Design of a 750 °F, 15 K packer for Enhanced Geothermal Systems, Supercritical CO2 - Sequestration and SAGD: Energy Transition Through Technology Synthesis

Abstract

Abstract Several technology building blocks are required for the growth of geothermal energy to match what is needed to enable the energy transition. One key technology required in this field is a reliable packer that can withstand the extreme environments frequently seen in geothermal wells: elevated temperatures (750°F/400°C); high differential pressures (up to 15K psi); and extremely corrosive fluids. The authors present a concept which is thought to offer a promising solution to this challenge. It builds upon the wealth of experience obtained by operators designing packers for the oil and gas wells and couples this with advancements in materials processing technology in elastomers, composites, and metals. The presented concept uses the sealing advantages that elastomers are known to offer, with a compound specifically designed by a strategic partner. This elastomer is then surrounded by a layer of flexible gel-insulation of extremely low thermal conductivity to shield it from the intense heat seen in geothermal wells. It is predicted that the elastomer core will see temperatures no higher than 400°F when the surrounding environment is at 750°F. The system is then encased in a Grain Boundary Engineered (GBE) nano-metallic flexible skin material to prevent contact with corrosive fluids. Though the elements are the greatest challenge, the other components of the packer design are also specially designed with material processing techniques tailored to both enhance mechanical properties and corrosion resistance. The technology behind the design is detailed and has been proven. The integrated concepts will be further tested at subcomponent level to show their merit, before integration into a full system for qualification to 750°F, 15K psi.