E-mail address: olaleyebm@yahoo.com doi: 10.1016/S1674-5264(09)60276-3 A review of light amplification by stimulated emission of radiation in oil and gas well drilling OLALEYE B M *
Department of Mining Engineering, Federal University of Technology, Akure, Nigeria Abstract: The prospect of employing Light Amplification by Stimulated Emission of Radiation (LASER) for well drilling in oil and gas industry was examined. In this work, the experimental works carried out on various oil well drilling operations was dis- cussed. The results show that, LASER or LASER-aided oil and gas well drilling has many potential advantages over conventional rotary drilling, including high penetration rate, reduction or elimination of tripping, casing, bit costs, enhanced well control, as well as perforating and side-tracking capabilities. The investigation also reveals that modern infrared LASERs have a higher rate of rock cuttings removal than that of conventional rotary drilling and flame-jet spallation. It also reveals that LASER can destroy rock without damaging formation permeability but rather, it enhances or improves permeability and that permeability and porosity in- creases in all rock types. The paper has therefore provided more knowledge on the potential value to drilling operations and tech- niques using LASER. Keywords: LASER; oil; gas; well drilling; simulation; specific energy; spallation 1 Introduction Rock disintegration and removal is a significant issue in the process of oil and gas well drilling and completion. Millions of cubic meters of rock have been removed, with tremendous capital investment, over the years as a result of drilling of oil and gas wells. Approximately 20000 wells of oil, gas and dry wells were drilled onshore in the United States of America in 1999, with an average depth of 1830 m. This is equivalent to approximately 37014 km or ap- proximately three times the diameter of the earth (12712 km) [1] . Nearly half of the time was spent on drilling, a quarter of the time on moving tools in and out of wells and the remaining quarter on casing and cementing activities. Major potential cost reductions related to well drilling were likely to come from in- creasing the rate of penetration of the drill bit into the earth, and reducing the time involved with moving tools, such as bits and pipes, in and out of holes, in general [1] . Other than the reservoir rock, a quantita- tive amount of time can be spent on drilling through rock strata. Drilling in hard rocks such as granite is extremely difficult and can expend a great amount of resources with little penetration resulting. Stuck pipes, fishing operations for lost tools down holes, and side tracking procedures, all of which are time and money consuming processes, are other costly problems as- sociated with drilling process. Reduction of costs associated with these drilling operations would have significant and qualitative economic impacts for ex- ploration and production operations. In order to make improvement in these areas, new technologies and tools would have to be applied that can take advantage of basic rock destruction mecha- nisms involving thermal spalling, fusion and vapori- zation, mechanical stresses and chemical reaction. All of these destruction mechanisms can be achieved using Light Amplification by Stimulated Emission of Radiation (LASER). It has been established that at lower LASER power levels, rock spalling (chipping) can be achieved. Increasing the power density of a LASER beam will result in phase changes and reac- tions in the rock, including dehydration of clays, and the release of gases and thermal stresses. Consistent increase in the beam power density will then melt or fuse the minerals within the rock and ultimately va- porize them [1] . The alternative method to mechanical well drilling have been considered and reviewed at cursory levels since rotary techniques were first in- troduced, however, none have been seriously consid- ered as a displacing technology. Industrial experts in the 1960s and 1970s considered the use of photonic energy in well construction, but the technical appli- cation of LASERs was dismissed as energy intensive Mining Science and Technology 20 (2010) 07520757 MINI NG SCIENCE AND TECHNOLOGY www.elsevier.com/locate/jcumt OLALEYE B M et al A review of light amplification by stimulated emission 753 and inefficient. Their conclusions four decades ago continue to influence industry misperceptions of LASER applications, despite massive developments in LASER system and application particularly those associated with LASER development programs [1] . In 1994, there was a breakthrough in adapting high-powered LASERs for use in drilling oil and gas wells. The results of the investigation showed that LASER could cut rock of all lithologies; sheer power shares importance in cutting rock with such parame- ters as wavelength, purge gas pressure and hole size and theoretical calculations of the LASER power needed to spall (break), melt and vaporize rock are significantly higher than experimental values, ob- served rock removal energy requirements, effects of pulsed versus continuous wave LASERs, and the effect of fluids on LASER/rock removal efficiencies and concluded that using pulsed LASERs could ac- complish removing material from rock more effi- ciently than continuous wave LASERs [2] . It was also observed that the efficiency of the cutting mechanism improved by saturating porous rock samples with water, and that a LASER beam injected directly through a water layer at a sandstone sample was able to spall and melt the sample [3] . 2 Potentials of LASER drilling and con- ventional drilling The potential use of LASER is broad and with a diverse range of control mechanisms. Using both the parameters of the LASER and the properties of the rock, the rock can be chipped, melted or even vapor- ized. Making a more direct comparison of the poten- tial of LASERs and the conventional drilling tech- niques, the apparent difference is in the equipment used which is smaller and requires fewer moving parts, but the mechanical differences between a drill and a LASER are easily seen. The implications of these are the persuasive aspect of the use of LASERs and may be the most valuable area of comparison. Laser drilling not only allows continuous information to be gathered over a subsurface profile but also al- lows for a continuous understanding of the subsur- face distribution of contamination [4] . In conventional drilling, the process is slow and much of the time used is with support services to help and facilitate the drilling rather than the actual drilling. Reference [5] found out that only 50% of the time spent on drilling actually saw the drill used to make the hole, 25% of the time was spent on tripping and the remaining 25% of the time was spent on cas- ing and cementing. The use of lasers offers the po- tential to reduce much of this non productive time and processes and as well reduces costs, for example, with a laser, there is no need for bit replacement, drill string removal and setting casings. It is also esti- mated that the use of LASERs will increase drilling speed at anywhere between 10 and 100 times the current rates of using the boring technology. Part of the increased speed is due to the lack of additional processes required, however, the use of LASERs is also potentially much faster than the drilling process itself. Considering that a typical oil or gas well on land will cost in excess of $400000 to build and a gas or oil well that is offshore can cost $4.5 million, a system that operates between 10 and 100 times faster will offer significant savings [5] . This means that many more limited wells where extraction had not been economically viable due to the costs of reaching the reserves may become viable. Comparing the cost using the example of a typical gas well of 3048 me- ters, in wind river, the cost using traditional tech- niques would be $350000, while the same well drilled with a LASER would be $35000 or less. The speed also lowers the time, the time taken to drill a well may be 10 days or even less, whereas the tradi- tional method could take 100 days or more. Also, the footprints of LASERs are also much smaller than traditional technology, potentially being as small as 9 square meters or less [6] . In addition, the high tem- peratures used to melt the walls of the well eliminate the need for steel and concrete casings. 3 LASER effect on rock properties There are different high power LASERs, including the Mid-Infrared Advanced Chemical Laser (MIRACL), Chemical Oxygen-Iodine Laser (COIL), and a CO 2 and CO laser. Reference [7] carried out laboratory investigations on different rock types with LASER beam interaction to determine how the beams size, power, repetition rate, pulse width and exposure time can affect the amount of energy trans- ferred to the rock for the purposes of spallation, melting and vaporization. The purpose of the LASER rock interaction investigation was to determine the threshold parameters required to remove a maximum rock volume from the samples while minimizing en- ergy input. Absorption of radiant energy from the laser beam gives rise to the thermal energy transfer required for the destruction and removal of the rock matrix. Results from the tests indicated that each rock type has a set of optimal LASER parameters to minimize Specific Energy (SE) values as observed in a set of linear track and spot tests. Also, observation shows the rates of heat diffusion in rocks are easily and quickly overrun by observed energy transfer rates from the LASER beam to the rock. As absorbed energy outpasses heat diffusion by the rock matrix, local temperature can rise to the melting points of the minerals and quickly increase observed SE values. Just prior to the onset of mineral melt, the lowest SE values are obtained in the spalling zone. Table 1 shows the SE of the different types of drilling meth- ods. Mining Science and Technology Vol.20 No.5 754 Table 1 Specific Energy of Conventional and LASER drilling techniques [8] Conventional drilling SE (kg/cm 3 ) LASER drilling SE (kg/cm 3 ) Cavitation jet High pressure water jet High pressure water jet High pressure water jet Rotary diamond Rotary drag Rotary roller drag 2.9 1.4 0.9 0.3 1.4 0.4 0.8 CO 2 laser CO laser COIL Nd: YAG 37.4 22.8 7.2 5.9 High temperatures induced by LASERs on rock samples could enhance porosity and permeability; high temperatures evaporate and alter cementation minerals and create additional connected pore space within the affected region. This helps to improve conditions for the fluid to flow from the formation into the wellbore, as compared to the damage created to the rock through conventional applications of ro- tary drilling and explosive perforations (Table 2). Table 2 Permeability and porosity before and after lasing for selected rock types [9] Permeability (md) Porosity (%) Sample Before lasing After lasing Before lasing After lasing Berea yellow sandstone (BY) 7754 7914 0.25 0.40 Berea gray sandstone (BG) 554 674 0.18 0.35 Sandstone reservoir (Sst) 11.1 30.1 0.18 0.40 Limestone (LS) 0.02 0.02 0.02 0.02 Shale (SH) 0.43 0.55 0.01 0.03 The increases in porosity and permeability are re- lated to the thermal properties of the rock, e.g., ther- mal conductivity. Sandstone, exhibit a wider range of temperature distribution and higher permeability dis- tribution because it has a high thermal conductivity. The presence of clays could help in enhancing per- meability of creating micro fractures in the formation. Water contained within the clays is subjected to flash vaporization at intense temperature differentials and with expansion creating fractures. Also, some clays collapse at specific temperature. For instance, smec- tite collapses at 550 o C. Figs. 1~4 depict the Scan- ning Electron Microscope imaging of the dehydration of smectite clay with increasing porosity and perme- ability and the various permeability improvement using LASER. As a function of temperature, the strength of the rock is reduced. High temperatures results in more evaporation, breaking in the cementa- tion and creating micro fractures, consequently re- ducing strength and increasing permeability.
(a) Before (b) After Fig. 1 Dehydration of smectite clay with increasing porosity and permeability Fig. 2 Profile permeameter showing improvement in permeability in sandstone using LASER energy application P e r m e a b i l i t y
( m d ) Fig. 3 Average permeability before and after lasing [8] Y o u n g
s
m o d u l u s
( p s i
1 0 6 ) Fig. 4 Decrease in Youngs Modulus in every rock type, using any LASER [8]
3.1 LASER effect on rock phase behavior
When LASER power is applied, the melting tem- perature determines any phase change observed in rock samples. Recent research showed that the melt- ing temperature of the rock samples increased as the percentage of quartz increased. Rock destruction de- OLALEYE B M et al A review of light amplification by stimulated emission 755 creased as the melting temperature of rock increased. Putting SE into consideration, in this concept, the greater the percentage of quartz in the rock sample, the higher the energy consumed in secondary mecha- nisms, including melting and vaporization. This con- cept applies more when making deep holes, however, it could be minimized with shallower holes. Other parameters, such as physical characteristics surface may play an important role in LASER/rock interac- tion, roughness, color, grain cementation, unconfor- mities in the matrix such as vugs and fractures; and thermal properties like conductivity, heat capacity and diffusivity. Two techniques are used in conjunc- tion to accomplish thermal analysis; Thermogravim- etric Analysis (TGA) and Differential Scanning Calorimetry (DSC). TGA examines thermal stability while DSC maps the material transitions. These en- dothermic and exothermic transitions indicate struc- tural and chemical changes in material. These meth- ods are used to determine when melting, disassocia- tion, dehydration and degasification take place. Fig. 5 shows an example of phase change observed in a shale sample as a function of measured average power applied and SE. The laser power ranged from 0.2 to 1.2 kW while all other parameters remained constant. Two regions were identified as to whether melted materials were observed after exposure to the laser. The data points plotted on the left size of the transition zone represent the samples that exhibit no traces of melting occurring on the samples, however, melted material was present on the samples repre- sented by the data points plotted to the right of the transition zone. The no-melt zone represents the samples exposed to lower laser power, and shows high SE. With a low lasing power, energy is con- sumed mainly by thermal expansion. As power is increased, fractures begin to form and mineral melt- ing temperatures approached. Additional increases in power result in faster heat diffusion and heating up the sample. At higher power, the minerals began to melt resulting in lower SE values. S p e c i I i c
e n e r g y
( k J / c m ) T r a n s i t i o n
z o n e Fig. 5 Phase diagram showing No Melt-Melt Zone of shale sample lased by Nd: YAG 3.2 LASER effects on well drilling/spalling The removal of rock with LASER spallation is the use of LASER induced thermal stress that fractures the rock which is then broken into small pieces prior to melting. High intensity LASER energy is targeted at the rock which will have only a very low level of thermal conductivity, and is focused on a local area of rock [2] . This focusing causes a sharp local tem- perature rise. The temperature can be maintained at a temperature just below the melting point of the rocks melting point. This level of temperature can then be maintained and is the right level for the rock to be spalled. This reveals new rock surfaces and can con- tinue with the aid of high pressure gas purging so that the rock fragment are blown out of the way. For smaller holes, single LASERs may be used, but in addition to this, the creation of larger holes can be created with the use of a multi LASER beam spot spallation technique [2] . According to Reference [7], the power for spallation in Berea Grey sandstone was noted to be 900 W/cm 2 while that of shale was 784 W/cm 2 . 4 Applying LASER spallation to oil and gas well drilling The LASER spalling technique can be used to ef- ficiently drill large diameter holes for oil or gas wells. Each LASER beam can spall a shallow hole as big as the spot size usually 1.27 cm in diameter. To cover large diameter area (20 cm or larger), either the small spot size beam has to be scanned or multiple, such beams are overlapped. Fig. 6 shows schematically, overlapping multiple beam method for drilling large diameter and deep hole. Because some relaxation time is needed in order to avoid melting of rock, the overlapped beam will fire on the rock sequentially or in groups to create a layer of nearly circular work face of a desired diameter. With the help of the purg- ing and flushing system, the rock fragments from this layer will be instantaneously removed. Then LASER beams will fire again to spall the second layer of rock. Layer by layer, a deep hole will be drilled out until the designed depth is reached. The LASER energy could be placed down hole by what is referred to as beam deliverability. This could be achieved by using fiber optics, hollow fibers, fiber LASERs, and an- other one most promising is the Direct Diode LASER which is compact enough to put the entire LASER mechanism down hole. Layer 2 Layer 3 Beam on Beam oII Fig. 6 Schematic showing overlapping multiple small LASER beams method to drill larger diameter and deep hole Mining Science and Technology Vol.20 No.5 756 4.1 Formation pressure control in LASER drill- ing Since the objective of LASER drilling is to get LASER beam energy to the rock face, and because traditional drilling fluids (mud) used for pressure control and cutting removal are not transparent to laser wavelength, drilling should be done with a transparent fluid. For the initial application, it is an- ticipated that pressure control and cutting removal would be accomplished using a high-pressure inert gas such as N 2 or CO 2 . Since the petroleum industry has used compressed gas as drilling fluid for many decades, this is not a new technology. 4.2 LASER effect on perforation of formation The perforation of the formation can take place with a wide range of different types of LASER de- pending on the rock type. The rock can then be chipped, melted or vaporized in order to bore through the rock formations. LASERs may equally be used for the extension of wells or perforation as a result of the micro fractures, and clay dehydrations that was created by the use of the LASER [8] . The material at the walls that is melted is impermeable but the prop- erties of the rock behind that melted wall also im- proved. However, current explosive charge perfora- tion method, while capable of creating the hole, sig- nificantly reduces the permeability of the rock. 4.3 LASER effect on casing and oil and gas well completion LASER drilling application has the ability to pos- sibly create its own ceramic wellbore casing. LASER spallation operations have indicated that one of the areas of cost saving is the ability of LASERs to melt the rock of the well creating an impermeable barrier that saves the need for casing and cementation. To achieve this, the rock needs to be melted without be- ing vaporized. Different-types of rock will have dif- ferent melting points and the temperatures will vary according to the condition such as pressure and composition of the rock. Looking at limestone, the rock should be heated to the level of disassociation temperature of the carbonates [7] . The temperature for the disassociation of the calcite is 989 o C at 760 mm of pressure and 100% CO 2 while that of dolomite is between 401 and 480 o C under the same conditions [10] . There is also the need to remove the CO 2 gas that is created with disassociation. Melting points must be monitored individually and the equilibrium between the compositions of the rock should be determined. For 10% CaO the temperature is 2625 o C, and for MgO is 2850 o C. The boiling point for a greater number of potential oil and gas wells to become viable. It can also be said that LA- SER beams not only cut rocks efficiently, but also significantly increase the permeability of spalling- drilled rock. An innovative LASER perforation sys- tem will allow the gas and oil industry to rejuvenate injection and production rates quickly and easily. 5 Results and discussion Table 1 shows the specific energy of conventional and LASER drilling techniques while Table 2 shows the permeability and porosity before and after lasing for selected rock types. Figs. 1 and 2 depict the de- hydration of smectite clay with increasing poros- ity/permeability and the profile Permeameter show- ing improvement in permeability in sandstone using LASER energy application respectively. Fig. 3 is the average permeability before and after lasing while Fig. 4 is the decrease in Youngs Modulus in every rock type, using any LASER. Figs. 5 and 6 are the phase diagram showing No Melt-Melt Zone of shale sample lased by Nd:YAG and the schematic diagram showing overlapping multiple small LASER beams method to drill larger diameter and deep hole respec- tively. Figs. 7 and 8 depict the differences between the different phases of spallation mechanism and LASER/rock destruction respectively. Fig. 7 Differences between the different phases Fig. 8 LASER/rock destruction layout From the tables and figures presented, it is obvious that the use of LASERs offers a great deal of poten- tial to reduce cost and increase efficiency as well as increase care for the environment and allow for CaO is 2850 o C and for MgO is 3600 o C. The differences between the different phases can be seen in Fig. 7 which shows fractures, melting and vaporization of a LASER rock while Fig. 8 shows LASER/rock de- struction in terms of vaporized, melted, dehydrated/ cracks and unaffected zones [8] . Specific energy is the major parameter used for comparison of different methods of rock removal. There are secondary effects that can impact specific 1. Vaporized 2. Melted 3. Dehydration and cracks 4. Unaffected OLALEYE B M et al A review of light amplification by stimulated emission 757 energy calculations, depending on mineralogy, ther- mal properties and rock properties. Greater percent- age of quartz present in the rock results to a higher melting point of rock, therefore greater Specific En- ergy. Higher power LASER-rock interaction tests have shown that LASERs can penetrate all rock types including granite, much faster than conventional methods. It can also induce fractures in the rocks by thermal expansion. Application of high power LA- SERs also can improve rock properties e.g. perme- ability and porosity as it is revealed that permeability and porosity increased in all rock types. It is also possible to control LASER parameters very precisely to achieve spallation, melting or vaporization of the rock base on the required application and the phase change in the rock depends mainly on the rock type, thermal properties and measured average power when all other parameters are held constant. Higher melting point of the rock is obtained if higher per- centage of quartz is present in the sample, hence more energy to melt and more energy to vaporize is required [11] . 6 Conclusions This paper has provided more knowledge on the potential value to drilling operations and techniques using LASER, including the ability to cut through rock more quickly than conventional and other non-conventional methods, and could also create its own ceramic wellbore casing. LASER can also de- stroy rock without damaging formation permeability but rather, it enhances or improves permeability. 7 Recommendations The high potential ability of LASER drilling in oil and gas well drilling has been recognized. Since, the most optimization objective of most oil and gas in- dustry is to save time and reduce cost, LASER drill- ing is highly encouraged. Its most energy efficiency, higher penetration rates, ability to drill surface to total depth continuously and to form a tough, ceramic sheath in the well during drilling are enough good reasons why the oil and industry should adopt the use of LASER energy in oil and gas well drilling opera- tions particularly in Nigeria. References [1] Batarseh S, Gahan B C, Graves R M, Parker R A. Well perforation using high-power lasers. Society of Petro- leum Engineers, 2003, 84418: 12-26. [2] Xu Z, Claude B, Reed C B, Graves R. Laser spallation of rocks for oil well drilling. In: 23rd International Congress on Application of Lasers and Electro-Optics. Scottsdale, 2003. [3] Reed C B, Xu Z, Parker R A, Gahan B C, Batarseh S, Graves R M, Figueroa H, Deeg W. Application of high powered lasers to drilling and completing deep wells. In: 23rd International Congress on Application of Lasers and Electro-Optics. Scottsdale, 2003. [4] Xu Z, Reed C B, Kornecki G, Gahan B, Parker R, Batarseh S, Graves R M, Figueroa H. Specific energy for pulsed laser rock drilling. Journal of Laser Applications, 2003, 15(1): 34-42. [5] Agha K R, Belhay H, Mustafiz A, Bjordalen N, Islam M R. Numerical investigation of the prospects of high en- ergy laser in drilling oil and gas wells. Petroleum Sci- ence and Technology, 2004, 22(9): 1173-1186. [6] Anon. Laser beams soon may be drilling oil and gas wells. Alexanders Gas and Oil connections, 2004, 9(2): 44. [7] Xu Z, Yanashita Y, Reed C B. Modeling of laser spalla- tion drilling of rocks for gas and oil well drilling. Soci- ety of Petroleum Engineers, 2005, 95746: 1-5. [8] Graves R. bringing science fiction down to earth: eco- nomic, fast, efficient, environmentally friendly oil and gas drilling and completing. In: Gas Technology Insti- tute Conference. Phoenix: GTI Press, 2003. [9] Gahan B C, Batarseh S, Rober W, Siegfried A. Improv- ing gas well drilling and completion with energy lasers. In: Gas Technology Institute Conference. Phoenix: GTI Press, 2003. [10] Parker R A, Gahan B C, Graves R M, Batarseh S, Xu Z, Reed C B. Laser drilling: effects of beam application methods on improving rock removal. In: Annual Tech- nical Conference and Exhibition of the Society of Petro- leum Engineers. Colorado: SPE Press, 2003. [11] Gahan B C, Parker R A, Graves R, Batarseh S, Skinner N, Reed C B, Xu Z, Figueroa H. Rock removal using high power lasers for petroleum exploitation purposes. In: SPIE International Symposium. New Mexico: SPE Press, 2002.