KVAL: Optimal Rate of Penetration

Down-the-Hole (DTH) Percussive Drilling tools are preferred for their high efficiency in excavating hard rock formations, met for instance in mining and geothermal systems. Nevertheless, optimization of the drilling efficiency remains challenging in the field situation, due to the large uncertainty and significant complexity of downhole dynamics in percussive drilling. As an outcome of a collaborative research between Sintef, NTNU and Professor Emmanuel Detournay (from UoM) a novel approach for data-driven automatic control system to improve the percussive drilling efficiency has been found. This could lead to the realization of new control tool (based on real-time measurements) with a response 10 to 100 times faster compared to existing systems. OptiRop has investigated the potential cost savings that can be anticipated with the use of the novel data-driven automatic control system to improve the percussive drilling efficiency through cases studies in quarrying, in mining and in deep geothermal drilling. The results of these case-studies indicated a good potential of profitability with an increase of ROP (within the range of 10 to 30% ROP gains) for deep geothermal well and mining applications. In addition, the needs from Norwegian industrial percussive drilling value chain were investigated, feedback received from the Norwegian industrial actors in percussive drilling highlighted: - the need for the development of the innovation as plugging product allowing the compatibility with simple surface instrumentation available in the rigs commonly used today. - and their concern for enough phases of demonstration of the innovation (through dedicated R&D projects) in various field conditions. Besides the possibility for patenting the control technology was evaluated in OptiROP by involving an external patent attorney (Dehns). The results from this search and other comparative feedback (from the research partners) with the closest identified prior art documents concluded that the novel control system appears to be patentable.

Feedback received from the industry confirmed that results anticipated will benefit both percussive drilling supplier companies and end-user companies (energy & mining companies).