This is a final technical report for the project: Foam Fracturing Study for Stimulation Development of Enhanced Geothermal Systems (EGS). The goal is to demonstrate the feasibility of foam fracturing in EGS applications. The project, led by Oak Ridge National Laboratory (ORNL), was conducted in collaboration with Temple University. The report describes the research activities with Task 1 at ORNL: foam fracturing testing system development and experimental study on foam fracturing, and Task 2 at Temple University: foam testing and foam characterization. Main findings are: 1. A foam fracturing test system has been developed at ORNL, which can be used to perform foam fracturing under pressure up to 6,000 psi. The system monitors foam density during fracturing online and is capable of testing materials in both monotonic and cyclic (up to 50 Hz) injections. 2. Foam fracturing tests were carried out on Charcoal black granite specimens with a blind borehole to the middle length. Two diameters of blind borehole were tested; G2 series: 9.53 mm and G3 series: 4.76 mm. N2-in-water foam was used with AOS as a surfactant. 3. There was a hole-size effect on fracture initiation pressure. The effect is smaller in the case of foam, which was influenced by the high penetrability of gas in foam. Breakdown pressure showed a behavior just as that of fracture pressure; namely an increased value for small hole samples, while the effect in water fracture was more impressive than in foam fracture. 4. Water mass was reduced in foam fracturing within similar range of breakdown pressures. In G2 series, it was decreased from 10.44 g for water fracturing to 5.17 g, representing more than 50% water reduction. Therefore, there is the potential to reduce water use in EGS stimulation through foam fracturing. 5. Use of cyclic injection has the potential to reduce the breakdown pressure and seismicity in EGS application. Experiments using 4-s cycle period found that specimens can be fractured with a low number of cycles. The fatigue pressure was approximately 64 - 77% of monotonic breakdown pressure for water fracturing and 58 - 94% of the breakdown pressure for foam fracturing. 6. A foam stability testing system has been developed that can test foam at 220 Deg C to 2,000 psi. Tested components of candidate foams included two gases: N2 and CO2; 4 surfactants: AOS, SDS, NP-40 and CTAC; 5 stabilizing agents: guar, bentonite clay, borate salt, silica NPs, and GO. 7. N2 and AOS provided the most stable performance over the tested ranges. Furthermore, the AOS foam with stabilizing agents of guar and borate salt (crosslinker) offered the highest half-life of 20 minutes at 200 Deg C and 1,000 psi. 8. Arrhenius equation and modified power law have been demonstrated to fit well the half-time vs. temperature and pressure data, respectively. These relations can be useful to provide the suggestion for future foam stability study. This submission contains the supporting data developed during the project: 1) A final technical report 2) Granite fracturing data in monotonic and cyclic injections with water and N2 foam Foam performance data in various temperatures and pressures, including half-time, is submitted separately.

Foam thermal stability was studies at Temple University in collaboration with Oak Ridge National Lab (ORNL). The goal of this project is to explore thermally stable foams as hydrofracking fluid media for potential applications in enhanced geothermal system (EGS). Data generated from this project will allow researchers to explore foam as potential fracturing fluid. More than 800 data points on the half-life of foams are recorded in Excel files in the included archive resource (Half-life of Foams with Different Surfactants and Stabilizing Agents). The Excel file within each surfactant folder contains half-life data of the respective surfactant with different stabilizing agents, pressure, and temperature. The respective folders also contains Word files describing the details of the data included in the respective Excel sheet.

Hydraulic fracturing is currently the primary method for stimulating low-permeability geothermal reservoirs and creating Enhanced (or Engineered) Geothermal Systems (EGS) with improved permeability and heat production efficiency. Complex natural fracture systems usually exist in the formations to be stimulated and it is therefore critical to understand the interactions between existing fractures and newly created fractures before optimal stimulation strategies can be developed. Our study aims to improve the understanding of EGS stimulation-response relationships by developing and applying computer-based models that can effectively reflect the key mechanisms governing interactions between complex existing fracture networks and newly created hydraulic fractures. In this paper, we first briefly describe the key modules of our methodology, namely a geomechanics solver, a discrete fracture flow solver, a rock joint response model, an adaptive remeshing module, and most importantly their effective coupling. After verifying the numerical model against classical closed-form solutions, we investigate responses of reservoirs with different preexisting natural fractures to a variety of stimulation strategies. The factors investigated include: the in situ stress states (orientation of the principal stresses and the degree of stress anisotropy), pumping pressure, and stimulation sequences of multiple wells.

At the beginning of this project, the Temple team spent significant effort to collect data relevant to foam fracturing. More than 40 articles/reports were found in the open literature that reported the properties of aqueous foams under various testing conditions. The foam properties included viscosity and stability in terms of half-life, while were influenced by the foam quality, shear rate, temperature, pressure, as well as surfactants and additives used in making the foam base solutions. As a result, more than 1100 data points were collected, which are included in a master worksheet named "Literature data on Foam Fracturing Fluid". These data points are organized based on following parameters: 1. Literature source, including authors and publication year 2. Gaseous phase (e.g. CO2, N2) 3. Liquid phase (e.g. tap water, DI water, salt water) 4. Surfactants and their concentrations 6. Additives 7. Foam quality 8. Pressure 9. Temperature 10. Viscosity 11. Foam stability, which was characterized by its half-life: Half-life Foam study data base with data analysis was completed and a webpage is designed hosted on public server at https://surfactant-dashboard.herokuapp.com

The primary objective of our current research is to develop a computational test bed for evaluating borehole techniques to enhance fluid flow and heat transfer in enhanced geothermal systems (EGS). Simulating processes resulting in hydraulic fracturing and/or the remobilization of existing fractures, especially the interaction between propagating fractures and existing fractures, represents a critical goal of our project. This paper details the basic methodology of our approach. Two numerical examples showing the capability and effectiveness of our simulator are also presented.

The primary objective of our current research is to develop a computational test bed for evaluating borehole techniques to enhance fluid flow and heat transfer in enhanced geothermal systems (EGS). Simulating processes resulting in hydraulic fracturing and/or the remobilization of existing fractures, especially the interaction between propagating fractures and existing fractures, represents a critical goal of our project. This paper details the basic methodology of our approach. Two numerical examples showing the capability and effectiveness of our simulator are also presented.

In addition to the foam data that were obtained from literature and that were collected from the current study, simulation data was also generated from finite element analysis (FEA) conducted in this study using COMSOL Multiphysics software. The FEA models were built to simulate the experiments conducted at Oak Ridge National Laboratory (ORNL) on cement and granite samples. In these FEA models, temperature was kept at ambient while the pressure profile resembled the loading conditions during the ORNL experiments, where pressure was either monotonically increased or applied cyclically. The cement material was used as a model material and was used to study Von Mises stress and tensile stress distribution for different bore hole length geometry using a parametric sweep with water as fracturing fluid using solid-fluid interaction module. For the granite material, FEA models were developed for stress analysis of cylindrical samples with water or foam fluids. The solid mechanics module in COMSOL was implemented to solve for Von Mises stress and tensile stress. The fluid-structure interaction module was implemented to solve for water-foam interaction on granite cylinder with addition of fluid-loading on structure, i.e., large deformation in solid mechanics with no impact on fluid deformation. Foam was considered as a pseudo single-phase compressible fluid for which material properties were calculated from water and gas (nitrogen) phases. The density of foam is calculated as a function of the densities of water and nitrogen, while viscosity is a function of temperature. Four types of FEA analyses were modelled: 1. Monotonic injection with water 2. Monotonic injection with foam 3. Cyclic injection with water 4. Cyclic injection with foam All the COMSOL files are converted to a zip file which is save in .mph.

Hydraulic shearing is an appealing reservoir stimulation strategy for Enhanced Geothermal Systems. It is believed that hydro-shearing is likely to simulate a fracture network that covers a relatively large volume of the reservoir whereas hydro-fracturing tends to create a small number of fractures. In this paper, we examine the geomechanical and hydraulic behaviors of natural fracture systems subjected to hydro-shearing stimulation and develop a coupled numerical model within the framework of discrete fracture network modeling. We found that in the low pressure hydro-shearing regime, the coupling between the fluid phase and the rock solid phase is relatively simple, and the numerical model is computationally efficient. Using this modified model, we study the behavior of a random fracture network subjected to hydro-shearing stimulation.

This paper describes the applications of the fractured continuum model to the different enhanced geothermal systems reservoir conditions. The capability of the fractured continuum model to generate fracture characteristics expected in enhanced geothermal systems reservoir environments are demonstrated for single and multiple sets of fractures. Fracture characteristics are defined by fracture strike, dip, spacing, and aperture. This paper demonstrates how the fractured continuum model can be extended to represent continuous fractured features, such as long fractures, and the conditions in which the fracture density varies within the different depth intervals. Simulations of heat transport using different fracture settings were compared with regard to their heat extraction effectiveness. The best heat extraction was obtained in the case when fractures were horizontal. A conventional heat extraction scheme with vertical wells was compared to an alternative scheme with horizontal wells. The heat extraction with the horizontal wells was significantly better than with the vertical wells when the injector was at the bottom.

This paper describes the applications of the fractured continuum model to the different enhanced geothermal systems reservoir conditions. The capability of the fractured continuum model to generate fracture characteristics expected in enhanced geothermal systems reservoir environments are demonstrated for single and multiple sets of fractures. Fracture characteristics are defined by fracture strike, dip, spacing, and aperture. This paper demonstrates how the fractured continuum model can be extended to represent continuous fractured features, such as long fractures, and the conditions in which the fracture density varies within the different depth intervals. Simulations of heat transport using different fracture settings were compared with regard to their heat extraction effectiveness. The best heat extraction was obtained in the case when fractures were horizontal. A conventional heat extraction scheme with vertical wells was compared to an alternative scheme with horizontal wells. The heat extraction with the horizontal wells was significantly better than with the vertical wells when the injector was at the bottom.