GEOTHERMAL RESEARCH PROGRAM BROOKHAVEN NATIONAL LABORATORY

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 OM costs
• Reducing well completion costs
• Ensuring the integrity and prolonging the life of
  geothermal wells

4
RELATIONSHIP TO PROGRAM STRUCTURE
Coatings and HX Liners
ESRT
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 250C.
• 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