PROCEEDINGS, Thirty-Seventh Workshop on Geothermal Reservoir Engineering

Stanford University, Stanford, California, January 30 - February 1, 2012

SGP-TR-194

ASSISTED IGNITION OF HYDROTHERMAL FLAMES IN A HYDROTHERMAL

SPALLATION DRILLING PILOT PLANT

P.STATHOPOULOS, T.ROTHENFLUH, M.SCHULER, D.BRKIC, Ph.RUDOLF VON ROHR

ETH Zürich – Department of Mechanical Engineering – Institute of Process Engineering

Sonneggstrasse 3
Zurich, CH-8092, Switzerland
e-mail: [email protected]

costs, for conventional - rotary drilling increase

ABSTRACT exponentially with depth (Tester 2007). Spallation
rock drilling (Rauenzahn 1989) is based on the rapid
Spallation drilling is a promising drilling technique local heating of rock inducing high thermal stresses
that could prove to be economically advantageous
on its surface due to its low thermal conductivity.
over rotary techniques for deep wells needed e.g. for
The heat flux required to fracture the rock can be
geothermal energy production. It takes advantage of
provided by high velocity flame jets impinging on the
the properties of certain rock types, to spall rock to
rock surface. For the concept to work in deep well
small disk-like fragments due to thermal stresses. In drilling, a flame ignited in a high-density water-based
water-filled boreholes two to three kilometers deep, drilling fluid at hydrostatic pressures exceeding the
water exceeds its critical pressure and hydrothermal
critical pressure of water (220.6 bar) should be used.
flames can provide the required heat to spall the rock.
An approach for the application of this technique,
One potential spallation drilling head consists of a
currently under investigation in our laboratory, is
combustion chamber fed by water, fuel and oxidant.
called "hydrothermal spallation drilling" (Augustine
The reactants are preheated and react to a 2009). Although the drilling concept has been well
supercritical, hydrothermal flame in the aqueous documented, many critical issues for its
environment of the burning chamber. The water in
implementation in deep boreholes are still open. The
the combustion chamber reaches high temperatures
most important relevant scientific topics, which are
and exits through a nozzle together with the
being investigated in our research group, are
combustion products. The resulting supercritical presented on Fig.1.
water jet is directed to the rock surface to induce
fragmentation.
Building on the investigations on hydrothermal
flames carried out in our lab for almost two decades,
the work presented in this paper focuses on the
assisted ignition of these flames. For the
investigation of spallation drilling, a novel
hydrothermal spallation drilling pilot plant was built.
The self-ignition methodology used in all the
previously published investigations is not an option
anymore, due to safety reasons. Additionally, the
assisted ignition of a hydrothermal flame is relevant
for the field application of the technique, where the
flame has to be ignited in a deep borehole. The
implemented ignition set-up, an ignition model and
the corresponding experimental results are presented.
Figure 1: Scientific topics investigated in our
INTRODUCTION research group
If geothermal power utilization for energy production Although research on hydrothermal flames in
is to become competitive in a large energy production supercritical water (SCW) is carried out the last three
scale, the drilling costs need to be reduced. These decades, no systematic solution of the assisted
ignition of such a flame has been presented so far. profile is presented Fig.2 for the cases with and
This work intends to fill this gap and propose a without an exothermic reaction. Hence it is expected
reliable method of assisted ignition, which could be that the highest temperatures in the flow will be
also implemented in a real borehole. located inside its boundary layer and therefore the
ignition conditions will be reached within this layer.
IGNITION METHODOLOGY - MODELLING Several simplifications are made to reduce the
complexity of the problem, the most important of
There are many different methodologies to ignite a
which are:
combustible mixture, two of which are the most used,
 The pre-ignition temperature rise is small in
namely spark ignition and ignition on a hot surface.
comparison to the temperature value at the
The first is used in internal combustion engines,
heated wall. This assumption implies that
while the second is implemented in gas furnaces.
RT<<E, in the computational field, where R,
Both methodologies are well known, but could not be
is the universal gas constant, E the activation
directly implemented in the application in question,
energy of the combustion reaction
due to the high density aqueous environment
(assuming one step Arrhenius kinetics) and
prevailing in flames in SCW, and due to the
T is the temperature in K.
respective high pressures.
 The reaction rate depends only on
Hot surface ignition has been chosen as the most
temperature of the gas. The dependence on
easily applicable in the aforementioned environment.
the concentration and on pressure is
An electrical resistance could be heated up with DC
neglected.
or AC voltage and heating powers up to one kW
could be easily reached if necessary.  The average temperature between the bulk
Adapting existing literature models on the specific and the wall is used for the calculation of the
conditions of our ignition setting we attempt to material properties.
understand the underlying mechanisms of the The approach in the current work considers only the
phenomenon and predict the parameters necessary for boundary layer, whose thickness of which is
ignition. Among the existing models in the literature, estimated from the value L/Nu, where “L” is the
the model presented from Adomeit (Adomeit 1961), length of the igniter and Nu is the Nusselt number of
which is based on the theoretical models of the flow. Because the thickness of the boundary layer
F.Kamenetskii (A.Frank-Kamenetskii 1969), has is much smaller than the length of the igniter, the
been chosen as a first approximation. The model geometry of the problem is approximated from a gas
predicts the surface temperature and the heat flux to a flowing between two parallel plates, which are at
fluid necessary for the ignition of combustible constant temperatures, Tw and T∞. Heat transfer takes
mixtures, flowing over hot surfaces, as sketched in place only through heat conduction between these
Fig.2. walls, and the convection comes into play only
through the definition of the distance between the
layers. The temperature distribution in this thermal
boundary layer can be calculated from the energy
balance equation for this layer. Based on the
assumption that ignition takes place when no solution
for the temperature distribution can be found, the
critical ignition conditions are calculated.
The energy conservation equation in this gas layer
can be written as:
(1)
And the corresponding boundary conditions are:
For , (2)
, (3)
In equations 1-3, λ is the thermal conductivity of the
Figure 2 Ignition model after Adomeit (Adomeit gas, Q is the heat of combustion of the gas, C is a
1961). constant for the reaction, R is the universal gas
constant, E is the activation energy of the reaction,
A fluid with a velocity U∞ flows over a surface, and T is the temperature of the system in K, Tw is the
which is kept at constant temperature Tw. In steady wall temperature, T∞ is the free stream temperature
state conditions a temperature boundary layer (profile and Nu is the Nusselt number of the flow.
T(x)) develops in the perpendicular direction to the Since the length of the cylinder is much higher than
wall, and a qualitative picture of its temperature the thickness of the boundary layer, one can simplify
the problem further in a one dimensional heat As Adomeit (Adomeit 1961) shows, the case where
conduction problem. Expressing the equations in a eq.(9) has only one solution corresponds to the
dimensionless form and simplifying the exponential ignition conditions of the mixture and the critical
part of the right hand side of the equation according value of parameter “ ”, which leads to ignition, is
to F.Kamenetskii (A.Frank-Kamenetskii 1969), we the solution of eq.(10).
come up with the following non-linear boundary
conditions problem: √ √

(4) (10)

with boundary conditions: √ √

(5) Eq. (10) has to be solved numerically. From the value
(6) of “ ”, calculated from eq. (10), one can calculate the
The dimensionless parameters for equations 4-6 are critical value of the parameter “ ” and through its
presented on table 1. definition the ignition wall temperature value for a
given Nusselt number or the critical value of the
Nusselt number for a given wall temperature.
Table 1 Dimensionless parameters of the problem.
CONVECTIVE HEAT TRANSFER
Parameter Definition
COEFFICIENT MEASUREMENTS
Dimensionless
( ) Motivation - Goal
Temperature
The boundary conditions and the computational field
of the presented ignition model are defined from the
convective heat transfer coefficient of the flow.
Dimensionless
Since no data can be found in the literature for the
Distance
heat transfer coefficient of the flow in the burner
setup of the plant, the actual heat transfer coefficient
Frank had to be measured prior to making any prediction
Kamenetskii ( ) for the ignition conditions.
parameter The heat transfer experiments had the goal to define
the average convective heat transfer coefficient “h”
over the surface of an igniter.
The boundary conditions problem 4-6 can be solved
analytically as shown from F. Kamenetskii (A.Frank- Measurement concept
Kamenetskii 1969), leading to an expression of the
temperature distribution in the computational field in From the definition of the convective heat transfer
question. The solution expressed as a function of two coefficient in eq. (11), one has to measure the
integration constants is: exchanged heat flux between a surface and a fluid,
the bulk temperature of the fluid and the surface
temperature, in order to measure the heat transfer
√ (7)
( ) coefficient as a product variable.
( ) (11)
The integration constants “a” and “b” should be Since the experiments are conducted in a high
calculated from the boundary conditions of the pressure vessel with limited space, a simple
problem (eq.(5) &(6)). experimental setup is designed to provide as much
From eq.(5) we calculate the value of “b” as: data as possible.
√ (8) A K-type thermocouple with a 3mm diameter was
Using the boundary condition (6) and substituting “b” used for the bulk temperature measurement, while the
from (8), we come up with an equation for the heat flux was calculated from the voltage and current
calculation of “ ” as a function of the system values fed to the igniter. The direct measurement of
parameters “ ” and “ ”. the surface temperature was more challenging,
because it is technically impossible to attach a
{ √ √ } (9) thermocouple on a heated surface at temperatures
between 350-800°C in desalinated water. This
Depending of the boundary conditions and the problem was solved by the implementation of a
material properties, equation (9) can have three, two, ceramic igniter made of silicon nitride, which had a
one or no solution for the integration constant “ ”. favorable temperature dependence of its resistance.
Calculating the resistance through measurement of from below in the future. The cooling mantle is fed
the voltage and current values fed to the igniter, the with water from two inlet holes (not shown on Fig.3)
average temperature of its heated length could be and water is provided to the inner space with two
estimated. holes opposite to one another, in order to provide a
homogeneous cooling to the burner of the setup.
Experimental Setup The pre-heated fuel mixture is fed axially to the
burning chamber through a specially designed burner
Spallation drilling pilot plant - short description nozzle. Oxygen is fed from a radial hole (not shown
The presented experiments were conducted in the on Fig.3) with an angle to the axis of the vessel equal
new hydrothermal spallation drilling plant of our lab. to 45°, and then through the annulus between the
The plant is using water-ethanol mixtures as a fuel burner nozzle and the reactor body.
and pure oxygen as an oxidation medium and is A detailed drawing of the burning chamber with its
capable of reaching fuel power 120 kW. Its dimensions and the operational data used during the
maximum working pressure is 350bar and it is experiments is presented on Fig.4.
designed to process rock probes with a diameter of
9.5cm and a length of 35 cm. The reactants are
preheated at temperatures reaching 420 °C, prior to
their injection in the pressure vessel of the plant. Two
high pressure water pumps provide the cooling water.
Core of the plant is its high pressure burning
chamber, where all experiments are carried out. It has
a volume of approximately 5.8 liters, and it was
designed to withstand pressures of 600bar at wall
temperatures of 500°C. Its inner diameter is 14cm
and the length of its inner space is 40 cm. Optical
access to the vessel is provided by two small sapphire
windows on its head. Probe access and positioning,
while under pressure, is achieved with two individual
positioning devices similar to the ones presented by
Prikopsky (Prikopsky 2007), the positioning accuracy
of which is 0.2mm.
The experiments presented in the current work
concentrate on the heat transfer conditions prevailing
in the burner setup of the plant. A technical drawing
of the upper part of the burning chamber is presented
on Fig.3.

Figure 4 Measurement setup with operational and

the dimensional data (dimensions are given in mm)

Igniter characteristics
The igniter used as a heated surface is a cylindrical
body consisting primarily of silicon nitride. The
electrical resistance is implemented in the main body
by a sintering procedure and it consists of 80% vol.
silicon nitride and the rest is additives, MoSi2 and
TaN. The outer surface of the igniter was electrically
insulating.
Figure 3 Technical drawing of the upper part of the The total length of the igniter is 90 mm, the diameter
used pressure vessel of its heated zone is 4mm and its length is 40mm.
The dependence of its resistance from its temperature
The inner space of the pressure vessel is divided in
was calibrated in a high temperature oven up to
the outer cooling mantle, where water keeps the load-
temperatures of 520 °C.
bearing walls at low temperatures, and the inner
The temperature in the calibration experiments was
space where the hydrothermal flame will be ignited at
measured with two K-type thermocouples positioned
its upper part and the rock probes will be inserted
near the igniter and its resistance was measured with
a multi-meter. The accuracy of the thermocouple Table 2 Fuel and gas steam mass flows and
measurement was ±1.5°C, and of the multi-meter compositions used in the experiments
0.8% of the measured value.
The calibration line is presented on Fig.5, together Mass flows
Fuel steam
with its confidence intervals, computed based on the Nitrogen
composition Fuel stream
orthogonal regression method (Gillard 2009). -1 stream
[wt.% Ethanol] [kghr ]
Technical reasons did not allow for the calibration of [Nlmin-1]
the igniter at higher temperatures (the material used 10
for soldering its electrical contacts melted above 20
0 130
550°C), but calibration data provided from the 30
construction company show a linear dependency up 40
to temperatures of 1000°C (Bach 2011). 10
The electrical connection system was custom made 20
and it is a combination of a ceramic capillary, 10 130
30
through which the bear wires were inserted for the 40
high temperature region and kapton insulated copper 10
wires for the low temperature region. The resistance 130
20
of the feeding line was subtracted from the total 20
30 180
resistance measurements, in order to account only for 35 220
the igniter resistance. 10
130
15
30
20 180
25 220
It must be stressed that the experiments in question
are performed in a pressure and temperature region
crossing the critical point of the mixtures used
(Abdurashidova 2007), (Wagner 2008) (Japas 1985).
In this region the material properties (especially the
cp and Pr values) exhibit a very strong dependency on
the pressure and the temperature. Due to this material
behavior, the convective heat transfer coefficient
depends not only on the flow conditions, but it is also
Figure 5 Igniter Calibration Curve. Confidence a strong function of the temperature of the fluid, the
interval ±0.5%. applied heat flux and the presence of buoyancy
effects (Pioro 2005), (Polyakov 1991).
The igniter can be fed with voltage values up to 230V For this reason the same experiments were carried
and current values up to 9A depending on its out for two heat flux values, namely 0.5 and 0.7
resistance. MWm-2.
The procedure implemented for each measurement
Experimental procedure consisted of the following steps:
As already mentioned the heat transfer measurements  Once the predefined fluid temperature and
will be the input for the ignition model, with the aim fluid mass flow was reached, voltage was
to predict the ignition conditions in the system in fed to the igniter.
question. For this reason experimental conditions  A defined ramp was followed for each
were chosen which simulate the ignition experiments measurement leading to the first heat flux
planned for the future. Accordingly, measurements value (see Fig.6).
were performed with both fuel and gas streams  This value of the voltage was kept constant
(nitrogen). for sixty seconds and the voltage value, the
All the measurements were performed at a constant current value and the bulk temperature were
pressure of 260±4 bar and the fluids were preheated recorded.
at temperatures between 350 and 420°C. Four fuel-  The next step in the voltage was adjusted to
stream compositions were used having reach the second value of the heat flux on
0%,10%,20%,30% wt. ethanol, and various mass- the igniter (see Fig.6).
flow values for nitrogen, in order to investigate its  After the sixty seconds of the second heat
influence. The mass flows used are presented in table flux measurement a ramp was followed for
2. the reduction of the voltage on the igniter.
  Once the voltage was switched off, the bulk resolution of our measurements does not allow for
temperature was recorded for sixty seconds. the accurate measurement of this temperature.
According to the values presented from Rogak
(Rogak 2001) for water – oxygen systems, the
addition of nitrogen should lower the pseudo critical
temperature of the working fluid in a similar manner
with the one observed in our measurements.
Nevertheless in our case we have a water-ethanol
mixture and we can only assume its pseudo critical
temperature from the data of its critical temperature
presented from Abduraslidova (Abdurashidova
2007).

Figure 6 Voltage ramps example for a measurement.

Experimental results
The results for two mass flows of the 10%wt. ethanol
fuel mixture are presented on Fig.7 and Fig.8 for two
heat flux values (0.5 and 0.7 MWm-2 respectively). In
these experiments the mass flow of nitrogen was kept
constant at 130 Nlmin-1.

Figure 8 Convective heat transfer coefficient values

for a mixture of water, ethanol (10%wt.) and
nitrogen (mf – fuel mixture flow rate; mN2 - nitrogen
flow rate).Heat flux from the heated surface to the
flow 0.7[MWm-2].

Moreover we are investigating mixtures which are

highly non-ideal and the data presented are only
indications that our mixture behaves in the same way.
Unfortunately there are no data for the ternary
mixture we are using at the present, and the only way
to interpret the results is through the material
Figure 7 Convective heat transfer coefficient values properties presented in the works of Abduraslidova
for a mixture of water, ethanol (10%wt.) and (Abdurashidova 2007), and Japas (Japas 1985).
nitrogen (mf – fuel mixture flow rate; mN2 - nitrogen Another expected observation was the dependency of
flow rate).Heat flux from the heated surface to the the heat transfer coefficient on the heat flux used in
flow 0.5[MWm-2]. the heated surface. The heat transfer coefficient falls
as the heat flux from the surface to the fluid is
From the data presented in Fig.7 and Fig.8 it can be
increased.
clearly seen, that the addition of nitrogen reduces the
The same results as for Fig.7 and Fig.8 are shown for
heat transfer coefficient of the flow.
a 30%wt. ethanol fuel mixture on Fig.9 and Fig.10. In
Another significant result is that for all the cases a
these experiments the mass flow of nitrogen was
peak of the heat transfer coefficient is observed.
adjusted to a value corresponding to oxygen - fuel
Similar effects were reported in many publications,
combustion equivalence ratio of 1.2. This value was
investigating the heat transfer coefficient of a
180 Nlmin-1 for a fuel mass flow 20 kghr-1 and 220
supercritical water flow in a pipe (Jäger 2011). The
Nlmin-1 for a fuel mass flow 25 kghr-1. The heat flux
reason for such a peak is the very strong change in
values used were the same as in the previous
the fluid properties. This peak gives also an
diagrams.
indication for the pseudo critical temperature (the
Comparing these diagrams with the ones on Fig.7 and
temperature at which the cp acquires its maximum
Fig. 8, one can see that the bulk temperature, at
value) of the ternary mixture under the reported
which the peak of the heat transfer coefficient is
conditions. Unfortunately the bulk temperature
observed, shifts to lower values. This is an additional The value of the surface temperature was measured
indication that the behavior the water-oxygen from the inverse regression line, resulted from the
mixtures described from Rogak (Rogak 2001) is calibration procedure of the igniter eq. (13).
similar with the ternary mixture in our case.
(13)

The error of the regression variables (b0 and b1) was

calculated from the error-in-variables orthogonal
regression procedure presented in the work of Gillard
(Gillard 2009). The error of the temperature
measurements was calculated from eq. (14).

(14)
√( ) ( ) (( ) )

The value of the heat transfer coefficient was

calculated from eq. (15).
Figure 9 Convective heat transfer coefficient values
for a mixture of water, ethanol (30%wt.) and
nitrogen (mf – fuel mixture flow rate; mN2 - nitrogen (15)
flow rate).Heat flux from the heated surface to the
flow 0.5[MWm-2].
From eq. (15) it can be seen, that the accuracy of the
heat transfer coefficient measurement depends
strongly on the temperature difference between the
wall and the bulk of the fluid. This is the reason why
the measurements with the lower heat flux values
have a higher measurement error.

IGNITION CONDITIONS PREDICTION

Based on the heat transfer coefficient measurements
presented in the previous section, a calculation of the
ignition conditions is performed. The calculated cases
will be some of the target cases for the first ignition
experiments, which will be carried out in our lab.
The simple ignition model presented in the respective
Figure 10 Convective heat transfer coefficient values section is herewith implemented, with the following
for a mixture of water, ethanol (30%wt.) and computational assumptions:
nitrogen (mf – fuel mixture flow rate; mN2 - nitrogen  The fluid properties are evaluated for the
flow rate).Heat flux from the heated surface to the average temperature between the bulk and
flow 0.7 [MWm-2]. the wall temperature. Mole averaged values
are taken for the mixture, based on
Error calculation-uncertainty estimation properties tables of each component (NIST
Chemistry WebBook 2012).
The uncertainty of the measurements was calculated
 The molecular values of thermal
by using simple Gaussian error propagation for each
conductivity and viscosity are taken.
product variable. The directly measured variables
 The values for the activation energy “E” and
were the voltage and the current on the igniter, and
the pre-exponential factor are taken form the
the bulk temperature. The accuracy of the voltage and
work of Mercadier (Mercadier 2007).
current measurements was 0.75 V and 50 mA
respectively. Hence the resistance measurement error  The value of the measured bulk temperature
was calculated from eq.(12). will be used as T∞ for the model.
Additionally, only the cases were taken into
consideration, where a homogeneous mixture is
√( ) ( ) (12)
expected. The model assumes a homogeneous
mixture for the calculations, and in the experiments
in question this is the case for temperature values high uncertainty. Apart from the simplifications of
above the critical point of the fuel stream. the model, this is the most significant source of
Accordingly only the bulk temperatures above 350°C uncertainty for the calculated ignition wall-
were considered. temperatures. Fig.13 shows an example of the
Fig. 11 and 12 present two curves for two different sensitivity of the model on the chemical kinetics data.
values of the mass flow. The composition of the fuel On this figure the ignition results are shown for the
stream is in both cases 10%wt. and the gas mass flow case presented in Fig.11 with two different activation
is the same as in the heat transfer experiments. energy values inside the uncertainty interval reported
from Mercadier (Mercadier 2007). In the case of
higher activation energy, the bulk temperature must
be at least 380°C, for ignition to occur with the
shown heat flux from the igniter.
It is apparent, that the presented model is a
qualitative approximation and its quantitative results
must be interpreted very carefully.

Figure 11. Values of the modeled ignition wall

temperature (red) and the igniter temperature (blue)
for two cases with 10%wt. ethanol in the fuel stream
and 0,5 [MWm-2] heat flux from the igniter.

The red curves show the critical ignition wall

temperature values calculated from the model for the
corresponding bulk temperatures in the y-axis. The
Figure 13. Activation energy sensitivity of the
blue lines are the wall temperature values of the
ignition conditions for the case shown on Fig.12 @
igniter, when it operates at the respective heat flux
40 [kghr-1]
with the bulk temperature shown in the y-axis and the
respective measured heat transfer coefficient.
CONCLUSION
A simple and robust ignition system has been
developed for hydrothermal flames. Voltage values
of 230 V could be fed to a ceramic igniter at 260 bar
and 400°C. The heat transfer conditions have been
characterized in the burning chamber, where the
ignition experiments will be carried out.
The measurement of the convective heat transfer
coefficient in the burner setup was the first step of the
assisted ignition project in our pilot plant. Based on
the performed measurements, a set of operational
points of the plant will be chosen and ignition
experiments will be performed for these points.
Figure 12.Values of the modeled ignition wall Additionally a simple model for the hot surface
temperature (red) and the igniter temperature (blue) ignition has been adapted to the hydrothermal flames
for the cases with 10%wt. ethanol in the fuel stream case and the ignition conditions have been calculated.
and 0,7 [MWm-2] heat flux from the igniter. The results of the model show, that ignition will most
probably be possible with the current setup.
When the temperature reached from the igniter Aim of the ignition project is to have a reliable
exceeds the critical ignition wall temperature ignition source, which will allow for the easy ignition
calculated from the model ignition takes place. This of hydrothermal flames in our plant. The
seems to be the case in both presented cases. investigations performed in this project will be very
Nevertheless, the model is very sensitive on the data useful input for applications in real boreholes,
used for the chemical kinetics of the reaction. The because many aspects of the assisted ignition of
values used are average literature values and have a hydrothermal flames will be solved. Data, like the
ignition temperature and the respective heat flux NIST Chemistry WebBook. NIST. n.d.
values for specified operational conditions of a flame http://webbook.nist.gov/ (accessed January
are valuable input for the dimensioning of an Monday 16, 2012).
industrial igniter for hydrothermal flames. Pioro, Igor L. "Experimental heat transfer in
supercritical water flowing inside channels."
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