High-temperature aquifer thermal energy storage (HT-ATES) can play a key role in the energy transition. For well completion of conventional low-temperature ATES and groundwater wells, grout and/or clay pellets are typically utilised as annular materials to ensure the long-term well integrity. It is not yet known if such materials can also be used in HT-ATES working conditions. In this work, a novel approach to evaluate the sealing performance for such completion materials is proposed and tested over multiple thermal heating and cooling cycles representative of the conditions of HT-ATES operation. The experimental framework utilises a novel experimental design to test the apparent transmissivity of the annular material, followed by micro-CT scanning. During each test, up to 11 thermal cycles are applied, with temperature variations between 22oC and 90oC. For grouts after 7 days of curing, micro-CT scans reveal debonding and the occurrence of micro-annuli with an equivalent diameter of approximately 26% of the original cross-section. After 28 days of curing, the thermal cycles had a much reduced impact on micro-annulus formation. The corresponding apparent transmissivity decreased up to 80% for samples containing a high percentage of cementitious minerals and a low water-to-grout ratio. The clay pellets, saturated with fresh water, demonstrated effective sealing capacity and an impermeable behaviour. However, clay pellets saturated with 0.25 mol/L NaCl, showed up to an 85% decrease in swelling capacity yet still exhibited impermeable behaviour. The results indicated that thermal cycles affect the integrity of grouts, while clay pellets show resilience to them. Furthermore, longer curing periods and specific chemical compositions improve sealing performance and provide resilience to thermal cycles.

In horizontal well operations, the prevalence of stuck pipe incidents is largely attributed to inadequate hole cleaning, underscoring the critical need for a thorough understanding of this process to mitigate non-productive time and financial losses. Increasing fluid velocity, the major drilling parameter of hole cleaning, diminishes the formation of cuttings beds in a wellbore. This study primarily centered on the mechanical displacement and removal of solid particles, employing advanced image processing techniques to elucidate the dynamic behavior of solid particles in deviated wellbores. The core objective of this study was to experimentally scrutinize the effects of a downhole clamp-on tool on fluid velocity to improve hole cleaning practices. To address this challenge, a customized flow loop was designed and constructed to accurately replicate the conditions encountered in horizontal wells. Pure water was used to demonstrate the effects of the clamp-on tool on cuttings transport for lightweight drilling fluid conditions. Strategically deployed, the clamp-on tool played a pivotal role in agitating cuttings, mitigating their accumulation at the bottom of the borehole. The tool's agitation mechanism noticeably improved cuttings removal by increasing velocity, extending the perturbation of cuttings transport in the tool's downstream flow, and reducing bedding formation. At lower flow rates, the tool led to an over fourfold increase in average particle velocity within the tool and a twofold increase after the tool. Our results demonstrate the substantial potential of mechanical assistance to address hole cleaning challenges and significantly advance horizontal well operations.

Drilling wells in unconsolidated formations is commonly undertaken to extract drinking water and other applications, such as aquifer thermal energy storage (ATES). To increase the efficiency of an ATES system, the drilling campaigns are targeting greater depths and enlarging the wellbore diameter in the production section to enhance the flow rates. In these cases, wells are more susceptible to collapse. Drilling fluids for shallow formations often have little strengthening properties and, due to single-string well design, come into contact with both the aquifer and the overburden. Drilling fluids and additives are experimentally investigated to be used to improve wellbore stability in conditions simulating field conditions in unconsolidated aquifers with a hydraulic conductivity of around 10 m/d. The impact on wellbore stability is evaluated using a new experimental setup in which the filtration rate is measured, followed by the use of a fall cone penetrometer augmented with an accelerometer to directly test the wellbore strengthening, and imaging with a scanning electron microscope (SEM) to investigate the (micro)structure of the filter cakes produced. Twelve drilling fluids are investigated with different concentrations of bentonite, polyanionic cellulose (PAC), Xanthan Gum, calcium carbonate (CaCO₃), and aluminum chloride hexahydrate ([Al(H₂O)₆]Cl₃). The filtration results indicate that calcium carbonate, average d_p <20 μm, provides pore throat bridging and filter cake formation after approximately 2 min, compared to almost instantaneous discharge when using conventional drilling fluids. The drilling fluid containing 2% [Al(H₂O)₆]Cl₃ forms a thick (4 mm) yet permeable filter cake, resulting in high filtration losses. The fall cone results show a decrease of cone penetration depth up to 20.78%, and a 40.27% increase in deceleration time while penetrating the sample with CaCO₃ compared with conventional drilling fluid containing bentonite and PAC, indicating a significant strengthening effect. The drilling fluids that contain CaCO₃, therefore, show high promise for field implementation.