed of approximately 0.5 inches in diameter
and 1-2 inches in length may be used. In other embodiments, axial
or radial flow reactors may be used. In other embodiments,
multiple catalyst beds may be used of the same or different
designs. The catalyst bed may include a catalyst on a
substantially non-reactive support and/or a porous support.  
  
[0095] A catalytic support may include for example, a zeolite
molecular sieve of porous extrudate, piece, pellets, powder, or
spheres, and/or porous alumina, silica, alumino- silicate
extrudate, pieces, pellets, powder, or spheres. Catalytic supports
may be chemically resistant to any unreacted or reacted fluid. In
one example embodiment, the catalyst bed includes about 0.5%
platinum on 1/16" alumina spheres having a surface area of at
least approximately 10 m<2>/g, or at least 100 m<2>/g
(e.g. a surface area of about 5 m<2>/g to about 15
m<2>/g or more). In one embodiment, the catalyst bed may be
about 5% platinum with a promoter on alumina grains e.g., with a
high surface area. In some embodiments, the catalyst or catalyst
bed may have plates or sheets. In an alternative embodiment, other
forms of catalysis are contemplated (for example using a hot
surface or a slug of hydrogen peroxide to initiate the reaction or
bring the catalyst bed up to temperature that may produce a
substantially self-sustaining reaction) may be used in place of,
or in addition to, catalytic reactions. In one embodiment, the
decomposition of a peroxide over a catalyst generates free oxygen
and heat which raises the temperature of the unreacted fluid to
initiate or help initiate the reaction; the pressure of the
unreacted fluid may be increased to raise the boiling point of the
decomposed fluid to initiate or assist initiation of the reaction.  
  
[0096] In an alternative embodiment, a catalyst bed can be used in
conjunction with a heat exchanger to initiate the reaction and
raise the temperature of a down flowing unreacted fluid, wherein
once the system has an appropriate temperature and/or the reaction
is self-sustaining, the catalyst bed may be by-passed and/or
isolated by e.g. a thermally- actuated mechanical valve, which may
improve catalytic longevity. A higher activity catalyst bed may
also be used to "light off the reaction, after which lower
activity beds may be used to maintain its high activity. The use
of higher pressures in the catalyst bed through e.g. choked flow
across the nozzle, mud weight in the borehole, or back pressure at
the wellhead, may increase the reaction rates per unit catalyst
and decrease the pressure drops across the catalyst bed which may
allow for smaller catalyst bed volumes and e.g. axial reactor
beds.  
  
[0097] In some embodiments, the catalyst may be disposed on a
moving rotating element, such as blades or screens on a
hydraulically driven turbine, which may increase the contact
between the catalyst and fluid. In another embodiment, the
catalyst may be on a support that can be e.g., mechanically,
thermally, or chemically removed, e.g. without having to pull a
drill string out. For example, if the catalyst performance
decreases or the catalyst is poisoned, the catalyst can be removed
(e.g. by dissolution of alumina in hydrofluoric acid) and a fresh
catalyst may be sent down in, e.g. in the form of a pill. The
catalyst may be supported on carbon that is combusted once the
reaction reaches full temperature.  
  
[0098] The catalyst may be regenerated, by for example, passing an
oxidant, hydrogen or a hydrogen source over the catalyst at
temperature, by acid or base washes, or any other technique
commonly used in catalytic combustion systems. Hydrogen or
additional oxidant may be added continuously to the unreacted
fluid to prevent e.g. coking while also reducing the light-off
temperature.  
  
[0099] A catalyst chamber may be a water cooled reactor. In
another embodiment, the catalyst chamber may be a transpiring wall
reactor from a porous material tube that includes metal or
ceramics.  
  
[0100] The catalyst chamber may have distinct zones. For example,
different zones may be responsible for different chemical
reactions, destruction or binding of catalyst poisons, or for
different temperatures or to reduce the amount of the most
expensive catalyst (e.g. noble metal) that is needed, or to
provide zones of less expensive, sacrificial catalysts. The
relative flow through different zones may be changed depending on
the temperature of the catalyst chamber or over time. Different
zones, for example, may have substantially the same catalyst and
geometry or different catalyst and geometry. For example, sending
the unreacted fluid over one bed at a time until the bed is no
longer active can extend the working life of a tool before it
needs to be pulled from the hole to replace the catalyst.  
  
[0101] In one embodiment, the unreacted fluid is an aqueous fluid.
In other embodiments, an unreacted fluid may be liquid and may
include water, oil, water or oil based drilling muds, aerated
fluids, and/or supercritical CO2, or any other appropriate liquid
for use as e.g. the working fluid. In one embodiment water can be
separated downhole from the unreacted fluid by cyclone separators
or other appropriate fluid separation systems and methods. For
example, an unreacted fluid may be liquid, gaseous, or a
supercritical fluid (e.g. H2O at temperatures above about
375<0>C and 3200 PSI (approximately 7400' water column).  
  
[0102] For example, the unreacted fluid may include water and/or
an oxidant and/or a fuel. In operation, the unreacted fluid may
be, e.g., pumped to a drill head assembly of a disclosed
spallation system. In the drill head, the unreacted fluid can be,
for example, passed over a catalyst configured (or otherwise put
in contact with the catalyst) to e.g., cause the flameless
reaction with an oxidant and/or a fuel that may be present in e.g.
the unreacted fluid. Such a reaction may produce a reacted fluid,
e.g. a fluid at an elevated temperature, that may then be directed
out of an e.g., distal jet nozzle of the spallation drill head
assembly and impinge upon a target rock surface, creating
thermally damaged rock and/or spalled rock. The reacted fluid, in
some embodiments, may include water in gaseous (steam) or
supercritical form, for example, may be a gas when in first
contact with rock. After contacting the rock, the expelled water,
gas or supercritical fluid can then, in some embodiments, flow up
the borehole, carrying the spalled rock with it. In some
embodiments, the reacted (hot) fluid is allowed to travel up the
borehole to further spall the borehole walls and expand the
diameter of the borehole. In other embodiments, the reacted fluid
is cooled e.g. just above the drilling assembly by a heat
exchanger and/or cooling-lift fluid, thereby substantially
stopping the spallation reaction. In other embodiments, the
reacted fluid is directed through a "shroud" which may reduce its
interaction with the sides of the rock wall, and also
substantially stopping the spallation reaction. In an alternative
embodiment, some of the reacted fluid does not travel up the
wellbore but rather enters the rock or formation through e.g.
fractures. In some embodiments, the spalls or rock fragments are
not carried up the wellbore but are allowed to fall further into
the hole or remain on the borehole wall.  
  
[0103] In one embodiment, a non-reacted or unreacted fluid
includes a fuel and/or oxidant. For example, the unreacted fluid
may include two or more components that are miscible with each
other. In another embodiment, an unreacted fluid and/or an
unreacted solid is present, for example, an unreacted solid may
include an oxidant (e.g. a solid encapsulated oxidant), or an
unreacted substantially solid fuel, e.g. a wax. An unreacted solid
may be dispersed, dissolved, undissolved or encapsulated within a
solid. In one embodiment at least one of the fuel and/or oxidant
may change state or dissolve, decompose, or otherwise react during
its transport along the borehole to the drill head, or upon
reaching a drill head. A catalyst or accelerant may be added to
the unreacted fluid, wherein the catalyst can be activated at the
bottom of the hole by heat or mechanical force, with or without
the use of a secondary permanent catalyst. The working fluid may
also contain an inhibitor to prevent the reaction from occurring
along the length of a drill string.  
  
[0104] In certain embodiments, a nonreacted fluid is pumped down
hole to a drill head at the distal end of the borehole at
approximately 1- 50 or 5-50 gallons per minute, e.g. about 20
gallons/minute. In one embodiment, an unreacted fluid may be
pumped down one or more small diameter tubes that may be nested
inside of a traditional steel coiled tubing system. Such small
diameter tube or tubes may have one or more periodic check valves
so as to prevent the unreacted fluid from back-flowing and to
limit uncontrolled reactions from propagating up the nested tube.  
  
[0105] In an alternative embodiment, any appropriate tubing system
for transporting the aqueous solution to the catalyst or drilling
head assembly may be utilized. In some embodiments, the fuel and
oxidant are transported to the catalyst or drilling head assembly
through one conduit, or in separate conduits. For example,
fuel/oxidant mixtures which are stable at desired concentrations
can be transported together in one tube. This may, for example,
have advantages over transporting the fuel and oxidant separately
in that it would require one less conduit to pass material to the
distal end of the borehole. It may also simplify storage, mixing,
or handling procedures on the surface. Fuels or oxidants which may
be carried in the bulk cooling-lift water (and separated at the
bottom of the hole) to also reduce the number of conduits.  
  
[0106] In one embodiment, the fuel and oxidant may be combined in
a number of different ways to allow for transportation of the fuel
and oxidant down the same conduit. For example, fuel and oxidant
may be transported down a single conduit through use of a single
molecule ("single-source") or network/complex. The chemical heat
source can be a monopropellant, such as hydrogen peroxide, nitrous
oxide, or hydrazine. Alternatively, fuel and oxidant may be
transported down a single conduit through use of methods
including, but not limited to, slug flow (i.e. gases and/or
liquids sent one after another), dissolved gases, or bubble flow
(i.e. small bubbles suspended in a fluid and transported along
with the fluid). In an alternative embodiment, the fuel and
oxidant may be transported down the same conduit as two solid
materials in one or more "pills". In a further alternative
embodiment, one or more of the fuel and/or oxidant may be
transported in an encapsulated form such as, but not limited to, a
material, such as a peroxide, encapsulated by e.g., wax.  
  
[0107] In some embodiments, fuel and oxidant may be sent down one
conduit in two separate fluid phases. For example, the fuel may be
carried in an oil-based phase, and the oxidant in the water based
phase. At the bottom of the hole, the two phases can be, for
example, homogenated, or the fuel and/or oxidant can be separated
from its respective phase by means of a hydrocylcone or other
separation device and then combined with its reactant.  
  
[0108] Contemplated fuels include carbonaceous fuel, such as a
fossil fuel (e.g. coal, biomass), gasoline, natural gas (e.g.
liquefied natural gas) diesel, biodiesel or kerosene. For example,
fuels contemplated for use in the disclosed methods include
alcohols, alkyls, cycloalkyls, alkenes, alkynyls, ethers,
alkoxyalkyls, (e.g. CH3CH2O CH2CH3,), dioxanes, glycols, diols,
ketones, acetone, aldehydes and/or aromatic organic compounds such
as benzene or naphthalene, or combinations thereof. Hydrocarbons
may be used as fuel, and include alkanes (e.g. C1-C2O alkanes)
such as methane, ethane, propane, butane, pentane, hexane,
heptane, octane, and higher alkyl fuels such as naptha, kerosene,
paraffin, hydrocarbon oligomers, and /or other waxes. Other
contemplated fuels include ethylene vinyl acetate (EVA), polyvinyl
chloride (PVC), boranes (such as B2H6 or B5H9), carboranes,
ammonia, kerosene, diesel, fuel oil, bio-based oils, such as
biodiesel, starch, sugars, carbohydrates, or other
oxyhydrocarbons. A fuel may be, or include, hydrogen, hydrogen
generating compounds, or hydrogen containing polymers such as
polyethylene, polypropylene, or paraffin polymers. A fuel may also
be, or include, reactive metals such as aluminum, beryllium, and
coated or encapsulated sodium.  
  
[0109] For example, contemplated fuels include alcohol fuels (e.g.
C1-Cg alcohols) such as methanol, ethanol, propanol, and/or
butanol, or mixtures thereof, which in some embodiments may be
optionally substituted by one or more halogens. In certain
embodiments, the fuel may be substantially miscible in water, e.g.
methanol, ethanol or benzene.  
  
[0110] Contemplated oxidants include air, oxygen, peroxides,
(e.g., hydrogen peroxide or methyl ethyl ketone peroxide)
percarbonates, permanganates, permanganate salts, as well as
combinations thereof. For example, contemplated oxidants include
inorganic and/or organic peroxides such as peroxides of alkali
metal peroxides, e.g. lithium, sodium, and/or potassium peroxides,
e.g. sodium peroxide and/or barium peroxide. Alkyl peroxides such
as t-butyl peroxide and benzoyl are contemplated. Oxidants
contemplated herein may include hypochlorite and/or hypohalite
compounds, halogens such as iodine, chlorite, chlorate or
perchlorate compounds, hexavalent chromium compounds, sulfoxides,
ozone, nitric acid, N2O, and/or persulfuric acid. Other possible
oxidants include F2, OF2, O2/F2 mixtures, N2F4, CIF5, CIF3, NxOy,
IRFNA Ilia: 83.4% HNO3, 14% NO2, 2% H2O, 0.6% HF: IRFNA IV HAD:
54.3% HNO3, 44% NO2, 1% H2O, 0.7% HF, RP-I, C10Hi8, and CH3NHNH9.  
  
[0111] As disclosed herein the peroxide may be in e.g. aqueous
form, or may be in a solid form e.g. pellets that may include
urea. An unreacted fluid that includes an e.g. oxidant, e.g.
hydrogen peroxide, may also include corrosion inhibitors and/or
passivating agents and/or anti- foaming agents and/or surfactants
and/or surface tension modifying agents. For example, an unreacted
fluid may include stabilizers such as phosphoric or phosphonic
acid or sodium pyrophosphate or tin compounds. In an embodiment,
an oxidant, e.g. high pressure or liquid oxygen may be metered
into a fuel stream (e.g. methane or methanol stream); mixing can
take place either at the surface or in the drill head. The mixture
may then travel into the drill head. In one embodiment the
drilling head is configured to withstand bottom hole pressures of
upwards of about 100 to 4000 PSI, 1000 to about 4000 PSI , or
about 1000 to about 30000 PSI (e.g. about 1 to about 200 MPa),
e.g. the pressures present at the bottom of a deep wellbore.  
  
[0112] In some embodiments, a provided unreacted fluid may include
an aqueous solution comprising by weight of about 5% to about 52%
oxidant, e.g. hydrogen peroxide, or about 30% to about 40%
oxidant, or about 5% to about 50% oxidant, and may include about
5% to about 20% fuel, e.g. methanol, or about 10% to about 20%
fuel, e g. 10% to about 15% fuel, or even about 5% to about 50%
fuel. For example, an unreacted fluid may include about 2% to
about 40% by weight hydrogen peroxide. In another embodiment, the
unreacted fluid may include about 10% to about 20% by weight
methanol or ethanol. In an exemplary embodiment, the unreacted
fluid includes about 15% methanol or ethanol and about a
stoichiometric amount of air, oxygen, or peroxide (e.g. hydrogen
peroxide). In another exemplary embodiment, the unreacted fluid
includes 38% by weight hydrogen peroxide and about 12% by weight
methanol, or e.g. about a 4:1 weight ratio of hydrogen
peroxide/methanol, e.g. about a 5:1 to about a 1:1 weight ratio of
hydrogen peroxide/methanol. [0113] In an exemplary embodiment, the
unreacted fluid is slightly oxidant rich to assure complete
combustion of the hydrocarbons to reduce the amount of by-products
caused by incomplete combustion, such as carbon monoxide,
formaldehyde, and/or formic acid. In other embodiments, the
unreacted fluid may be T-Stoff (80% hydrogen peroxide, H2O2 as the
oxidizer) and C-Stoff (methanol, CH3OH, and hydrazine hydrate,
N2H4^wH2O) as the fuel); nitric acid (HNO3) and kerosene;
inhibited red fuming nitric acid (IRFNA, HNO3 + N2O4) and
unsymmetric dimethyl hydrazine (UDMH, (CH3)2N2H2), nitric acid 73%
with dinitrogen tetroxide 27% (AK27), and kerosene/gasoline
mixture, hydrogen peroxide and kerosene; hydrazine (N2H4) and red
fuming nitric acid; Aerozine 50 and dinitrogen tetroxide,
unsymmetric dimethylhydrazine (UDMH) and dinitrogen tetroxide; or
monomethylhydrazine (MMH, (CH3)HN2H2) and dinitrogen tetroxide. In
another embodiment, the unreacted fluid may include 50-98%
hydrogen peroxide. The products from decomposing the 50-98%
peroxide (e.g. H2O and/or O2) over a catalyst (e.g. platinum,
silver, or palladium), may then be allowed to react with a fuel
(e.g. methanol). The heat from the decomposition of the hydrogen
peroxide, combined with downhole temperatures and pressures and/or
the use of a heat exchanger, may auto-initiate or sustain the
reaction of fuel and oxidant, such as peroxide and/or oxygen with
methanol and/or ethanol.  
  
[0114] An unreacted fluid or solid, when contacted with the
catalyst, may generate a reacted fluid, e.g. a fluid for use in
the thermal systems disclosed herein. The reacted fluid may
include water and may also include nitrogen, carbon dioxide and/or
carbon monoxide, as well as smaller amounts of unreacted fuels
and/or oxidants and/or side products. For example, an unreacted
fluid that includes methanol and hydrogen peroxide, reacting with
a catalyst, produces exothermically water and carbon dioxide. In
some embodiments, little or no heat, and/or other initiator (e.g.
spark, glow plug, or flame holder), is required to initiate the
reaction. In some embodiments, contacting the unreacted fluid and
catalyst produces substantially continuously reacted fluid.  
  
[0115] In some embodiments, the reacted or working fluid, e.g.,
hot water, is focused out of the jet nozzle of the drill head
assembly and directed against the target rock surface. In one
embodiment, the jet temperature (reacted fluid temperature) and/or
heat flux may be controlled by adjusting the mixture of the
aqueous solution (for example, by increasing the methanol and/or
oxygen concentration to increase the jet temperature). In another
embodiment, the jet temperature and/or heat flux may be controlled
by increasing the flow rate of the unreacted and e.g., hence
reacted fluid. In another embodiment, the jet temperature and/or
heat flux may be controlled by adjusting the flow rate of the
unreacted fluid to adjust for complete or incomplete reaction. The
jet temperature and/or heat flux may also be controlled by, for
example, adjusting the flow rate of the unreacted fluid to reduce
the amount of heat exchange between the reacted and unreacted
fluids.  
  
[0116] A drill assembly may include a drill head with a nozzle. An
exemplary drill head may have a diameter of approximately
<3>A inches with a 0.1 inch center nozzle through which the
reacted fluid is expelled. In alternative embodiments, nozzles
with different configurations and/or geometries may be utilized,
such as a larger or smaller nozzle diameter. For example, the
drill head may be about 5 to about 15, or 4 to about 29 times the
diameter of the nozzle. In one embodiment, the drill head assembly
may include a plurality of jet nozzles directed in either the same
or different directions from a distal portion of the drill head
assembly. In another embodiment, the drill head assembly includes
one center jet nozzle. Rock "spalls" (e.g. grains or platelets of
less than about 0.025 inch to about 0.1 inch) can be ejected and
may be swept up the borehole by the reacted fluid (after the
reacted fluid contacts the rock). In one embodiment, a larger flow
of cooling-lift water (e.g., traveling in the annulus between the
nested tube and coiled tubing), can be introduced after the heat
exchanger (if used), to cool the fluid and help transport the
spalls to the surface.  
  
[0117] In one embodiment, a heat exchanger is placed above the
catalyst bed so that some of heat of the upflowing (e.g. reacted)
fluid is transferred to the down flowing (e.g. unreacted) fluid,
both conserving energy and preheating the solution prior to the
e.g. the catalyst bed, heater, or drill head. In an exemplary
embodiment, a nested drill string may act as a heat exchanger. In
some embodiments, the catalyst may be preheated by sending some
chemical, e.g. an oxidant (e.g. peroxide) in the down-flowing
fluid, with or without fuel, which may in some embodiments,
initiate a reaction, for example heating the catalyst. For
example, heat provided by a heat exchanger to a down flowing fluid
may provide enough heat to initiate the combustion reaction
without the need for a catalyst, which may allow flow to be
directed away from the catalyst bed (and thus may preserve or
prolong the useful lifetime of the catalyst). In some embodiments,
hot gas may be used to dry the catalyst bed prior to contact with
the fuel and oxidant. [0118] In another embodiment, approximately
0.12 gallons per minute of a 15-20% aqueous solution, such as, but
not limited to an aqueous methanol solution, is pumped through a
preheater to bring the temperature up to 290 <0>C. In an
alternative embodiment, a greater or lesser volume of aqueous
solution may be pumped. In further alternative embodiments the
preheater may bring the temperature of the aqueous solution up to
a greater or lesser temperature, as required. In a further
alternative embodiment, no preheater is required  
  
[0119] In one embodiment spallation takes place with stand-off
distances (i.e. the distance from the nozzle exit at which the
target surface is placed) ranging from approximately 0.2-10.0
inches. In an alternative embodiment, stand-off distances of less
than 0.2 inches or greater than 10 inches may be achieved. This
may, for example, allow a one inch diameter hole to be drilled at
a rate of greater than 0.5 inches per minute. In one embodiment,
the standoff distance is varied, either periodically or randomly,
in a controlled or relatively uncontrolled manner, or in response
to a downhole measurement or physical, mechanical, electrical
thermal, or chemical condition. This variation in standoff may
improve the tools ability to reliably under ream or to produce a
borehole of consistent or desired geometry. Standoff distance, for
example, may be controlled by acoustic monitoring, e.g. analysis
of the sound of the jet can be used to determine the shape of the
bottom of the hole and distance between the nozzle and the bottom.
Parameters of the jet, (e.g., nozzle geometry, flow, temperature,
stand-off) can be adjusted to optimize drilling, either through
communications to the surface or by downhole processors or
actuators. The backpressure of the flow through the nozzle may
also be used for feedback to adjust e.g., the geometry of the
nozzle, the flow rate, the stand-off, and/or the rate of drill
string displacement.  
  
[0120] An example drill head assembly, a small scale axial flow
reactor, for a spallation system is shown in FIGS. 3 A to 3C. In
this embodiment, a catalytic heater drilling spallation system 31
may be used to create high temperature high pressure fluids in a
reaction chamber or cell 26, initiated by a stream of hot water
mixed with 20% methanol to which gaseous oxygen is added. In
alternative embodiments, a higher or lower percentage methanol may
be used. This stream of fluid flows into the cell 26 through an
inlet fitting 18. In one embodiment, the cell body 26 is
constructed with an insulating gap 24 filled with an insulating
material, such as, but not limited to, nitrogen gas at the same,
or substantially the same, pressure as the fluid flowing into the
cell 26. This gap 24 may assist in preventing heat loss from the
reaction chamber within the cell 26 into the cooling water
surrounding the cell 26, and also helps maintain the cell
integrity at the high temperatures of the reaction occurs. The
nitrogen enters the gap through a tube fitting 19 and into a
collar 20. A replaceable o-ring seal 21 allows the inner region to
thermally expand without loss of the nitrogen pressure blanket. A
threaded nut 22 secures the o-ring in place. In alternative
embodiments, alternative insulating materials and systems may be
utilized in place of, or in addition to, the nitrogen gas layer.  
  
[0121] The reaction chamber within the central region of the cell
26 is filled with a catalyst, such as, but not limited to,
platinum coated alumina spheres 25, that are held in place by two
stainless steel filter screens 23. In an alternative embodiment,
other appropriate materials and/or means of positioning and
holding the catalyst may be used. In operation, the reacted fluid
passes out of the reaction chamber, after reacting with the
catalyst 25, at an elevated temperature. A nozzle body 27, such as
a threaded nozzle body, focuses the high temperature jet 28 of
reacted fluid out of a nozzle exit 29 onto a target location on a
rock surface. The nozzle body 27 may be, for example, screwed into
place on the distal end of the system 31 using the two drilled
holes 30 and a spanner wrench.  
  
[0122] FIGS. 3D and 3E show the system 31 in operation. Prior to
starting the system 31, a granite block 39 is predrilled with a
small borehole 40. A seal-interface block 36 isolates the nozzle
27 from the coolant fluid, and provides a means for venting spalls
and oxidation fluids/gases from the borehole. The interface block
36 may, for example, have a cap 33 which is held in place using a
number of screws 34. The cap retains in place a thin metal washer
and ceramic felt pad 35 which makes a sliding seal for the system
31, thereby preventing inflow of coolant. The interface block 36
may be sealed to the outside using, for example, an o-ring 38. A
jet 37 of hot reacted fluid exits the nozzle exit 29 and enters
the predrilled borehole 40, where it spalls the rock at the distal
end of the borehole and flows upward and out of the interface
block through the chimney tube 32.  
  
[0123] Another example, as depicted in FIG. 11, is a convergent
radial flow reactor housed within a 2 7/8" OD drill head for
producing 4" holes in granite using the laboratory test system or
deployed on a coiled tubing unit. This system is comprised of a
steam generation assembly 132 containing a catalyst bed 135, a
drill head 136, and a connector 134 that couples the unit to other
downhole subassemblies and the drill string. Unreacted fluid is
pumped down a single capillary in the drill string, through 133,
and into the steam generation assembly 132 where it flows through
a catalyst bed and reacts producing reacted that exits out a
nozzle 136. Pressures and temperatures inside the steam generation
assembly 132 are measured at specific locations 137, 138 which can
be used to monitor the performance of the system. Flow schematics
of this steam generation assembly 140, 144 for a thermal
spallation drilling system are shown in FIG. 12A and FIG. 12B. A
converging flow design is shown in FIG. 12A. Fuel and oxidant
enter the cell 141 and flow across a catalyst bed 142 where they
react producing the working fluid which exits down a tube 143 to
the drill nozzle (not shown). A diverging flow design is shown in
FIG. 12B. Fuel and oxidant enter the cell 145 and flow across a
catalyst bed 146 where they react producing working fluid which
exits down and annulus which converges to a tube 147 that leads to
a drill nozzle (not shown). For surface demonstrations of the
drill head shown in FIG. 11, an example of a spallation drilling
test system rock core confinement apparatus 148 is shown in FIG.
13A, FIG. 13B, and FIG. 13C. The system can be used to simulate
spallation drilling at the surface where there is low stress on
the rock. The system is comprised of a steel concrete mold 149
that encases a rock sample 156 which is surrounded by concrete
157. A wellhead 151 is secured to the rock sample prior to the
sample being encased in concrete. The entire system rests on a
pallet 150 for ease of transportation. Bolts 153 on the side on
the concrete mold 149 can be tightened after the concrete has
hardened in order to induce a compressive stress on the rock
sample. A drill 158 enters as shown. Cooling water or drilling mud
is pumped through injection tubes 152 and enters the wellbore at
injection points 154. A flow barrier 155 prevents the cooling
water from entering the hot thermal spallation region downhole
while the drill is in operation. Unreacted fluid is pumped into
the drill through a tube 159 and reacted fluid exits the drill
nozzle 160.  
  
Thermochemical  
  
[0124] In an alternative embodiment, a working fluid including an
aqueous fluid comprising water and hydroxides of Group I elements
of The Periodic Table of Elements, and mixtures thereof, may be
used. For example, an aqueous fluid may include a hydroxyl ion
concentration of the hydroxides of Group I elements of The
Periodic Table of Elements and mixtures thereof at ambient
conditions is in the range of about 0.025 to 30 moles of hydroxyl
ion per kilogram of water. In some embodiments, an upper limit of
the range can be determined by the solubility of the Group I
hydroxide. For example, a fluid may include about 0.1 to about 52
grams sodium hydroxide per 100 grams of solution at room
temperature (but may include more at higher temperatures). In some
embodiments, the fluid may comprise alcohols such as methanol or
ethanol with hydroxides, which produce alkoxides. Such alkoxides
may help solubilize minerals in rock.  
  
[0125] In some embodiments, concentrated aqueous or alcohol
solutions of hydroxides of alkali metals can react with subsurface
rock formations and may be capable of forming one or more water
soluble complexes with at least one of Si or Al. For
aluminosilicate rocks, the high alkoxide or hydroxyl ion
concentration in the fluid may provides the dual benefit of (i)
enhancing the dissolution rate by fully ionizing the chemical
surface groups on the formation rock, thus maximizing the density
of surface sites vulnerable to hydrolysis, and (ii) enhancing
solubility of reaction products by forming thermally stable
soluble complexes. Such fluids may dissolve rock and consume
hydroxide stochiometrically until e.g., the hydroxyl ion
concentration drops to near 0.01 moles of hydroxyl ion per
kilogram of water or alcohol. Materials to achieve hydroxyl ion
concentration above 0.01 moles of hydroxyl ion per kilogram of
water include, but are not limited to alkali metal and alkaline
earth metal components such as hydroxides, silicates, carbonates,
bicarbonates, mixtures thereof and the like. In example material
is sodium hydroxide. Other solutes may be added in any desired
quantity to achieve other objectives, as long as the hydroxyl ion
concentration is maintained  
  
Coupled Thermal and Mechanical
Systems  
  
[0126] One aspect of the present invention relates, at least in
part, to drilling systems, and associated methods of use, that
includes a heat source to thermally affect a target material and a
mechanical drilling system. The drilling systems may be used to
create boreholes or increase the diameter of existing boreholes in
any of the target materials described herein including, but not
limited to, crystalline rock material, silicate rock, basalt,
granite, sandstone, limestone, or any other rocky material. The
drilling systems may be used to create vertical boreholes,
horizontal boreholes, angled boreholes, curved boreholes, as well
as slots, perforations, fracture enlargement, or other forms of
hole opening, or any combination thereof. In one embodiment, the
methods and systems described herein provide for improved deep
borehole drilling, for example from approximately 10,000 feet to
approximately 50,000 feet below the surface, or more. [0127] A
borehole may be created, for example, through the combined use of
a heated fluid and a mechanical drilling and/or reaming or milling
system. Combining a mechanical drilling system with e.g. a thermal
drilling system such as those described above may overcome certain
limitations of thermal systems alone, by, for example, the
combination may provide for controlling stand-off and/or rate of
penetration or bit advancement, penetrating unspallable or
thermally-insensitive or unspallable zones, comminuting larger
pieces of rock that may be produced or fall from the borehole
wall, penetrating fractures which have inflowing or potential for
outflowing fluids. Combining the use of a heat source to thermally
affect a target material with a mechanical drilling system may
overcome certain limitations of conventional mechanical drilling
systems alone by, for example, preventing the wear and fatigue to
the drill bit that is produced through traditional mechanical
drilling technologies. More particularly, by utilizing one or more
heat sources to thermally affect a rock portion in advance of one
or more conventional drilling and/or milling systems, the
mechanical and physical strength of the rock to be drilled and/or
milled can be reduced forward of, and/or simultaneously with, the
mechanical drilling process. This may allow for increased
penetration rates with reduced bit wear, vibration and drill
string fatigue, and uncontrolled trajectory deviations compared to
conventional drilling processes. For example, new cutter materials
such as TSP can operate at temperatures above 1000 <0>C, as
shown, e.g., in FIG. 15, where hard rocks such as granites are
significantly softened, as shown, e.g., in FIGS. 8, 9, 10, and 16.
Therefore, a thermal jet which reduces the rock strength by, e.g.
partially spalling and/or microfracturing and/or softening
combined with a mechanical drilling process using a high
temperature bit material, has the possibility of a corresponding
ROP exceeding that of either process along. As a result, the
efficiency of conventional mechanical drilling methods may be
significantly increased by the use of a heat source to modify the
properties of the rock in advance of the mechanical drilling
system.  
  
[0128] In one embodiment, the mechanical drilling and/or reaming
system may, for example, include a traditional mechanical,
chemical, or other appropriate drilling and/or reaming mechanism.
Embodiments of the invention may, for example, incorporate any
appropriate mechanical bit design, including, but not limited to,
roller cone bits, tricone bits, polycrystalline diamond compact
(PDC), reaming bits, milling bits, hammer drill bits or coring
bits, or other appropriate drilling bits. The design of these
bits, including cutting and rock reduction surfaces, can be
optimized so that the depth-of-cut and rate-of-penetration can be
maximized while keeping the wear, vibration, and trajectory
deviations within acceptable limits. Materials and novel designs,
including high temperature metals and alternative methods for
inclusion of cutting surfaces, may be optimized for use under
these relatively high temperature conditions. The use of high
temperatures may also allow for the use of ultra-hard materials
that tend to be brittle at lower temperatures. In an alternative
embodiment, the drilling system may include other physical or
chemical processes such as, but not limited to, sonication, sonic
drilling, laser drilling, arc/plasma, particle assisted drilling,
chemical dissolution, or other appropriate physical or chemical
processes of use in drilling applications in addition to, or in
place of, a mechanical drilling system.  
  
[0129] In order to thermally affect the rock to be drilled and/or
reamed or milled by the mechanical drilling system, one or more
heat sources may additionally be incorporated into the system.
This heat source may include any appropriate heat source adapted
to thermally affect a rock through spallation, microfracturing,
macrofracturing, dissolution, partial melting, softening,
modification of grain boundaries, change in crystalline phase,
decrystallization, erosion, or the like. For example, certain
materials such as shales and clays may be modified (e.g.,
dehydrated at high temperatures) to reduce or eliminate bit
baling.  
  
[0130] In one embodiment of the invention, a combined thermal and
mechanical borehole creation system may include a spallation
drilling mechanism, such as, but not limited to, any of the
thermal spallation systems described herein, with mechanical
drilling mechanism such as, but not limited to, a drilling,
reaming, milling, and/or hole opening process. A downhole chemical
reaction (e.g. hydrothermal oxidation of methanol and peroxide
over a catalyst) may provide both thermal energy as well as the
mechanical energy (e.g. expansion of the hot fluid to e.g. drive a
hammer).  
  
[0131] In one embodiment, a small pilot borehole may be formed,
e.g. with the thermally produced pilot borehole being
substantially smaller than the target diameter of the final
borehole. The pilot borehole may thereafter be milled, drilled, or
otherwise enlarged, by a mechanical system such as a reaming
system, or other appropriate hole opening system, to form the
final borehole of the required diameter. This method may, for
example, allow for more precise control of borehole geometry, and
provide substantial cost and time benefits for producing the final
reamed borehole. The pilot hole may serve as a guide, stay, or
centralizer for the reaming bit. In addition, removal of rock from
the circumference of a lead borehole (that has been created by
spallation system) through a reaming process may be, for example,
faster, easier, and/or produce less bit wear than traditional
drilling of the entire borehole. The spallation drilling mechanism
and reaming mechanism may be part of a single device, or be
separate devices. The pilot borehole may be used, for example, as
an exploratory, test, monitoring, or scientific borehole to e.g.
determine the quality of the resource and evaluate if a larger
borehole should be created.  
  
[0132] The use of a working fluid for e.g., creation of a lead
borehole, may affect one or more properties (e.g. a thermal,
mechanical, chemical or physical property) of the material at the
surface of the pilot borehole wall. This may, in turn, make it
easier for the reaming system to ream the surface of the lead
borehole to create the final borehole. In one embodiment, the
reaming operation may also remove rock that is not structurally
stable. Such rock could, if not removed, fall into the hole,
bridge the hole, or form ledges that prevent the advance of casing
or stick the casing before it is on-depth. Bridges that form in
the casing annulus can e.g. divert or disrupt the placement of
cement which may jeopardize the success of well completion. The
reduced mechanical strength of the thermally affected zone, if not
removed, may also reduce the overall integrity of a completed
well.  
  
[0133] In each of the embodiments described above, a working
fluid, such as those described herein, may be used to weaken
and/or remove the rock at a distal end of a borehole prior to, or
simultaneously with, the drilling, reaming, and/or milling action
of a mechanical bit coupled to the thermal spallation system. In
different embodiments of the invention, a working fluid can be
configured to spall or thermally affect the entire bottom surface
of the distal end of the borehole. In an alternative embodiment,
the thermally- affected zone produced by a working fluid does not
cover the entire surface under the drill bit. Rather, the fluid
stream can be directed so as to target certain regions under the
bit to be weakened. Damage to or removal of these regions can
cause structural weakening of the remainder of the surface so that
it may be easily removed by a separate feature on the drill bit.
In another embodiment, a working fluid may be focused toward the
sides of the borehole, with or without additional working fluid
being focused toward the bottom of the borehole.  
  
[0134] In various embodiments of the invention, the mechanical
drilling and/or milling or reaming operation may be carried out
concurrently with a thermal drilling operation, e.g. use of a
working fluid. For example, a mechanical drilling/reaming element
may be located either substantially close to the thermal treatment
operation and/or substantially offset along the drilling assembly,
thereby allowing the mechanical drilling process to be carried out
concurrently, or substantially concurrently, with a thermal
drilling operation. The mechanical drilling elements, (e.g. drill
bits or reaming bits) may therefore remove the thermally modified
portion of the geological formation and/or thermally unmodified
rock surrounding the thermally modified rock, thereby creating the
borehole and, in some embodiments, improving the geometry or
integrity of a wall of the borehole created by the spallation
system or other thermal treatment system.  
  
[0135] The system may be adapted to remove both spalled or
thermally affected rock and non-spallable rock. In addition, the
system may be adapted to reduce the size of rock pieces that are
too large to be removed from the borehole in a circulating fluid.
As a result, the mechanical drilling system, in combination with
the thermal treatment system, may be used to create boreholes in a
number of different geological formations including a number of
different properties. For example, a coiled tubing deployed
thermal spallation drill head can be combined with a coiled tubing
deployed mud-motor drill; in formations where the thermal
spallation process is not effective, the mud motor may be used to
turn a conventional coiled tubing drill bit. Likewise, a drill
pipe deployed hydraulically driven turbo-generator can be used to
produce electricity for resistance heating elements used to
initiate thermal spallation or treatment of the rock. A
thermally-stable rotary drill bit serves to maintain proper
stand-off of the jet during pure spallation drilling, assist in
some sections via thermomechanical drilling, and be the sole
mechanism for drilling in others. This is particularly
advantageous over prior, uncoupled, systems, wherein, for example,
a thermal treatment or thermal drilling system may need to be
removed from the borehole if unspallable rock is found at the
bottom of the borehole, or created by over-heating the rock, and
temporarily replaced by a mechanical drilling system. This removal
of a drilling system, and insertion of another type of drilling
system, whenever materials with different properties are met may
be extremely costly and time consuming. By coupling a thermal
system with a mechanical system within a single drilling system,
the need to replace the system when different materials are met
may be avoided.  
  
[0136] In an alternative embodiment, the mechanical drilling
process may be performed as a secondary operation while some
tubing or pipe remains in the hole. In a further embodiment, the
mechanical drilling process may be performed as a secondary
operation after the thermal drilling assembly has been removed. In
one embodiment, different processes, such as a thermal drilling
process and a mechanical drilling and/or reaming process, may be
performed concurrently along different portions of a single casing
interval or wellbore.  
  
[0137] In one embodiment, one or more thermal treatment nozzles
can be distributed throughout the front of a mechanical drill bit,
or through slots radially extending from an outlet port. The
nozzles can also be shrouded with a protective gas or fluid stream
to reduce cooling and mixing with the drilling fluid and/or
increase the potential for thermally damaging the rock surface.
Gas shrouds, fluid streams, solid insulation such as a ceramic or
syntactic ceramic, vacuum gaps, or gas or fluid filled gaps can
also be used to protect the materials of construction or
mechanical drilling equipment from high temperatures.  
  
[0138] In one embodiment, the drilling process includes rotary or
coiled tubing drilling. As a result, a thermal jet, or a portion
thereof, may be configured to rotate. In an alternative
embodiment, one or more thermal jets, or a portion thereof, may be
fixed, for example, through either a center or peripheral ring
jet.  
  
[0139] In some of the embodiments described herein, a thermal
system including a single nozzle may be incorporated into a
mechanical drilling system. The single nozzle may be located
centrally along a central elongate axis of the system. As a
result, the thermal system may include a fixed, non-rotating,
structure. A mechanical drilling and/or reaming or milling
mechanism may then by positioned over or in the thermal system,
and rotate around or in the thermal system, to mechanically drill
and/or ream the borehole being created in conjunction with the
thermal system. Providing a single, centrally located,
non-rotating thermal system may be advantageous, for example, in
simplifying the structure of the system by reducing the number of
necessary moving parts and reducing the mechanical complexity of
the overall system. This may, for example, reduce the cost of the
system while also allowing for a more structurally sound and
sturdy borehole creating tool. In one embodiment, by minimizing
the moving parts within the thermal system, stronger and more
robust materials may be used in the construction of the thermal
system, and the resulting structure may therefore be better
adapted to withstand the high pressures, temperatures, impact, and
mechanical wear that are generated at the bottom of a borehole
during drilling operations. [0140] In one embodiment, a heat
source may be incorporated into a mechanical drilling system such
that the distal end of the mechanical drilling system extends a
specified distance from the distal end of the heat source. As a
result, the impingement of the distal end of the mechanical
drilling system against the target portion of the rock results in
the substantially constant stand-off distance between the rock
surface and the heat source. This may be advantageous, for
example, in applications where a set distance is required between
the target surface and the distal end of the heat source to ensure
that the temperature, flow, and heat flux produced at the surface
of the target portion of the rock is within the required limits
for efficient spallation. Also provided herein are methods that
may achieve e.g., softening of rock at a radius proportional to
the wear rate of e.g. mechanical cutters such that the life of the
cutters is more uniform.  
  
[0141] An example drilling system is shown in FIG. 3A and FIG. 3B.
In this embodiment, the drilling system 400 includes a pilot hole
thermal spalling system 54 and borehole reamer 55 in conjunction
with coiled tube drill rig system 410. The pilot hole thermal
spalling system 54 is powered by a fuel and oxidant fed through a
nested tube 42 contained in a motor driven shaft 41. The reactants
move through the assembly to a pilot drill reaction chamber 47.
The reaction chamber 47 is filled with a catalyst to initiate a
thermal reaction with the fluid passing therethrough to change at
least one property of the fluid such as, but not limited to, a
temperature, a pressure, or a state of the fluid. In one example,
the reaction between the fluid and the catalyst increases the
temperature and decreases the density of the fluid. As a result of
the thermal reaction, a jet 50 of hot gases/liquids is directed
out of a nozzle 49 at the distal end of the chamber 47. The
reaction chamber 47 may, in one embodiment, be thermally insulated
from the main body by, e.g. a gas filled cavity 48. The exit jet
50 spalls the rock at the distal end of the borehole, thereby
drilling a hole in the rock 52 and creating a damaged zone 51
around the bore.  
  
[0142] The spalled rock can then be carried away from the target
location at the end of the borehole by the recirculating fluid or
drilling mud within the borehole. The nozzle portion 49 may, in
one embodiment, be constructed from a high temperature resistant
material such as, but not limited to, at least one of a ceramic,
ceramic composite, high temperature steel alloy, or the like.
[0143] The pilot spallation sub assembly 54 is attached to a
rotating reamer sub-assembly 55 which carves away the damaged
rock. The reamer 55 has multiple blades 43 having attached carbide
or diamond compacts 44 to cut away at the damaged rock zone 51.
Coolant, such as, but not limited to, a water or drilling mud, may
be introduced just below the reamer blades 43 with imbedded
compacts 44 through one or more outlets 45 to help cool the
assembly and remove cuttings.  
  
[0144] In one embodiment, where the system is attached to a coiled
tube drill rig 410, the downhole assembly, or a portion thereof,
may need to be rotated through the use of a downhole motor 56
attached, for example, to a connector 57 and then to the nested
coiled tube 66 and powered by high pressure fluid supplied by
surface pumps 70.  
  
[0145] The hard rock 58 found at depth can be effectively drilled
by this system. In one embodiment, shallow depth rock 59 can be
drilled, cased 61, and cemented 60 to prevent loss or introduction
of fluid during drilling. Drilling fluids including drilling mud
water and spalls are removed from the borehole through a flow line
62 to be separated and possibly recirculated. A rubber packoff in
a stripper head 63 diverts the returns into the flow line away
from the drill rig 410. On the surface, the coiled tube rig 400
contains a coiled tubing injector 64a which is used to drive the
coiled tube within the borehole, a tube straightener 64b and a
gooseneck 65 which is used to guide the tubing from the injector
64 into or off of the reel 67. Fluid, including e.g. reactants,
can be fed in from a source 69 through a rotating coupling 68 into
the reel assembly 67.  
  
[0146] One example drilling system may include a drill string
based thermally assisted tricone drilling system. An example
thermally assisted tricone drilling system 500 is shown in FIGS.
5A-5C. In this embodiment, heat to power a downhole spallation
system such as, for example, a hydrothermal spallation drill
system, can be provided by electrical resistance heating. A
tricone bit 510 is incorporated into a distal end of the drilling
system 500. In one embodiment, the tricone bit 510 has multiple
rotating rollers 80a which incorporate hard segments, constructed,
for example, from carbide, steel or ceramic segments, that are
used to grind and wear away at the rock and are held in place by
sleeve or roller bearings 80b.   
  
[0147] In one embodiment, electrical power may be generated using
a downhole turbine 83 in conjunction with an electrical generator
82. Power from the generator 82 is carried to a heater 75 through
one or more power cables 71. Water 72 is pumped into the heater
and boiled producing superheated fluid at high pressure that is
ejected through one or more nozzles 79 in the drill bit. The
heater 75 may include an insulating gap 74, as described above.
Drilling mud and/or coolant is pumped down through an annular
region 73 and into the borehole through one or more conduits 78. A
surface assembly 90 may be attached to the tricone bit 510. The
surface assembly 90 may include a conductor pipe and conductor
casing 87 cemented in place 86 in a surface rock portion 85 to
protect the potable water zones and provide a high pressure seal
to the earth. A segmented drill string 88 is driven into the
ground and rotated by the drill rig 90 and connected to a drilling
fluid circulating pump 91.  
  
[0148] In alternative embodiments of the invention, a drilling
system may include a spallation system, such as any of the
spallation systems described herein, coupled to other types of
mechanical drill bit, such as a PDC drill bit, diamond-
impregnated coring bit, or hammer drill bit. Example drilling
systems including a thermal spallation system coupled to various
drill bits are shown in FIGS. 6-8B.  
  
[0149] For example, FIG. 5 shows a PDC bit 600 incorporating a
spallation system such as a hydrothermal spallation system. In
this embodiment, fluid, including water, fuel, and oxidant, is
introduced through an inlet tube 92 into a reaction chamber 95.
The reaction chamber 95 may be insulated by, e.g. a pressurized
air gap 96. Upon passing into the chamber 95, the reactants within
the fluid contact a catalyst located within the chamber 95 and
react, producing high temperature reacted fluid. The reacted fluid
exits through one or more openings 100 as jets directed against a
target rock face. The spallation system is contained in the drill
body 94 of the PDC bit 600 and connected to a drill string at a
threaded tool joint or threaded connection 93. Drilling mud or
coolant is pumped down through an annular gap 97 and down to one
or more outlet feeders 101 and vents 102 close to the bottom of
the drill bit 600. Rotation of the bit engages flutes 98 mounted
on which the compacts 99, such as, but not limited to carbide or
PDC compacts, cut away at the thermally affected target rock
surface. The compacts 99 are cutting elements set in the matrix of
the bit body on ridges, sometimes called blades, with flutes
between the blades for mud flow and cuttings passage to the
annulus.   
  
[0150] In an exemplary embodiment, nozzles 100 leading a PDC drill
bit 600 may be sized to soften the rock just ahead of each cutter
element (compacts) 99. Drilling through the presoftened rock will
reduce the wear on the tool 600, especially the compacts 99.  
  
[0151] FIGS. 7 A and 7B show a drilling system 700 including an
abrasive/grinding bit incorporating a hydrothermal spallation
system. In this embodiment, water is pumped downhole through an
opening 103 in a segmented drill string 104 into a downhole
turbine or motor 105 located within a subassembly 106. The motor
105 is connected by a shaft to a water cooled rotating magnet
assembly 107 contained within a housing 108. The magnet assembly
107 surrounds a non-rotating metal core 109 having a series of
holes to allow a fluid to flow therethrough to remove heat
generated by induction from the rotating magnets 107. This
resulting super-heated fluid exits into a chamber 110 which may be
insulated by an air gap 111 from a coolant fluid channel 112. The
heated fluid exits through one or more nozzles 113 to interact
with a target rock surface. Coolant is directed from coolant exit
ports 114. An abrasive material, such as, but not limited to
diamond, are surface set into or impregnated in a plurality of
cutter segments (pads) 115. In operation, the super-heated fluid
exiting the nozzles 113 and impinges upon the target rock surface,
thereby damaging the rock and assisting the cutting of the rock by
the cutter segments (pads) 115.  
  
[0152] FIGS. 8 A and 8B show a drilling system 800 including a
thermal spallation system coupled to a hammer drill bit. In
general, a hammer drill is a drill with a hammering action. The
hammering action provides a short, rapid hammer thrust to
pulverize relatively brittle material and provide quicker drilling
with less effort. In one embodiment, the hammer drill may
additionally include a rotating motion that may be used separately
or in combination with the hammering motion. When used in the
hammer mode, the tool provides a drilling function similar to a
jackhammer.  
  
[0153] In the embodiment of FIGS. 8 A and 8B, coolant and/or
drilling fluid is introduced into a bit 800 through a drill string
connector 116 (e.g. a connection to a drilling assembly that
includes drill collars to provide a hammer with a large and stiff
inertial load to push off of.) The drill string connector 116
connects to the drill assembly. An upper valve plunger 118 and
return spring 119 is integrated into the hammer bit 800 to rapidly
press a driver 121 into an anvil 124, thereby driving the distal
end of the anvil 124 from a distal end 128 of the bit 800 to
transmit a blow to a target rock surface. The driver 121 may
include seals 120, 122, and a return spring 123. The anvil 124 is
attached to the body of the bit 800 through a guide nut 125, which
also prevents rotation of the bit. Integral to the anvil 124 is a
thermal combustion chamber 127 which is fed a fluid including a
fuel, water, and an oxidant from the surface through a separate
tube 117. The combustion chamber 127 may be thermally insulated
through, for example, a pressurized air gap 126. Hot fluid/gas
exits the chamber 127 through one or more jets 131 distributed
across the drill face. The distal end of the drill bit 128 is
cooled by water or drilling mud exiting through exit ports 129.
Stress to the thermally altered rock is created by the hammering
action combined with drill string rotation through the carbide
buttons 130.  
  
[0154] In other embodiments, improved well control may also be
achieved through the use of a hydrostatic column of a fluid such
as, but not limited to, water or geothermal drilling mud, to
increase hydrostatic pressure e.g. to balance formation pressure
in exposed formation using, e.g., deep surface or intermediate
casing and high pressure blowout prevention equipment installed on
a wellhead. Thermal spallation, coupled with high velocity liquid
flow through nozzles, may produce high pressure jets, pulsating
jets or abrasive jets to produce a dual spallation/jet drilling
system. Such dual systems may include a combination of hot and
cold jets or include operating spallation jets at higher flow
rates than needed to produce spallation (and thus have a jet
drilling process substantially directly ahead of the nozzle and a
spallation process in the wall jet that forms beyond the radius of
the jet produced hole.). For example, the use of high temperature
fluids may greatly reduce the pressure required to achieve jet
drilling in high strength rock. Additionally, the use of fluids
with temperatures below the brittle-ductile transition of the rock
may prevent the rock from being overheated and becoming
unspallable. Alternatively, the rock may be heated above the
ductile-brittle transition far enough to soften the rock enough
that it can be swept away or drilled like soft to medium
sediments. This may be advantageous, for example, for materials,
such as basalts, which are typically less prone to spallation and
not significantly damaged by heating to a temperature below the
ductile-brittle transition.  
  
[0155] A thermal degradation process or spallation formation may
not be used continuously. Rather, certain embodiments of the
invention may include pulsed heat treatment, such as a cyclically
pulsed heat treatment. In a further alternative embodiment, the
heat treatment may be alternated with a cooling treatment. Such
alternation may increase the damage to the rock or may help
moderate the temperature of the drilling mechanism and materials
of construction while still imparting high temperature, at times,
against the rock surface. In one embodiment, the thermal
spallation jet(s), or other appropriate heat source, may be
activated and turned off as required, thereby allowing the use of
the spallation system to assist in the penetration through certain
sections of a target rock, while allowing the thermal spallation
process to be turned off when penetrating other sections or target
rock, for example where thermal spallation is either not required
or advantageous.  
  
[0156] One embodiment of the invention includes a drill bit design
for use with a thermally assisted mechanical drilling method. In
one embodiment, for example in very deep/hot formations, the
thermal treatment can be a cooling process, where a very low
temperature jet causes microfracture of the surface through a
reduction in temperature.  
  
[0157] In one embodiment, the bulk of the fluid flow through the
drilling assembly - e.g. the portion used for cooling and cuttings
lift - may be relatively cool, while only a small portion - e.g.
that used for thermal degradation - is hot. As a result, some, or
all, of the cold fluid can be used to provide cooling to at least
a portion of the drilling device. For example, cold fluid may be
sent through or around the mechanical drilling structure to reduce
its temperature and improve survivability. In one embodiment, cold
water may be sent through flow channels in a traditional PDC or
tricone bit, while the hot portion of the fluid is insulated
directed substantially down against the rock. The channels
transporting the hot water may be isolated from the bit by a layer
of insulation, such as, but not limited to, a substantially solid,
liquid, gas, or vacuum insulation layer, or a combination of the
different insulation layers. In one embodiment, the relative ratio
of hot/cold can be adjusted to balance the performance of the two
drilling mechanisms.  
  
[0158] One embodiment of the invention includes a spallation
system including control systems, and associated methods, adapted,
for example, to control the diameter of the wellbore produced by a
e.g., hydro thermal jet, maintain the desired well hole
trajectory, control the distance between the nozzle and the bottom
of the hole (i.e. the "stand-off), and/or ensure a sufficient
temperature differential so as to induce spallation. These control
systems may include software and/or hardware based control
elements designed to ensure optimum performance of the thermal
drilling system. [0159] Disclosed methods may include introducing
a flow of water into the borehole. This flow of water may be used,
for example, to at least partially form an ascending fluid stream
to carry loose material such as, but not limited to, the spalled,
drilled, or otherwise loose rock from the bottom of the borehole.
The returning fluid may also travel up the borehole in reverse
circulation, e.g., where the fluid can be directed upward through
a separate tube or annulus in the main drill string. The water
flow may also be used to provide cooling for one or more parts of
the system and/or surrounding rock. The provided cooling may be
produced by at least one of temperature cycling, thermal
protection, and a circulated cooling fluid.  
  
[0160] In one embodiment, a heat exchanger may be coupled to a
portion of the system above the nozzle of the thermal spallation
system. This heat exchanger may be used, for example, to exchange
heat between a working or heating fluid (e.g. a reacted fluid),
spallation fluid, and loose material ascending through the
borehole and the fluid being pumped to the thermal spallation
system, e.g. an unreacted fluid, within a conduit extending from
the surface to the thermal spallation system.  
  
[0161] In one embodiment, one or more of properties of working
fluid and jet may be selected to ensure that that the required
conditions are met for optimum spallation. These jet properties
may include, but are not limited to, a temperature, a heat flux,
an exciting jet velocity, a heat capacity, a heat transfer
coefficient, a Reynolds number, a Nusselt number, a density, a
viscosity, and/or e.g., a mass flow rate. For example, these
properties may be obtained through selection of the specific
fluids used, by mixing of multiple fluids, and/or by treatment of
the fluid through heating, cooling, pressurizing, chemically
treating, or otherwise adjusting the composition of the working
fluid. Exemplary ranges, without being limiting, for a thermal
system for borehole creation from 1,000-30,000 feet, using a
working fluid, may include those provided in Table 1 below. Such
parameters may be determined by using a disclosed working fluid in
several different or similar rock formations, as exemplified
below, and assessing preferable ranges.  
  
Table 1: Example property ranges
for Hydrothermal Spallation drilling of boreholes.  
  

![](table1.jpg)

  
[0162] For example, a temperature at least that of the onset of
rapid thermal spallation but below the, e.g. brittle ductile
transition of the rock may be maintained.  
  
[0163] The total heat output - the thermal power of the drill
divided by the cross sectional area of the borehole to be drilled
- may be kept, for example, between 0.1 and 100 MW/m2. The heat
flux - a product of the heat transfer coefficient and the
temperature difference between the wall jet and the rock surface -
may be kept, for example, between 0.1 and 100 MW/m . In certain
embodiments, if too low a value of heat flux is used, a thermal
gradient may propagate and build in the rock, reducing the
relative strain of the surface rock to the underlying layer,
thereby reducing or preventing spallation. In one embodiment, it
is possible to increase the heat flux by increasing the Reynolds
number - a dimensionless number that gives a measure of the ratio
of inertial forces to viscous forces - in the nozzle exit. In
certain embodiments, the heat flux of a thermal jet for spallation
drilling may be increased without having the jet exceed the
temperature e.g. brittle-ductile transition of the rock, by
increasing the mass flow, and/or reducing the nozzle diameter (to
increase the exiting jet velocity). Increasing the velocity or
mass flow of the jet may also provide a mechanical or erosive
means of removing material or spalls from the rock surface,
clearing and providing a freshly exposed surface for further
spallation, and/or help with spall and cuttings lift.  
  
[0164] The Nusselt number - a dimensionless ratio of convective to
conductive heat transfer across (normal to) the rock-fluid
boundary - may, in a non-limiting example, for a working fluid in
one or more of the disclosed systems, be between about 30 and
1040, depending on hole size. In one embodiment, working fluid
properties can be optimized so as to produce an induced strain
within the grains of the rock of between about 0-30%, thereby
generating enough stress to cause structural failure, which may
make use of existing flaws, discontinuities, or grain boundaries
in the rock and/or in-situ stresses  
  
[0165] Spall sizes may, in one embodiment, be optimized so that
80% of the transported spalls maintain a range of 0.001-3 mm. If
the produced spalls are too large, they may not be lifted by the
drilling fluid and may plug small openings in heat exchangers and
internal returns tubes used in reverse circulation. If the
produced spalls are too small, it may be an indication that the
heat flux is too high, causing excessive microfracturing beyond
what is needed for drilling and cuttings lift, thereby wasting
energy and sacrificing efficiency, as well as increasing mineral
dissolution. Spall size may also be controlled to help plug
fractures leading to lost circulation or intrusion of fluids
during drilling, or to attempt not to plug fractures in producing
zones during e.g. hole opening for enhanced wellbore impedance.  
  
[0166] In one embodiment, at least one property of the spalls
and/or working fluid (e.g. reacted fluid) may be monitored to
provide information relating to the spallation process. For
example, the spall size, shape, chemical composition, and/or
number of created spalls may be monitored to provide information
on the efficiency of a spallation process. In addition, or in the
alternative, one or more properties of the reacted fluid may be
monitored to provide information on the efficiency of the
catalytic reaction between the unreacted fluid and the catalyst.
By monitoring one or more of these properties, information on the
spallation process, such as, but not limited to, the efficiency of
the heating reaction, the rate of spallation, the composition of
the spalled rock, the temperature of the fluid leaving the nozzle,
and/or the heat flux at the target surface may be deduced.  
  
[0167] In an embodiment, the properties of the fluids may be used
to inform the adjustment or addition of any additives into the
unreacted or cooling-lift water streams. Such additives may
include cleaning agents (e.g. to remove deposits from a catalyst,
nozzle or heat exchanger), and additives that increase or decrease
tendencies for materials in returning fluids to crystallize,
precipitate, or agglomerate. Contemplated cleaning agents may
include solids that are significantly abrasive to unwanted
deposits but not to the ceramic or metal of the nozzle. A cleaning
agent may be added continuously to a flow, or sent down
periodically. Additives may also assist in the opening of existing
fractures in production zones, or by preventing the produced
spalls and minerals from plugging the existing fractures by e.g.
mineral redeposition.  
  
[0168] The monitoring may be carried out using at least one of a
thermal measurement, an optical measurement, an acoustic
measurement, a chemical measurement, and a mechanical measurement
(e.g. a flow meter). For example, a laser-based optical system may
be used to measure one or more properties of the spalls exiting
the borehole. In alternative embodiment, any appropriate
measurement device may be used.  
  
[0169] If a change in one or more properties is observed, a
property of the fluid and/or spallation system may be adjusted to
compensate for the observed change and ensure optimum spallation.
This adjustment may be made, for example, by adjusting one or more
properties of the unreacted fluid being sent down the borehole to
adjust the fluid temperature and/or heat flux created by the
spallation process to maintain e.g., a pre-determined spall size.
The unreacted fluid may be adjusted by changing a parameter such
as, but not limited to, a chemical composition, a fluid mixture, a
pressure, and/or a temperature. [0170] In one embodiment, control
of the Reynolds number of the fluid jet at the exit of the nozzle
by, e.g. controlling the mass flow exiting the nozzle, controlling
the nozzle size, and/or controlling the viscosity of the fluid,
may assist in controlling the heat flux at the surface of the rock
at the target location.  
  
[0171] The spalls and/or reacted fluid may be monitored at the
surface (i.e. after traveling from the distal end of the borehole
to the surface in the ascending fluid stream). In an alternative
embodiment, the spalls and/or reacted fluid may be monitored at a
location part way down the borehole and/or at the distal end of
the borehole. In one embodiment the spalls and/or reacted fluid
are monitored at a single location. In an alternative embodiment,
the spalls and/or reacted fluid are monitored at multiple
locations.  
  
[0172] One embodiment disclosed herein includes a method for
excavation of a borehole in a geological formation by using a heat
source, such as, but not limited to, a thermal drilling system to
create a pilot borehole in a geological formation, measuring at
least one property of the geology of the pilot borehole,
evaluating the at least one measured property to determine whether
to enlarge the pilot borehole, and enlarging the pilot borehole if
the at least one measured property meets a set requirement. The
pilot borehole may be enlarged by inserting at least one of a
spallation drilling system and a mechanical drilling system into
the pilot borehole.  
  
[0173] This method may be advantageous in situations where a pilot
borehole is to be formed in order to test the properties of the
geology to determine whether further drilling and completion is
warranted. The smaller pilot borehole is cheaper to drill than a
larger diameter borehole, but may still allow access to the
subterranean geology for testing. The pilot borehole may also be
used as a guide hole for the larger borehole drilling, and may
weaken the structure of the rock surrounding the pilot borehole to
facilitate easier drilling of the larger borehole.  
  
[0174] The evaluating step may include evaluating whether the
geological formation is suitable for use as, for example, an
injection or production borehole for at least one of a geothermal
system, oil and gas, mining, excavation, or CO2 or nuclear
sequestration or storage. As discussed above, one or more
properties of the geology of the pilot borehole may be evaluated
by evaluating at least one property of spalls and/or the fluid
(e.g. the reacted spallation fluid, a cooling fluid, and a
drilling mud) exiting the borehole. In various embodiment, any of
the drilling systems described herein may be used to create the
pilot borehole and/or larger borehole.  
  
Self-Casing  
  
[0175] The fluids used in the systems described herein, and/or the
loose materials created by the process described herein, can, in
one embodiment, strengthen and seal the walls against structural
collapse and wellbore fluid loss, thereby greatly extending time
interval between casing of the borehole. This may happen through
processes such as, but not limited to, precipitation of materials
on the surface walls of the borehole and/or depositing of loose
materials within cracks and other cavities on the walls of the
borehole.  
  
[0176] In some applications, however, it may be desirable to
install casing in addition to any self-casing processes produced
by the systems and methods described herein. For larger diameter
borehole, for example, casing may be accomplished employing
conventional telescoping casing strings using methods familiar to
those skilled in the art. For small diameter boreholes, the slim
borehole can be cased, for example, using an expandable casing
string that is inserted into the borehole and then radially
expanded. The casing may be made of a malleable material, and when
it is placed in the borehole, it can be radially expanded against
the borehole wall upon application of an internal radial load.  
  
[0177] The examples which follow are intended in no way to limit
the scope of this invention but are provided to illustrate the
methods and apparatus of the present invention. Many other
embodiments of this invention will be apparent to one skilled in
the art.  
  
Example 1  
  
[0178] An example method of testing the efficiency of a thermal
spallation system is described below. This method may be used to
test any appropriate spallation system on a material.  
  
[0179] In the embodiment of Example 1, a Sierra White granite rock
core measuring 4" in diameter and 6" long was prepared by
pre-drilling a 0.75" diameter hole 0.5" deep on the top surface.
The core was then loaded into a stainless steel pressure vessel. A
preheater was assembled by winding a 20' long section of 0.125" ID
stainless steel tubing in a machined groove around a 4" brass
block in which contained a series of rod heaters.   
  
[0180] The thermal spallation system included a 0.5" ID x 3" long
catalyst chamber which exits through a single, 0.09" diameter
non-rotating nozzle located along the central axis. The catalyst
chamber is filled to a height of roughly 1.5" with 0.5% platinum
on 1/16" spheres having a surface area of 100 m<2>/g. A
series of stainless steel screens, spacers, and diffusers allow
fluid to pass through while holding the catalyst bed in place. The
drill head is insulated from surrounding cooling water by a 0.040"
gap pressurized with nitrogen.  
  
[0181] Before the start of a test, the drill head is driven to the
bottom of the predrilled hole and a depth is read off of a dial
indicator. The drill head is then retracted approximately 1.5"
from the bottom of the hole into a large cooling water chamber.  
  
[0182] The hydrostatic pressure in the vessel is then raised to
1600 PSI by means of a backpressure dome regulator. An axial load
of 6000 PSI and confining pressure of 3000 PSI are applied by
separate pumps acting upon the core to simulate deep geological
formation conditions. An air actuated pump is used to deliver 3
g/s of a 20% by volume methanol in deionized water through the
preheater which raises the temperature of the unreacted fluid to
250-300 <0>C. A high pressure oxygen flow is metered into
the preheated aqueous methanol solution at sub-stoichiometric
ratios.  
  
[0183] The thermal spallation system may use a methyl alcohol
fuel, and an O2 oxidant. The aqueous methanol/02 solution travels
through the spacers, screens, and diffuser and over or through the
catalyst bed. The catalyst is not preheated and does not need an
additional heat source such as a glow plug, spark, or flame for
the reaction to initiated or maintained. The substantially
flameless catalytic oxidation of the methanol produces heat within
the water which raises the temperature of the fluid to 800-900
<0>C.  
  
[0184] The high temperature fluid exiting the nozzle into the
cooling chamber is initially diverted and cooled by a 4 GPM water
flow. The flow of aqueous methanol is increased to 9 g/s over 2
minutes while simultaneously adjusting the oxygen flow. The drill
head is then driven by a high pressure fluid pump at a rate of
1.0'Vmin through a stainless steel seal, isolating it from the
cooling water, and into the predrilled hole to a standoff of 0.25"
from the rock surface, as measured by the dial indicator. The
displacement of the drill head is then reduced to 0.5"/min. The
drill head penetrates into the rock until it reaches the full
stroke of the equipment, roughly 1.5" below the predrilled rock
surface. In one embodiment, the drill head is then held at this
position to demonstrate the ability of the center jet nozzle to
drill in advance of the drill head and under ream. In an
alternative embodiment, the drill head need not be held
consistently at the bottom. Fluid and spalls exit the borehole
into the cooling water above the rock via a 0.189" tube
approximately 1.5" in length. The bulk fluid then passes through a
series of screens which remove the bulk of the spalls before the
bulk fluid passes the back pressure dome regulator and then
through a low pressure hydrocyclone to remove very small size
spalls. The spalls from may be separated from the bulk fluid by
filtering through a 200 mesh screen which retained approximately
88% of mass of the excavated rock. Size analysis may be performed
by laser light scattering.  
  
[0185] After being held for 10 minutes at this depth, the drill
head is rapidly retracted through the borehole seal, allowing
cooling water to fill the hole and the jet to be diverted,
quenching the spallation process. Aqueous methanol and oxygen flow
rates are gradually reduced and the preheater is turned off.  
  
[0186] The sample may then be removed from the cell. The volume of
excavated rock may thereafter be determined from the mass of water
required to fill the volume of the new borehole, less the volume
of the predrilled hole. The rock core may then be dried and
weighed. A image of a rock core sectioned axially following the
test with the drill head that produced the borehole is shown in
FIG. 17. A graph showing spalled particle size distribution for
the system of Example 1 can be seen in FIG. 21.  
  
Example 2 Repeatability and Other
Rock Types  
  
[0187] An experiment as in Example 1 was been repeated on Sierra
White Granite, as shown in Table 2:  
  
Table 2: Additional hydrothermal
spallation drilling of boreholes in Sierra White Granite  
  

![](table2.jpg)

  
[0188] The process was conducted on other rock types including
Sioux Quartzite, Wausau Granite, Berea Sandstone, and
granodiorites, as shown in Table 3, as well as Barre, and Westerly
granites:  
  
Table 3: Example results for
hydrothermal spallation drilling of boreholes in other rock
types  
  

![](table3.jpg)

[0189] Other tests were conducted on Sierra White Granite while
independently varying a number of parameters including
temperature, mass flow, axial stress, confining stress, nozzle
diameter, jet velocity, heat flux, rate of drill head
displacement. Table 1, above, indicates determined parameters used
to enable hydrothermal spallation in one embodiment of the
invention.  
  
[0190] Other tests following Example 1 were conducted with
hydrostatic pressures including near ambient, 1500 PSI
(subcritical), and 3500 PSI (supercritical), to demonstrate the
viability of this system from shallow to deep wellbores. Example 3
Borehole Drilling- 4" diameter in hard rock  
  
[0191] A 4" diameter hole is pre-drilled to a depth of 5" in
Sierra White granite rock block measuring 24x24" square and 36"
tall. A drill head interface is placed in the pre-drilled hole and
sealed in place with high temperature cement. The block is
centered in cylindrical steel mold 38" diameter, 44" in length,
with a 0.375" wall. This mold had been split down the side and
support railings were welded onto the outside edge. Bolts are used
to clamp the two halves of the mold together. Concrete is poured
to fill the empty volume between the rock block and mold. The
concrete is allowed to cure for 10 days, after which time the
bolts are tightened to provide 150 psi clamping pressure on the
sample. A diagram of the apparatus is shown in FIGS. 14A-C.  
  
[0192] Approximately 450 g of Instant Steam catalyst obtained from
Oxford Catalyst PLC is loaded into a converging radial flow
reactor and placed inside a 2 7/8" OD drill head, as shown in FIG.
11. The drill head is slid into the drill head interface. Before
the start of a test, the drill head is driven to the bottom of the
predrilled hole and a depth is read off of the computer controls.
The drill head is then retracted approximately 10" from the bottom
of the hole to allow cooling water from the drill head interface
to enter the bottom of the hole. A mixture of 38% hydrogen
peroxide and 12% methanol by weight is pumped into the catalyst
bed at 3200mL/min. Neither the catalyst nor the fuel/oxidant fluid
is preheated, and no additional heat source such as a glow plug,
spark, or flame for the reaction is used. The mixture "lights off
over the catalyst bed producing a 800 <0>C jet of steam
which exits a single, 0.189" diameter non rotating nozzle located
along the central axis.  
  
[0193] The drill head interface is advanced quickly through a
stainless steel seal in the drill head interface, isolating it
from the cooling water, and into the predrilled hole a to a
distance of 5" off the bottom of the hole; the advance rate is
then reduced to a setpoint drilling rate of 10'/h by a stepper
motor, gear reducer, drive screw, ball nut, and static and sliding
support members. A load cell is included to measure the drive
force transmitted to the drill assembly. The drill is advanced to
its full stroke, roughly 13" below the depth of the predrilled
hole.  
  
[0194] The reaction is immediately quenched by stopping the flow
of the reactants, and the drill is removed to reveal a hole that
extends 5" past the final depth of nozzle exit. The sample is
removed from the concrete and sectioned to display the hole that
is created, as shown in FIG.  
  
14. Example 4 Field Drilling  
  
[0195] A thermal spallation system can be deployed on a customized
AmKin 800 V track mounted coiled tubing unit. A 20' long 2 7/8-3
<[iota]>[Delta]" OD bottom hole assembly is prepared from
instrumentation and controls subassembly (or "sub"), a release
sub, a dynamic barrier sub, stabilizers and centralizers, and an
iteration of the steam generation sub described in Example 4. The
steam generation sub houses an axial catalyst bed 2 <1>A" in
diameter and 12" long filled with Oxford Catalysts Instant Steam
catalyst. The bottom hole assembly is attached to a Tenaris HS-90
2.00" steel coiled tubing with a 0.134" wall through a connector
sub. Inside of the coiled tubing, a 3/8" OD nitric-acid passivated
stainless steel capillary is housed to transport the unreacted
fluid to the steam generation sub, and a 5/16" 7-conductor
wireline cable is used for communication in the instrumentation
controls sub.  
  
[0196] A starter well is drilled into competent rock and lined
with 4" ID casing. At the top of the casing is mounted a wellhead
diverter with stripper rubber. The bottom hole assembly and coiled
tubing is run through a wellhead diverter seal to the bottom of a
water-filled 300' hole.  
  
[0197] The unreacted fluid is prepared at the surface by
continuously metering 52% high test peroxide, reagent grade
methanol, and deionized water into a mix tank to produce 38%
peroxide and 12% methanol. The mixture is pumped through the
capillary at 1 gallon per minute to the catalyst bed where it
self-energizes and reacts with the catalyst element without the
need for an external energy source (such as a spark, glow plug or
flame holder) thus generating a 800 C reacted fluid, without an
inherently unstable flame or the need for cooling water to protect
the materials of construction or overheating of the rock. This
reacted fluid is then emitting through a 0.189" nozzle and
directed at the bottom of the hole, causing rapid spallation of
the rock. The coiled tubing is fed into the hole at a rate of
2O'/h by means of the coiled tubing injector on the AmKin 800 V
continuously drilling a 4" borehole in the solid granite. Spalls
are swept through the dynamic seal assembly where they meet a 50
gallon per minute flow of water flow, which has travelled down
inside the 2" coiled tubing and exited a series of upward pointing
jets, to cool the reacted fluid and carry the spalls to the
surface. At the surface, the spalls are removed by a series of
"shakers", cyclones, and filters, the water is cooled by a 200 kW
mud cooler, and continuously recirculated. Example 5 Multilaterals
with hole opening  
  
[0198] A system as described in Example 4 can be used to create
multilaterals. At the desired depth, the bottom hole assembly is
deviated, the spallation jet is directed at the wall of the
borehole causing the drill to create a hole off-axis from the
existing borehole. The bottom hole assembly is advanced using the
coiled tubing injector and intersects additional fracture networks
which can provide flow to the main wellbore. When the final target
depth ("TD") is reached, the unreacted fluid is directed through a
second catalyst bed that is in fluid communication with 6 jets
oriented normal to the axis of the bottom hole assembly and spaced
60 degrees apart around the circumference of the tool. The
unreacted fluid is pumped again and reacted fluid exits the
circumferential jets, expanding the diameter of the wellbore as
the bottom of the hole assembly is withdrawn on the coiled tubing.
Periodically, this hole opening process is paused and the well is
allowed to produce fluid, blowing produced spalls and loose rock
from the fractures. Flow sensors including "spinners", and
thermocouples are used to infer the flow rate from a given
fracture. If additional hole opening is required, the hole opening
is restarted. In certain sections of the well where larger/global
hole opening is desired, the bottom hole assembly can be held in
place, causing extensive spallation, macrofracturing, breakout and
collapse of sections in the producing zone.  
  
Example 6 Hole opening of a 0.75"
borehole  
  
[0199] Using the procedure of Example 1, a Sierra White granite
rock core measuring 4" in diameter and 6" long was prepared by
pre-drilling a 0.75" diameter hole 4" deep on the top surface. The
core was then loaded into a stainless steel pressure vessel
described in Example 1.  
  
[0200] The thermal spallation system includes a 0.5" ID x 3" long
catalyst chamber which exits through a single, 0.04" diameter
non-rotating nozzle oriented perpendicular to the existing
predrilled hole. The catalyst chamber is filled to a height of
roughly 1.5" with 0.5% platinum on 1/16" spheres having a surface
area of 100 m<2>/g. A series of stainless steel screens,
spacers, and diffusers allow fluid to pass through while holding
the catalyst bed in place. The drill head is insulated from
surrounding cooling water by a 0.040" gap pressurized with
nitrogen. The drill head is held in a large cooling water chamber
during start up.  
  
[0201] The hydrostatic pressure in the vessel is then raised to
1600 PSI by means of a backpressure dome regulator. An axial load
of 4500 PSI and confining pressure of 3000 PSI are applied by
separate pumps acting upon the core to simulate deep geological
formation conditions. An air actuated pump is used to deliver 3
g/s of a 20% by volume methanol in deionized water through the
preheater which raises the temperature of the unreacted fluid to
250-300 <0>C. A high pressure oxygen flow is metered into
the preheated aqueous methanol solution at sub-stoichiometric
ratios.  
  
[0202] The thermal spallation system uses methyl alcohol fuel, and
an O2 oxidant. The aqueous methanol/02 solution travels through
the spacers, screens, and diffuser and over or through the
catalyst bed. The catalyst is not preheated and no additional heat
source is used. The catalytic oxidation of the methanol produces
heat within the water which raises the temperature of the fluid to
800-900<0>C.  
  
[0203] The high temperature fluid exiting the nozzle into the
cooling chamber is initially diverted and cooled by a 4 GPM water
flow. The flow of aqueous methanol is increased to 9 g/s over 2
minutes while simultaneously adjusting the oxygen flow. The drill
head is then driven by a high pressure fluid pump at a rate of 7.5
cm/min through a stainless steel seal, isolating it from the
cooling water, and into the predrilled hole. The reacted fluid
spalls the wall of the borehole until it reaches the full stroke
of the equipment, roughly 1.5" below the predrilled rock surface.
Fluid and spalls exit the borehole into the cooling water above
the rock via a 0.189" tube approximately 1.5" in length. The bulk
fluid then passes through a series of screens which remove the
bulk of the spalls before the bulk fluid passes the back pressure
dome regulator and into a large collection tank.  
  
[0204] The drill head is rapidly retracted through the borehole
seal, allowing cooling water to fill the hole and the jet to be
diverted, quenching the spallation process. Aqueous methanol and
oxygen flow rates are gradually reduced and the preheater is
turned off.  
  
[0205] The sample is then removed from the cell. A large slot is
formed along the length of the predrilled hole in the same
orientation as the jet, increasing the diameter by roughly 2x.  
  
[0206] Effective experiments, following Example 5, holding the jet
stationary to open the hole globally; using axial jets, multiple
jets, and diffuse heating; and where rock is intentionally
fractured either or parallel or normal to either the existing
borehole or the jets have also been conducted. In one embodiment,
as shown in FIG. 18, using a vertical spallation jet in a
predrilled 7/8" hole 1" deep (shown as dashed lines) into a 4"
diameter rock core increased the diameter by roughly 2x and
created a thermally affected zone (shown by arrow) of highly
altered materials with reduced strength, as determined by
SEM-EDAX, thin sections, microscopy, punch and modified Chercar
testing.  
  
Example 7 Thermal and Mechanical
Drilling  
  
[0207] Spalls and/or a reacted rock region can be formed as
described above. A reamer element, including one or more reamer
elements mounted to the housing and located back from the distal
portion of the thermal spallation system, can then be used to ream
the thermally effected rock at the outer sides of the borehole
created by the thermal spallation system to enlarge and/or shape
the borehole, as required.  
  
Example 8 Thermal Heating and TSP
Drag bit  
  
[0208] Spalls and/or a reacted rock region can be formed as
described above. A drag bit with TSP cutters is then used to
remove the thermally effected rock from the borehole more easily
than if the rock was not heated.  
  
Example 9 Rock sample tests  
  
[0209] Thin sections: samples extracted from rocks in Examples 1-4
were cut into small sections using diamond blades and sent to a
thin section preparation laboratory. The samples were evacuated
and saturated with a blue epoxy to identify pores and fractures.
The samples were polished and then mounted to a glass slide and
the section ground down to a thickness required using a
transmission microscope with polarizing lens to determine mineral
structure alteration and other microscopic features.  
  
[0210] Microscopic observations on the regions near the borehole
suggest thermal fracturing of grains especially quartz and
feldspars but little or no alteration of these minerals is
apparent in the micrographs.  
  
[0211] Binocular microscope: samples were inspected with a
binocular microscope looking for evidence of alteration fractures
and other feature associated with changes in the physical or
chemical properties due to the rapid heating accompanying
hydrothermal spallation. Radial crack were identified in many of
the samples that have the appearance of being filled with small
quartz remnants (spalls). A general bleaching of the thermally
altered surface suggests removal of iron and other color
generating compounds. [0212] Punch tests: a small spring loaded
punch (pointed tool steel) was used to remove small amounts of
rock. The spring force on each punch when triggered is
approximately 15 pounds total. The removed rock was collected and
the total amount weighed. A series of punches tests (20 ea) were
used on each sample on the thermally affected zone and on virgin
rock, and results shown below:  
  

![](results.jpg)

  
Dye penetrant: a visual dye penetrant was applied to the surface
of the thermally altered rocks to see the extent and depth of the
fracturing/alteration. After application the rocks were visually
inspected with the binocular microscope. FIG. 20 shows an image of
an example diorite sample indicating the depth of penetration of
the dye into the altered zone and the flow of dye into two smaller
fracture zone perpendicular to the altered region. In various
embodiments of the invention, dye penetration from about 0.7 cm,
at the regions closest to where the jet is impacting the rock, to
approximately 1.5 cm further up the annulus, where the rock has
been exposed to the superheated fluid longer, may be achieved.   
  
References  
  
[0213] All publications and patents mentioned herein, including
those items listed below, are hereby incorporated by reference in
their entirety as if each individual publication or patent was
specifically and individually incorporated by reference. In case
of conflict, the present application, including any definitions
herein, will control.  
  
US5,771,984; US7,742,603; US7,025,940; US2008/0093125  
  
"Feldspars and Feldspathoids, Structures, Properties, and
Occurrences: Structures, Properties and Occurrences," by William
L. Brown, North Atlantic Treaty Organization Scientific Affairs
Division,   
Published by Springer, 1983.  
  
"Hydrolytic weakening of quartz and other silicates," by D. T.
Griggs, Geo-phys. J. Roy. Astron. Soc, 1967.  
  
"Origin of granite in the light of experimental studies," by
Tuttle, O. F. and N. L. Bowen, Geol. Soc. Am. Mem. 74, 1958.

  


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