Field of the invention
[0001] The present invention relates to electro-pulse-boring (EPB). More specifically it
relates to a drill head suitable for drilling large-diameter holes, i.e. diameters
equal or larger than 40 cm, with EPB.
Description of prior art
[0002] EPB has been proposed as an alternative for rotary drilling of deep holes. The use
of a rotary drilling technique is generally limited for holes up to a depth of about
5 km, whereas EPB can be applied going from shallow depth drilling to deep drilling
(i.e. 3-5 km) and further to ultra-deep drilling (i.e. 5-10 km). EPB has a higher
performance for drilling through hard rock formations when compared with rotary drilling
and EPB drilling heads have a longer life span than a rotary drill-bit.
[0003] The drilling of ultra-deep holes has gained interest in view of the ongoing transition
from non-renewable primary energies to renewable primary energies. Indeed, by drilling
ultra-deep holes, geothermal heat could be recovered and be applied for the generation
of electricity or be used as a heat supply.
[0004] The principle of EPB is to apply electro-pulses in the range between 100 and 1000
kV between a high-voltage electrode and a grounded electrode. Each pulse represents
an energy in the range between 1 to 10 kJ. The electrodes are part of a drill bit
arrangement which forms part of the drill head. The electro-pulses have a typical
duration in the nanosecond range, for example a pulse duration of 200 ns, and are
applied at intervals in the millisecond range, for example a pulse interval of 100
milliseconds. An electrical discharge passing through for example a rock results in
the rock mass to fracture into smaller pieces, i.e. rock cuttings. The electrodes
together with the rock portion to be excavated are immersed in a drilling liquid,
also named discharge liquid. The drilling liquid is a liquid that has a conductivity
that is lower than the conductivity of the material in which the drilling is carried
out, such that the generated electric fields are steered into the rock in the region
of the electrodes. An example of a typical fluid used as a drilling liquid for EPB
is transformer oil.
[0005] For novel geothermal applications large-diameter holes are required. Large-diameter
holes have to be construed as holes having a diameter of about 40 cm or more.
[0006] Although the use of EPB has been proposed for drilling ultra-deep holes, no workable
solution has been disclosed of an apparatus that efficiently can drill holes suitable
for the novel geothermal applications. Developing an EPB apparatus for drilling large
diameter holes at km depths is challenging and involves numerous issues to be solved.
[0007] A problem related to large diameter holes is the drill speed that can be obtained,
i.e. the number of meters per hour that can be drilled. In order to limit the total
drilling time for a 5 to 10 km hole, the drill speed should be of the order of several
meters to tens of meters per hour and this high drill speed should be maintained during
the entire drilling process. For a 50 cm diameter hole, this corresponds to excavating
several m
3 of rock per hour, which is challenging with current technology. It is also important
that the high drill speed is maintained when drilling to deeper regions where the
environmental conditions become more severe. Examples of environmental conditions
are pressure, temperature and the potential occurrence of harder rock formations at
large depths.
[0008] To maintain a high drill speed it is also important to efficiently evacuate the excavated
matter, e.g. rock cuttings, towards the surface. Even if sufficient power is available
to repetitively provide high-energy pulses to crush the rock, a rock debris evacuation
system should be able to evacuate at a high rate a large volume of rock cuttings mixed
with drill liquid over a long distance from the bore hole up to the surface. For example,
if the evacuation rate of the rock is too slow or inefficient, the primary chunks
of the rock can be further broken into smaller and smaller pieces before being discharged
and which can reduce the efficiency of EPB operation. Ideally, the primary rock cuttings
should have a diameter in the range of 2 to 3 cm and the primary rock cuttings should
be evacuated without delay after the formation of the cuttings such that no secondary
smaller rock cuttings can be formed.
[0009] A further problem is related to the use of the drilling liquid, such as transformer
oil. Filling up the borehole up to the surface requires large quantities of drill
liquid and hence the drill liquid becomes a non-negligible cost of the EPB system.
The drill liquid can also be a potential risk of pollution.
[0010] A number of drilling apparatuses based on the EPB concept have been described. However,
most of the publications in the field of EPB drilling apparatuses for large diameters
are theoretical studies and designs without much comparison with actual drilling tests
under deep drilling conditions. As of today, no detailed designs of an operating and
hence proven EPB-based drilling apparatus using a down-hole pulse generator that can
drill holes having a diameter larger than 40 cm at large depth has been published.
Hence there is room for improving designs of EPB apparatuses for solving the above
mentioned problems and challenges.
[0011] In patent publication
US164388, an EPB apparatus comprising two concentric pipes separated by electric insulators
is disclosed, and wherein an inner pipe corresponds to a high-voltage pipe coupled
to a high-voltage electrode and an outer pipe is grounded and coupled to a ground
electrode. The high voltage pipe is coupled with a pulse generator that is located
at the surface, i.e. outside the bore hole. A debris collecting device is described
wherein the debris is evacuated through a space between the wall of the drilled hole
and part of an external wall of the drilling apparatus.
[0012] In patent publication
EP1711679, an EPB-based drilling apparatus is described using a down hole pulse generator and
wherein electrodes are moveable relative to each other in order to secure bottom contact
for each of the electrodes. A number of hydraulic nozzles for nozzle jetting of the
drill fluid and thereby directing and lifting the rock cuttings are described as well.
The rock cuttings are removed from the periphery of the bottom-hole up to the surface
by pumping the drill fluid together with the cuttings through an annular spacing between
the wall of the drilled borehole and an outer perimeter of the drilling apparatus.
[0013] In patent publication
RU2477370, a drill head is proposed for drilling bore holes of a diameter of 36 cm using EPB
and wherein a high-voltage pulse generator is integrated in the drill head. The drill
fluid is supplied to the electrodes through a central pipe and the rock cuttings together
with the drill liquid are evacuated through an annular spacing between the drill head
and the wall of the drilled borehole.
[0014] In order to fulfil the demand for ultra-deep drilling of large-diameter bore holes,
there is a need to provide a reliable, cost-effective and working alternative EPB
drilling apparatus that overcomes the problems and challenges mentioned above.
Summary of the invention
[0015] It is an object of the present invention to provide a drilling apparatus using the
EPB technique for drilling bore-holes of a diameter of at least 40 cm, preferably
at least 50 cm at a speed of several meters per hour and at the same time perform
the drilling in a cost-effective way. Nevertheless, although the drilling apparatus
of this invention is particularly suitable for the drilling of bore-holes with such
large diameters, it is also suitable for drilling bore-holes with smaller diameters
of for example 5, 10 or 20 cm or the like.
[0016] The present invention is based on insights of the inventors and based on experiments
performed. These insights supported by the experiments resulted in the conclusion
that by limiting the volume of the circulating drilling liquid, not only can be saved
on the cost price of the drilling liquid, being for example a transformer oil or a
bio-oil, but also that the excavated matter, e.g. rock cuttings, can be evacuated
in a more efficient way by providing dedicated return pipes for evacuating the rock
cuttings mixed with drill fluid from a bottom portion of the borehole.
[0017] The present invention is defined in the appended independent claims. The dependent
claims define advantageous embodiments.
[0018] According to a first aspect of the invention, a drill head for electro-pulse-boring
suitable for drilling a borehole having a diameter equal or larger than 50 cm is provided.
[0019] The drill head for electro-pulse-boring according to the invention comprises a high-voltage
pulse generator enclosed in a hermetically sealed container such that the container
is fillable with an electrically insulating fluid. The container comprises i) a circumferential
wall extending along a central axis coaxial with a drilling axis of the drill head
and ii) a first and a second axial cover for sealingly closing respectively a first
and a second end of the circumferential wall. A drill bit is mechanically coupled
to the container and comprises an electrode assembly electrically coupled with the
high-voltage pulse generator for receiving high-voltage pulses. A supply pipe is configured
for supplying drill liquid to the drill bit such that when in operation a borehole
bottom portion is filled with drill liquid so as to immerse the drill bit with drill
liquid. Generally, the supply pipe is mechanically coupled to the container.
[0020] In a preferred embodiment, the supply pipe is traversing the container along the
central axis from a supply pipe entrance portion traversing through the first axial
cover to a supply pipe exit portion traversing through the second axial cover.
[0021] The drill head according to the invention comprises a circumferential seal for separating
drill liquid in the borehole bottom portion from a stabilisation liquid that is filing
up the borehole up to a surface. At least a portion of the circumferential seal is
surrounding a part of the circumferential wall of the container.
[0022] Generally, the circumferential seal extends in a direction parallel with the central
axis. The circumferential wall of the container has a height measured along the central
axis between the first and the second end of the circumferential wall. Hence the circumferential
seal can also be construed as extending in a height direction of the container, being
parallel with the central axis, along part of the height of the container.
[0023] The drill head according to the invention further comprises one or more return pipes
for evacuation excavated matter mixed with drill liquid from the borehole bottom portion.
These one or more return pipes are mechanically coupled to the container. The excavated
matter comprises for example rock cuttings when a borehole is drilled through rock
formations.
[0024] Advantageously, by providing an circumferential seal surrounding the circumferential
wall of the container, only a bottom portion of the borehole comprising the drill
bit with the electrodes needs to be immersed with the drill liquid and an upper portion
of the bore hole up to the surface can be filled with any fluid capable of acting
as a stabilisation liquid for example a stabilization liquid such as water. Moreover,
as the amount of circulating drill liquid is reduced, the risks and/or effects of
environmental pollution by the drill liquid are reduced.
[0025] Advantageously, by providing the return pipe or pipes to evacuate the excavated matter
mixed with the drill liquid, an increased flow speed is obtained when compared to
prior art drill heads where no return pipes are used and where the excavated matter
are to be evacuated through the annular spacing between the bore head and the borehole.
[0026] The skilled person will be capable of configuring a cross sectional area of the return
pipes relative to the cross sectional area of the supply pipe such that supply of
the drilling liquid is not hampered by evacuation of the excavated matter, or in other
words wherein supply of the drilling liquid and evacuation of the excavated matter
are equilibrated.
[0027] Advantageously, the return pipe or pipes can be coupled with a return channel of
a drill string for transporting the excavated matter mixed with drill fluid from the
drill head to the surface, thereby maintaining the increased flow speed to evacuate
the excavated matter from the borehole up to the surface.
[0028] By using a combination of return pipes and a seal for sealing a space around the
drill head, no drilling liquid mixed with rock cuttings is flushed between the annulus
formed by the wall of the borehole and an outer wall of the drill head as is the case
with prior art EPB machines. As the mixture of rock cuttings and drill liquid is returning
through pipes instead of an annular ring around the drill head and drill string, the
overall volume of circulating drill liquid may be further limited. The annulus is
filled with stabilisation liquid, which can be selected to provide an optimum compromise
between cost and optimal stabilisation of the bore hole wall.
[0029] In some embodiments, the one or more return pipes are either coupled or partly coupled
to an inner side of the circumferential wall of the container, while in other embodiments
the one or more return pipes are coupled to the outside of the circumferential wall
of the container.
[0030] In preferred embodiments, the one or more return pipes are traversing the container
and each of the return pipes comprises i) a pipe entrance portion traversing through
the second axial cover and ii) a pipe end portion, and wherein the pipe end portions
of the return pipes are traversing through the first axial cover. Alternatively, the
pipe end portions can also be coupled to a common feedthrough for traversing through
the first axial cover.
[0031] Advantageously, by providing the return pipe or pipes having a pipe entrance portion
traversing the second axial cover of the container, i.e. the bottom flange of the
container, the entrance of the return pipes are located on top of the electrode region
allowing to efficiently evacuate the rock cuttings.
[0032] Additionally, by providing the return pipes having a pipe entrance portion traversing
the bottom cover of the container, the height of the bottom portion of the borehole
to be filled with drill liquid can be limited to a strict minimal height which is
the distance between the borehole bottom where the electrodes are resting and the
bottom cover of the container.
[0033] According to a second aspect of the invention an electro-pulse boring system is provided.
The electro-pulse boring system comprises a drill head for electro-pulse-boring as
discussed above, a lifting device located at the surface and configured for lifting
the drill head from the borehole, a drill string assembly, a drill liquid circulation
system. The electro-pulse boring system will further comprise any additional parts
known to the skilled person needed for the functioning of the boring system, for example
without being limited thereto, a dedicated power supply, a mud supply system for stabilising
the bore hole, a separator for separating the drilling liquid from the excavated matter
etc.
[0034] The drill string assembly comprises at least i) a feed channel for supplying drill
liquid from the surface to the drill head, ii) a power cable, running from the surface
to the drill head for supplying power to the electro-pulse generator and iii) one
or more return channels for transporting a mixture of excavated matter and drill liquid
up to the surface.
[0035] The drill liquid circulation system comprising at least i) a drill liquid reservoir,
ii) a pump for pumping drill liquid from the drill liquid reservoir to the drill head
through the feed channel of the drill string assembly, and iii) a drill liquid recovery
device configured for receiving the mixture of excavated matter and drill liquid from
the one or more return channels of the drill string assembly and configured for separating
the excavated matter from the drill liquid and transporting the recovered drill liquid
to the reservoir.
Short description of the drawings
[0036] These and further aspects of the invention will be explained in greater detail by
way of example and with reference to the accompanying drawings in which:
- Fig.1
- shows a cross-sectional view of a first embodiment of a drill head according to the
present invention,
- Fig.2
- shows a cross-sectional view of part of a second embodiment of a drill head according
to the present invention,
- Fig.3
- shows an isometric view of a further example of a drill head according to the invention,
- Fig.4
- shows an isometric view of an example of drill bit comprising an electrode assembly
formed by ground and high-voltage electrode tips,
- Fig.5
- shows a projection of a further example of a drill bit comprising an electrode assembly
having circumferential electrode components,
- Fig.6
- schematically illustrates an example of a container of an electro-pulse generator.
[0037] The drawings of the figures are neither drawn to scale nor proportioned. Generally,
identical components are denoted by the same reference numerals in the figures.
Detailed description of embodiments of the invention
[0038] The present disclosure will be described in terms of specific embodiments, which
are illustrative of the disclosure and not to be construed as limiting. It will be
appreciated by persons skilled in the art that the present disclosure is not limited
by what has been particularly shown and/or described and that alternatives or modified
embodiments could be developed in the light of the overall teaching of this disclosure.
The drawings described are only schematic and are non-limiting.
[0039] Use of the verb "to comprise", as well as the respective conjugations, does not exclude
the presence of elements other than those stated. Use of the article "a", "an" or
"the" preceding an element does not exclude the presence of a plurality of such elements.
[0040] Furthermore, the terms first, second and the like in the description and in the claims,
are used for distinguishing between similar elements and not necessarily for describing
a sequence, either temporally, spatially, in ranking or in any other manner. It is
to be understood that the terms so used are interchangeable under appropriate circumstances
and that the embodiments of the disclosure described herein are capable of operation
in other sequences than described or illustrated herein.
[0041] Reference throughout this specification to "one embodiment" or "an embodiment" or
"some embodiment" means that a particular feature, structure or characteristic described
in connection with the embodiments is included in one or more embodiment of the present
disclosure. Thus, appearances of the phrases "in one embodiment" or "in an embodiment"
in various places throughout this specification are not necessarily all referring
to the same embodiment, but may. Furthermore, the particular features, structures
or characteristics may be combined in any suitable manner, as would be apparent to
one ordinary skill in the art from this disclosure, in one or more embodiments.
[0042] When the wording "coupled", "mechanically coupled" or "electrically coupled" is used,
it is to be construed as either directly or indirectly coupled. An indirectly coupling
between a first and a second element can for example be made by placing a third element
in between the first and second element.
[0043] The present invention is related to a drill head for electro-pulse-boring of a borehole
having a diameter equal or larger than 40 cm, preferably equal or larger than 50 cm.
The drill head is a component that is part of an electro-pulse boring system. Some
components of the system are located on the surface and some components are located
inside the borehole. The EPB boring system typically comprises at least a lifting
device, a drill string assembly, a high voltage supply, a drill liquid circulation
system and a drill head. The drill head is the component that is lowered in the bore
hole and comprises a drill bit with electrodes or drill tips. For EPB systems, a high-voltage
generator is required and generally this generator can either be located on the surface
or it can be part of the drill head and be lifted down the borehole together with
the drill bit. The drill head of the present invention is a drill head configuration
that comprises the high-voltage pulse generator, which for these configurations is
generally named down-hole generator.
Drill head, general
[0044] Examples of a drill head 1 according to the present invention are schematically shown
on Fig.1 to Fig.3. Not all components of the drill head are shown on these figures,
only those components needed for understanding the invention are shown. Reference
number 100 on Fig.1 schematically illustrates, as an example, a rock formation through
which a hole is to be drilled.
[0045] The drill head 1 according to the present disclosure comprises a high-voltage pulse
generator enclosed in a hermetically sealed container 10 such that the container can
be filled with an electrically insulating fluid 90. An electrically insulating fluid
90 is for example nitrogen or an inert gas. As illustrated on Fig.1, the container
10 of the high-voltage generator comprises a circumferential wall 11 extending along
a central axis Z. The central axis Z is coaxial with a drilling axis of the drill
head 1. A first axial cover 12 and a second axial cover 13 are sealingly covering
respectively a first and a second end of the circumferential wall 11. The first and
second axial cover can respectively also be named top and bottom cover in the sense
that the bottom cover is positioned deeper in the borehole than the top cover. The
high-voltage pulse generator enclosed inside the container 10 is not shown on Fig.1.
[0046] In embodiments, the circumferential wall 11 is for example formed by a hollow pipe
and hence has the shape of a cylinder. In other embodiments, the circumferential wall
11 defining the outer wall of the container 10 can have any other shape such as a
prism or a square. The circumferential wall of the container has a height measured
along the central axis Z between the first and the second end of the circumferential
wall. For some embodiments, the height of the container can be several meters, depending
on the size of the high-voltage pulse generator.
[0047] The drill head 1 further comprises a drill bit that is mechanically coupled to the
container 10, preferably coupled to the second end of the circumferential wall, for
example by attachment to the axial cover 12. In other words, the drill bit is mechanically
supported through the container, preferably through the bottom side of the container
10. The drill bit comprises an electrode assembly 40 that is electrically coupled
with the high-voltage pulse generator for receiving high-voltage pulses. Typically,
the electrode assembly 40 includes a ground electrode 41 and a high-voltage electrode
42, as shown for example on Fig.2 and Fig.3.
[0048] The circumferential wall 11 and the first 12 and second 13 axial cover are typically
made or partly made of a metal such as stainless steel and are electrically grounded.
The ground electrode of the electrode assembly 40 is then coupled with the second
cover or with the circumferential wall in order to form a grounded connection. The
ground electrode is for example welded to the second cover plate or welded to a portion
of the circumferential wall. A high-voltage feed-through is passing through the second
axial cover 13 and is configured for providing high-voltage to the high-voltage electrode
42.
[0049] As discussed above, to operate an EPB drill head, a drill liquid, also named discharge
liquid, is required. The drill head according to the present disclosure comprises
a supply pipe 31 for supplying drill liquid to the drill bit such that when in operation
a borehole bottom portion 70 is filled with drill liquid so as to immerse the drill
bit with drill liquid.
[0050] Generally, the supply pipe 31 is mechanically coupled to the container. In the embodiment
shown on Fig. 1, the supply pipe 31 is traversing the container 10 along the central
axis Z from a supply pipe entrance portion traversing through the first axial cover
12 to a supply pipe exit portion traversing through the second axial cover 13. However,
any other arrangement of the supply pipe with respect to the container considered
suitable by the skilled person may be used as well.
[0051] As further illustrated on Fig. 1 and Fig.3, the drill head 1 according to the present
disclosure is characterized in that it comprises a circumferential seal 50 for separating
drilling liquid in the borehole bottom portion 70 from a stabilisation liquid 80 that
is filing up the borehole up to the surface. At least a portion of the circumferential
seal 50 is surrounding part of the circumferential wall 11.
The use of the word surrounding has to be construed as enclosing. For example, for
a cylindrically shaped circumferential wall 11, as shown in the embodiment on Fig.1,
the circumferential seal 50 surrounding the cylindrically shaped circumferential wall
corresponds to encircling the circumferential wall by 360°. As illustrated on Fig.1,
the circumferential seal 50 surrounding part of the circumferential wall 11 of the
container, is also extending in a height direction of the circumferential wall, i.e.
in a direction parallel with the central axis Z. The height direction of the container
can also be construed as an axial direction of the container, which is a direction
parallel with the central axis Z of the container.
[0052] In some embodiments, as shown for example on Fig.1, the entire circumferential seal
50 is surrounding part of the circumferential wall 11 of the container. In this example
shown on Fig.1, a lower part of the circumferential wall, near the second end of the
circumferential wall where the second axial cover 13 is located, is surrounded by
the circumferential seal 50.
[0053] In other embodiments, as shown for example on Fig.3, only a first portion of the
circumferential seal 50 is surrounding part of the circumferential wall of the container
and a second portion of the circumferential seal is surrounding the drill bit. In
other words, when an embodiment of a drill head as shown on Fig.3 is in operation,
the second portion of the circumferential seal is located in the bottom portion of
the borehole where the drill bit is located.
[0054] The stabilisation liquid 80 is for example water. The stabilisation liquid stabilises
the wall of the bore hole. As a circumferential seal is provided that is surrounding
the circumferential wall of the container of the high-voltage pulse generator, the
excavated matter mixed with the drill liquid cannot be evacuated anymore through an
annulus of the borehole, as is the case with prior art devices. The drill head according
to the present disclosure is therefore further characterized that it comprises one
or more return pipes 32a, 32b for evacuation excavated matter, such as rock cuttings,
mixed with drill liquid from the borehole bottom portion 70. In a preferred embodiment,
the drill head according to the present disclosure comprises two or more return pipes
mechanically coupled to the container 10. The container 10 together with the supply
pipe 31 and the return pipes 32a,32b is illustrated in more detail on Fig.6. The electro-pulse
generator enclosed inside the container is not shown on Fig.6.
[0055] The drill head according to the present invention is suitable to drill through rock,
e.g. sandstone, granite and other hard rock materials, and evacuate the rock cuttings
via the return pipes. The drill head is of course also suitable to drill through any
sediment underground layer and evacuate debris through the return pipes.
[0056] The circumferential seal is for example made or partly made out of an elastic material
and/or a compressible material. The seal is for example made out of rubber. In some
embodiments, the circumferential seal 50 is inflatable in order to provide for a robust
sealing.
[0057] In embodiments, the return pipes 32a,32b are made of a metal such as stainless steel.
[0058] In embodiments, the supply pipe 31 is made of or partly made of an electrically insulating
material such as fiberglass or another insulator.
[0059] To mechanically couple the return pipes to the container 10 of the high-voltage pulse
generator a number of options exist. A number of detailed embodiments of a drill head
according to the present disclosure will be further discussed.
[0060] In the embodiment schematically shown on Fig.1, the one or more return pipes are
traversing the container 10. Therefore, each of the return pipes 32a, 32b comprises
a pipe entrance portion traversing through the second axial cover 13 and a pipe end
portion traversing through the first axial cover 12. Holes can for example be made
through the first and second axial cover to receive the end portions of the return
pipes and the end portions can be placed through the holes and welded such that the
interior of the container remains hermetically sealed for receiving the electrically
insulating fluid 90.
[0061] As further illustrated on Fig.1, each of the one or more return pipes is coupled
or partly coupled to an inner side of the circumferential wall 11. In embodiments,
the return pipes can be welded to the inner side of the circumferential wall 11.
[0062] In the embodiment shown on Fig.1, an inner circumferential side of the circumferential
seal 50 is attached to an outer side of the circumferential wall 11. For example,
the inner side of the circumferential seal can be attached to the circumferential
wall by using metallic ring connectors, not shown on Fig.1.
[0063] In an alternative embodiment, similar to the embodiment of Fig.1, the pipe end portions
of the return pipes are coupled to a common feedthrough for traversing through the
first axial cover 12. The feedthrough can then be further coupled to a single return
channel to transport the rock cuttings mixed with drill liquid to the surface. Advantageously,
with this alternative embodiment, only one dedicated hole needs to be made in the
first axial cover for receiving the common feedthrough.
[0064] A cross-sectional view of a second embodiment of a drill head according to the present
invention is shown on Fig.2. In this embodiment the return pipes 32a and 32b are mounted
on the outside of the circumferential wall 11 of the container. The circumferential
seal is not shown on Fig.2.
[0065] On Fig.3 an isometric view of a drill head is shown comprising return pipes 32a and
32b mounted on the outside of the circumferential wall of the container 10. In this
embodiment shown on Fig.3, a circumferentially extending flange 15 is surrounding
and attached to the circumferential wall 11 so as to form a collar around the circumferential
wall 11. The circumferentially extending flange is for example welded to the circumferential
wall. In embodiments where the container has a cylindrically circumferential wall
11, the circumferentially extending flange 15 is for example a ring-shaped flange.
[0066] The circumferentially extending flange 15 is used for both coupling the circumferential
seal 50 and for coupling the return pipes as discussed below.
[0067] As shown on Fig.3, at least a portion of an inner circumferential side of the circumferential
seal 50 is attached to an outer side of the circumferentially extending flange 15.
In other words, this is an example of an indirect coupling of the circumferential
seal to the circumferential wall by using the circumferentially extending flange located
between the circumferential wall and the circumferential seal. As already mentioned
above, in this embodiment, the circumferential seal 50 has a first portion, being
the portion that is attached to the extending flange 15, and a second portion surrounding
the drill bit.
[0068] In the embodiment shown on Fig.3, the one or more return pipes 32a, 32b are attached
to the outer side of the circumferential wall 11, for example by welding. The circumferentially
extending flange comprises for each of the return pipes a corresponding feedthrough
opening and each feedthrough opening is receiving a corresponding return pipe entrance
portion. After placing a return pipe entrance portion through a hole of the circumferentially
extending flange it can be welded to the circumferentially extending flange 15.
[0069] The invention is not limited to the number of return pipes but there should be at
least one return pipe, preferably at least two pipes. The reason being that due to
the fact that there is not much space between the circumferential wall and the borehole,
the diameter of the return pipes 32a, 32b is limited and more than one pipe is needed
for obtaining a combined drill liquid evacuation capacity that is equal or larger
than the drill liquid supply capacity through the supply pipe 31.
[0070] In general, the one or more return pipes have a cross sectional area configured such
that the sum of the cross sectional areas of each of the return pipes is equal to
a cross sectional area of the supply pipe within an accuracy of 30%, preferably within
an accuracy of 25%, more preferably within an accuracy of 20%.
Hiah-voltaae pulse generator
[0071] The electro-pulse generator comprises a plurality of capacitors forming part of what
is named a Marx generator, known in the art and disclosed in for example
RU2477370. The plurality of capacitors are repetitively charged and de-charged and the high-voltage
that is outputted is the sum of the voltages on the capacitors. Such a generator is
optimized to generate high-voltage pulses with short pulse duration time, typically
up to 300 ns, for example in the 100 to 200 ns range or lower, as required for EPB.
[0072] In embodiments where the supply pipe 31 is traversing the container 10 along said
central axis Z from a supply pipe entrance portion traversing through the first axial
cover 12 to a supply pipe exit portion traversing through the second axial cover 13,
the capacitors are positioned around the supply pipe 31. Alternatively, each of the
capacitors have a ring-shape and are circumscribing the supply pipe 31.
Electrode assemblies
[0073] As discussed above, the drill bit 20 comprises an electrode assembly 40. The present
invention is however not limited to the specific type of electrode assembly 40 or
the specific shape or geometry of the electrode assembly 40 , as illustrated on fig.
4 and 5.
[0074] In embodiments, the electrode assembly has for example a circular perimeter with
an outer diameter D
E measured in a plane perpendicular to the central axis Z, and wherein D
E ≥ 40 cm, preferably D
E ≥ 50 cm. This outer diameter of the electrode assembly defines the diameter of the
borehole that can be drilled.
[0075] In embodiments, the circumferential wall 11 of the container has a cylindrical shape
with an outer diameter D
PG and wherein generally D
PG < D
E. Indeed, the outer diameter D
PG has to be smaller than D
E such that there is at least sufficient space for placing the circumferential seal
50.
[0076] The perimeter of the electrode assembly 40 is not limited to a circular shape but
the perimeter can for example also be an oval, a square or any other shape depending
on the required cross-sectional shape for the borehole.
[0077] A distinction can also be made between electrode assemblies having a single-segment
electrode or a multi-segment electrode. A single-segment electrode assembly 40 is
an electrode assembly comprising a single ground-electrode 41 and a single high-voltage
electrode 42, as shown for example on fig.3.
[0078] An example of a drill bit 2 comprising a single-segment electrode assembly is shown
on Fig. 4. The electrode assembly shown on Fig.4 comprises a single ground electrode
and a single high-voltage electrode formed by respectively a plurality of ground electrode
tips 41a and a plurality of high-voltage electrode tips 42a. These ground and high-voltage
electrode tips are radially positioned with respect to the central axis of the drill
head.
[0079] In further embodiments, as illustrated on Fig.5, the drill bit 20 comprise an electrode
assembly wherein the ground and high-voltage electrodes have respectively a circumferential
ground electrode component 41b and a circumferential high-voltage electrode component
42b. The circumferential ground electrode component 41b and the circumferential high-voltage
electrode component 42b are forming an outer perimeter of respectively the ground
and high-voltage electrode. These circumferential electrode components 42b,42b have
for example a circular shape as shown on Fig.5. An advantage of using electrode components
forming a closed periphery of the electrode assembly is that generally a drilled borehole
is obtained that has a smoother surface.
[0080] In alternative embodiments, the electrode assembly 40 is not a single-segment electrode
assembly but a multi-segment electrode assembly comprising a plurality of electrode
segments. In these embodiments, each of the electrode segments has a ground 41 and
high-voltage 42 electrode. For example, the electrode assembly can comprise two, three,
four or more electrode segments. The segments are preferably connected to each other
so that they are capable of drilling as one entity. In an example, the electrode assembly
is circular and can comprise two, three, four or more electrode segments which are
mechanically coupled to form a unity. The electrode segments may be arranged to be
individually steerable or controllable to permit directional boring, or they may be
controllable as a whole.
[0081] In embodiments comprising a multi-segment electrode assembly, the high-voltage pulse
generator is configured for individually powering each of the electrode segments.
[0082] The use of segmented electrodes has a number of advantages. A first advantage of
using a multi-segment electrode is that the power pulses generated by the high-voltage
pulse generator can sequentially be applied to each of the plurality of segments and
hence the delivered power can be used more efficiently and be better distributed over
the entire cross-sectional area of the borehole to be drilled. Remark that if the
diameter of the bore hole is increasing, for a given operational frequency of the
high-voltage pulse generator, the total power needed to excavate the borehole is in
a first approximation quadratically increasing with the diameter of the borehole.
The use of a segmented electrode allows to divide the total power to be delivered
among the various segments. This may be advantageous in situations where boring of
bore holes with large diameters of for example 50 cm or 100 cm diameter is intended,
and a drill speed is envisaged which approaches or is the same as a conventional drill
speed used for the boring of bore holes with a smaller diameter. The use of a segmented
drill head permits limiting the electric power that is supplied to each segment as
well as the pulse frequencies to conventionally used values. Drilling of bore holes
with increasing diameters would otherwise involve an almost exponential increase of
the electric power to be delivered by the high-voltage pulse generator with increasing
bore hole diameter.
[0083] A second advantage of using multi-segment electrode assemblies is that the drill
direction can be changed or corrected by a proper control of the individual electrode
segments. For example, the drill head direction could be changed by delivering more
pulses to one of the segments compared to the other segments.
[0084] In a particular embodiment, the electrode assembly is segmented and one of the electrode
segments is configured for drilling a locally enlarged bore hole resulting in the
formation of a borehole having a longitudinal groove or channel in the wall of the
borehole. This makes the device of the present invention suitable for horizontal boring
as well. Indeed, the local enlargement may serve as a channel for evacuating the excavated
matter mixed with drill liquid.
Rock evacuation testing
[0085] The inventors have performed a series of tests with a drill head according to the
present invention to investigate the evacuation efficiency of rock cuttings. A prototype
drill head as shown on Fig.3 was used for testing purposes. The supply pipe 31 used
has a diameter of 10,16 cm, i.e. 4 inches, and the two return pipes have a diameter
of 6,35 cm, i.e. 2.5 inches. The drill head was dimensioned to drill bore holes of
50 cm which results in a bore bottom portion having a volume of 54977 cm
3 and which was filled with 54 liter of drill liquid. The drill liquid supply rate
was optimized in order to suck a maximum rate of rock cutting through the two return
pipes. An optimum rock cutting recovery was obtained with a drill liquid supply rate
of 1000 liter/minute which resulted in a recuperation of 2,35 m
3 of rock cuttings per hour.
[0086] The drill head used for the testing uses a Marx-type high-voltage generator providing
pulses of 500kV at a rate between 1 up to 25 Hz. Further experiments have demonstrated
that with the drill bit having a 50 cm diameter electrode configuration used in combination
with the high-voltage generator, the drill head is capable of crushing 2,35 m
3/ hour of rock. Hence the evacuation system according to the invention using return
pipes combined with a seal to reduce the total drill liquid volume is capable of efficiently
evacuating the rock cuttings at a rate that is equal to the rate the rock cuttings
are produced. With such a system a drill speed of 12 m/hour or more can be reached.
Electro-pulse boring system
[0087] As mentioned above, the drill head is a component of an EPB system. An EPB system
comprises besides the drill head also a lifting device located at the surface and
configured for lifting the drill head from the borehole. The EPB system also comprises
a drill string assembly comprising i) a feed channel for supplying drill liquid from
the surface to the drill head, ii) a power cable which may for example run from the
surface to the drill head for supplying power to the electro-pulse generator, and
iii) one or more return channels for transporting a mixture of excavated matter and
drill liquid up to the surface.
[0088] The EPB system also comprises a drill liquid circulation system comprising at least
i) a drill liquid reservoir, ii) a pump for pumping drill liquid from said drill liquid
reservoir to the drill head through said feed channel of the drill string assembly,
and iii) a drill liquid recovery device configured for receiving said mixture of excavated
matter and drill liquid from said one or more return channels of the drill string
assembly and configured for separating the excavated matter from the drill liquid
and transporting the recovered drill liquid to the reservoir.
[0089] In embodiments, the supply pipe entrance portion of the supply pipe comprises a first
coupling means configured for coupling with the feed channel of the drill string transporting
the drill fluid from the surface to the drill head. The coupling means can for example
be a coupling flange.
[0090] In embodiments, each of the pipe end portions of the return pipes traversing the
first axial cover comprises a second coupling means and wherein the second coupling
means is configured for coupling with the return channel of the drill string transporting
the excavated matter mixed with drill fluid from the drill head to the surface. In
alternative embodiments comprising a common feedthrough traversing the first axial
cover, as discussed above, the common feedthrough comprises a second coupling means
configured for coupling with the return channel of the drill string.
1. A drill head (1) for electro-pulse-boring of a borehole, comprising
• a high-voltage pulse generator enclosed in a hermetically sealed container (10)
such that the container (10) is fillable with an electrically insulating fluid, and
wherein said container (10) comprises i) a circumferential wall (11) extending along
a central axis (Z) coaxial with a drilling axis of the drill head (1) and ii) a first
(12) and a second (13) axial cover for sealingly closing respectively a first and
a second end of said circumferential wall (11),
• a drill bit (20) mechanically coupled to said container (10) and wherein said drill
bit comprises an electrode assembly (40) electrically coupled with said high-voltage
pulse generator for receiving high-voltage pulses,
• a supply pipe (31) for supplying drill liquid to said drill bit such that when in
operation a borehole bottom portion is filled with drill liquid so as to immerse said
drill bit with drill liquid,
characterized in that said drill head (1) comprises
• a circumferential seal (50) for separating drill liquid in the borehole bottom portion
from a stabilisation liquid that is filing up the borehole up to a surface, and wherein
at least a portion of said circumferential seal (50) is surrounding a part of said
circumferential wall (11),
• one or more return pipes (32a, 32b) for evacuation of excavated matter mixed with
drill liquid from the borehole bottom portion, and wherein said one or more return
pipes are mechanically coupled to said container (10).
2. A drill head (1) according to claim 1 wherein said one or more return pipes are traversing
said container (10) and wherein each of said return pipes (32a, 32b) comprises i)
a pipe entrance portion traversing through said second axial cover (13) and ii) a
pipe end portion, and wherein the pipe end portions of the return pipes are traversing
through said first axial cover (12) or the pipe end portions are coupled to a common
feedthrough for traversing through the first axial cover (12) .
3. A drill head (1) according to any of previous claims wherein each of said one or more
return pipes is coupled or partly coupled to an inner side of said circumferential
wall (11).
4. A drill head (1) according to any of previous claims wherein at least a portion of
an inner circumferential side of said circumferential seal (50) is attached to an
outer side of said circumferential wall (11).
5. A drill head (1) according to any of previous claims wherein a circumferentially extending
flange (15) is surrounding and attached to said circumferential wall (11) so as to
form a collar around the circumferential wall (11) and wherein at least a portion
of an inner circumferential side of said circumferential seal (50) is attached to
an outer side of said circumferentially extending flange (15), and
wherein said one or more return pipes (32a, 32b) are attached to an outer side of
said circumferential wall (11), and
wherein said circumferentially extending flange (15) comprises for each of said return
pipes a corresponding feedthrough opening, and wherein each feedthrough opening is
receiving a corresponding return pipe entrance portion.
6. A drill head (1) according to any of previous claims wherein said one or more return
pipes have a cross sectional area configured such that the sum of the cross sectional
areas of each of the return pipes is equal to a cross sectional area of the supply
pipe within an accuracy of 30%, preferably within an accuracy of 25%, more preferably
within an accuracy of 20%.
7. A drill head (1) according to any of previous claims wherein said circumferential
seal (50) is inflatable and/or wherein said circumferential seal (50) is made of a
compressible material or an elastic material.
8. A drill head (1) according to any of previous claims wherein said electrode assembly
has a circular perimeter with an outer diameter DE measured in a plane perpendicular to the central axis (Z), and wherein DE ≥ 40 cm, preferably DE ≥ 50 cm and wherein said circumferential wall (11) has a cylindrical shape with an
outer diameter DPG wherein DPG < DE.
9. A drill head (1) according to any of claims 1 to 7 wherein said electrode assembly
(40) is a segmented electrode assembly comprising a plurality of electrode segments,
wherein each electrode segment has a ground (41) and high-voltage (42) electrode,
and wherein the high-voltage pulse generator is configured for individually powering
each of the electrode segments.
10. A drill head (1) according to claim 9 wherein one of the electrode segments is configured
for drilling a locally enlarged bore hole resulting in the formation of a borehole
having a longitudinal groove or channel in the wall of the borehole.
11. A drill head (1) according to any of previous claims 1 to 7 wherein said electrode
assembly (40) comprises a ground-electrode (41) and a high-voltage electrode (42)
and wherein said circumferential wall and said first and second cover are made of
a metal and are electrically grounded and coupled with said ground electrode (41),
and wherein a high-voltage feed-through passing through said second axial cover (13)
is configured for providing high-voltage to said high-voltage electrode (42).
12. A drill head (1) according to any of previous claims wherein said supply pipe (31)
is traversing said container (10) along said central axis (Z) from a supply pipe entrance
portion traversing through said first axial cover (12) to a supply pipe exit portion
traversing through said second axial cover (13), preferably said electro-pulse generator
comprises a plurality of capacitors wherein said capacitors are positioned around
the supply pipe (31) or wherein each of the capacitors have a ring-shape and are circumscribing
the supply pipe (31).
13. A drill head (1) according to anyone of claims 1 to 11 wherein a supply pipe entrance
portion of the supply pipe (31) comprises a first coupling means configured for coupling
with a feed channel of a drill string transporting the drill fluid from the surface
to the drill head.
14. A drill head (1) according to any of previous claims wherein each of said pipe end
portions of the return pipes traversing the first axial cover (12) comprises a second
coupling means or wherein said common feedthrough traversing the first axial cover
(12) comprises a second coupling means, and wherein the second coupling means is configured
for coupling with a return channel of a drill string transporting the excavated matter
mixed with drill fluid from the drill head to the surface.
15. An electro-pulse boring system comprising
• a drill head (1) according to any of previous claims,
• a lifting device located at the surface and configured for lifting the drill head
(1) from the borehole,
• a drill string assembly comprising
i) a feed channel for supplying drill liquid from the surface to the drill head,
ii) a power cable running to the drill head for supplying power to the electro-pulse
generator,
iii) one or more return channels for transporting a mixture of excavated matter and
drill liquid up to the surface,
• a drill liquid circulation system comprising at least
i) a drill liquid reservoir,
ii) a pump for pumping drill liquid from said drill liquid reservoir to the drill
head through said feed channel of the drill string assembly, and
iii) a drill liquid recovery device configured for receiving said mixture of excavated
matter and drill liquid from said one or more return channels of the drill string
assembly and configured for separating the excavated matter from the drill liquid
and transporting the recovered drill liquid to the reservoir.