Geothermal research program brookhaven national laboratory
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GEOTHERMAL RESEARCH PROGRAM BROOKHAVEN NATIONAL LABORATORY. CAPABILITIES. Evaluation of engineering properties of cement- and polymer-based materials. Numerical modelling of material behaviour. Coatings and alloys for corrosion control. Recovery of geothermal silica and other minerals.

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Geothermal research program brookhaven national laboratory

GEOTHERMAL RESEARCH PROGRAM BROOKHAVEN NATIONAL LABORATORY


Capabilities
CAPABILITIES

  • Evaluation of engineering properties of cement- and polymer-based materials.

  • Numerical modelling of material behaviour.

  • Coatings and alloys for corrosion control.

  • Recovery of geothermal silica and other minerals.

  • Formulation of materials with specific properties.

  • Computational structural mechanics.

  • Heat transfer analysis.

  • Non-destructive testing.


Overall objectives
OVERALL OBJECTIVES

  • Meet the need for high performance, cost effective materials technology in geothermal applications.

RELATIONSHIP TO PROGRAM GOALS

  • Support programmatic goals of reducing the overall cost of geothermal energy by:

    • Reducing power plant capital and O&M costs

    • Reducing well completion costs

    • Ensuring the integrity and prolonging the life of geothermal wells


Relationship to program structure

Acid Resistant Cements

Structural Response Analysis for Well Cements

RELATIONSHIP TO PROGRAM STRUCTURE

Coatings and HX Liners

ESR&T

Non-Destructive Testing, Integrity Assessment and Repair of Piping

Drilling & Completion


Work scope
WORK SCOPE

  • Synthesis of new materials

  • Better use of existing materials

  • Experimental characterization of material properties

  • Improved techniques for monitoring material performance and assessing integrity of equipment

  • Computational analysis to predict material response behaviour to mechanical and thermal loads

  • Field validation in collaboration with industry partners and technology transfer


Organization
ORGANIZATION

BNL PROGRAM ON MATERIALS FOR GEOTHERMAL APPLICATIONS

Program Leader: M.L. Berndt

Materials Engineering and Analysis

Materials Chemistry

M.L. Berndt

A.J. Philippacopoulos

T. Sugama




Activities i coatings and acid resistant cements
ACTIVITIES (I): Coatings and Acid Resistant Cements

  • Development of PPS powder coating technology for HX tubes and well head pipes.

  • More field tests on PPS-based HX liners.

  • Continued development of high-temperature PPS and PEEK and organometallic coatings for various applications.

  • Scale up of OMP coating technology for 20-ft.-long condensers.

  • Development of low surface energy coating for steam separators at temperatures up to 250°C.

  • Continued development of sodium silicate and sodium phosphate-activated well cements.

  • Developing setting retarders in enhancing resistance to acid of CaP cement.

  • Monitoring integrity of N2-foamed CaP cement being placed in Coso wells and fiber-reinforced CaP cement liner for well-head pipe at CalEnergy power plant.


Activities ii ndt and piping integrity assessment
ACTIVITIES (II): NDT and Piping Integrity Assessment

  • Field demonstration of long range guided wave NDT method on piping at Mammoth Pacific.

  • Remaining strength assessment of corroded piping to develop guidelines for repair/replacement decisions.

  • Develop and evaluate specific composites for in-situ repair and life extension of corroded geothermal piping systems.


Activities iii structural response analysis of well cements
ACTIVITIES(III): Structural Response Analysis of Well Cements

  • Working to develop an engineering-based approach for selection of well cements.

  • Integrating experimental testing, modelling and end-user input.

  • Evaluating thermoelastic response using FE coupled models representing the casing-cement-formation system.

  • Collaborating with geothermal operators in US and Mexico to obtain well data and analyze response to pressure transients (FY04).


Highlights results from structural response analysis of well cements
HIGHLIGHTS: Results from Structural Response Analysis Of Well Cements

  • Received 2003 GRC Best Paper Award: “Properties and Thermoelastic Response of Conventional and Fiber Reinforced Well Cements”.



Highlights results from structural response analysis of well cements2
HIGHLIGHTS: Results from Structural Response Analysis Of Well Cements

Thermoelastic Response (Transient)


Knowledge gaps
KNOWLEDGE GAPS Well Cements

  • Prediction of long-term materials behaviour in complex and dynamic environments.

  • Appropriate materials selection criteria.

  • Gaps can be addressed by:

    • Detailed analysis/parametric studies to increase our understanding of material behaviour in geothermal systems.

    • Development and verification of predictive models to determine factors controlling failure.

    • Engineering-based approach to materials selection rather than trial and error or “hand waving”.


Industry collaboration
INDUSTRY COLLABORATION Well Cements

  • Needed to determine materials problems and viable solutions.

  • Enhancements in industry collaboration include:

    • Providing detailed data on request e.g., operating parameters, material performance

    • Long-term commitment to projects in terms of field applications and cost sharing

    • Consensus and consistency on specific needs

    • Continuity in staff support

    • Greater interest, interactions and enthusiasm

    • Revitalization of GDO and GPO, or similar


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