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GEOTHERMAL RESEARCH PROGRAM BROOKHAVEN NATIONAL LABORATORY

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

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  1. GEOTHERMAL RESEARCH PROGRAM BROOKHAVEN NATIONAL LABORATORY

  2. 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.

  3. 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

  4. 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

  5. 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

  6. 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

  7. FY04 PROJECTS

  8. FTE STAFF LEVELS

  9. 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.

  10. 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.

  11. 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).

  12. 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”.

  13. HIGHLIGHTS: Results from Structural Response Analysis Of Well Cements

  14. HIGHLIGHTS: Results from Structural Response Analysis Of Well Cements Thermoelastic Response (Transient)

  15. KNOWLEDGE GAPS • 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”.

  16. INDUSTRY COLLABORATION • 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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