Laboratory studies of hydraulic fracture growth in quasi-brittle rocks with different grain sizes

Brice Tanguy Alphonse Lecampion, Dong Liu
2020
Poster talk

Abstract

Well completion for oil and gas, geothermal energy as well as CO2 storage sometimes require stimulation to achieve economical fluid flow rates (for both injector and producer wells). Predicting the growth of fluid-driven fractures in geological systems is essential for the sustainable and efficient engineering of those reservoirs. The quasi-brittle nature of rocks complexifies the coupling between fluid flow and fracture growth – especially in the fracture process zone. To better understand the impact of the non-linear fracture in such materials, we perform different laboratory hydraulic fracturing experiments under controlled stresses and fluid injection conditions in a cubic block of 250250250 millimeter in size. We choose two different rocks (marble and gabbro) with an order of difference in grain sizes (and as a result most likely different process zone size) but both with very low permeability. We report a series of experiments performed under different regimes of propagation (lag-viscosity as well as toughness dominated) in these two rocks under different levels of confining stress. We use active acoustic monitoring to reconstruct the evolution of the fracture front with time with a spatial resolution of a few millimeters every 4 seconds in time (see Liu et al. (2020) for details). We show that the fracture growth is also consistent with other measurements such as fluid injection pressure and displacement measured. Attenuation of the transmitted acoustic energy also indicates the existence of a damage zone (often denoted as a process zone) ahead of the fracture. This process zone grows differently inside these two rocks during fracture propagation. Its final size appears limited by the specimen dimensions with a decrease of the fracture apparent toughness at later time.

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Brice Tanguy Alphonse Lecampion, Dong Liu
2020
Poster talk

Abstract

Official source

https://infoscience.epfl.ch/record/281886?ln=en

About this result

Related concepts (16)

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Related publications

Propagation of a Radial Fluid-driven Fracture in Nonlinear Solid --around the tip of a fluid-driven fracture: process zone vs deviated fluid flow

Brice Tanguy Alphonse Lecampion, Dong Liu

Deviations from conventional hydraulic fracturing simulators’ predictions are sometimes observed in the field and laboratory. This questions the basic assumptions adopted in linear hydraulic fracture mechanics (LHFM): a linear elastic solid and a simplified fluid flow in the fracture. Some rocks encountered in the domain of hydraulic fracturing show a strong non-linear behavior with the existence of a process zone, and fluid flow in small rough apertures also presents a departure from the Poiseuille law. By relating the solid non-linearity to the deviated fluid flow through the fracture roughness, we study the propagation of a radial fluid-driven fracture in quasi-brittle materials. We adopt a linear-softening cohesive zone model to simulate the non-linear behavior in the solid and introduces a friction factor to characterize the deviated fluid flow. We investigate the interplay between the fluid front and the process zone and verify that the solid non-linearity will impact the growth of hydraulic fractures through the fracture roughness by decreasing the permeability of the fracture tip. Fluid driven fracture propagation in quasi-brittle materials shows a similar behavior as in linear elastic solid under the assumption of a zero fluid lag. The cohesive zone develops with time and reaches a stable value, which depends on the fluid viscosity. When considering a non-zero fluid lag, an interplay exists between the fluid front and process zone. Deviated fluid flow pushes the fluid away from the fracture tip and results in a larger fluid lag. We observe a localization of the pressure drop near the tip. Cohesive zone length will either be shortened or enlarged by the deviated lubrication, depending on whether the squeezing or bubbling effect is dominant. However, normal stress drives the fluid front to the tip, leading to a smaller fluid lag and higher net pressure. Cohesive length is shortened as a result of a strengthened suction effect in the lag region. Due to this interplay, more energy dissipation is expected during propagation.

2018

Hydraulic fracturing is a technique often used in the oil and gas industry to enhance the production of wells in low-permeability reservoirs. It consists of fluid injection at a sufficiently large injection rate to create and propagate tensile fractures inside the rock formation. The growth of a hydraulic fracture is a highly non-linear moving boundary hydro-mechanical problem. Many physical processes get tightly involved and influence the fracture growth, such as the elastic deformation of the material, fracture surface creation, viscous fluid flow inside the propagating fracture, and fluid leak-off into the solid principally. The linear hydraulic fracture mechanics (LHFM) theory describes well this coupled process, with adequate comparisons between predictions and observations in the linear elastic medium. However, deviations from LHFM predictions have been reported at the laboratory and field scales in some cases, notably a larger fluid pressure and a shorter fracture length. These deviations are often associated with the non-linear nature of rock fracture deformation. However, the impact of these material non-linearities on the coupled problem of hydraulic fracture propagation has not been fully understood. In this context, this thesis investigates numerically and experimentally the effect of the quasi-brittle nature of rocks on hydraulic fracture growth. We first solve the propagation of a hydraulic fracture using a power-law fracture length-dependent fracture energy to model macroscopically the effect of an enlarging process zone. The use of Gauss-Chebyshev quadrature and barycentric Lagrange interpolation techniques reduces the hydraulic fracture propagation problem to a set of non-linear ordinary differential equations. We find that this increasing apparent toughness leads to a slower fracture growth compared with constant toughness LHFM solutions and a faster transition to the toughness dominated regime. We show that the solution can be approximated by the self-similar constant toughness solutions with the instantaneous toughness value. We then explore the impact of the quasi-brittle nature of rocks by using a cohesive zone model in combination with elastohydrodynamic lubrication to simulate HF growth. We notably account for fluid cavitation at the fracture tip and the effect of fracture roughness on flow. The fracture growth finally converges toward the LHFM predictions but deviate from LHFM predictions when the cohesive zone cannot be neglected. These deviations indicate an increase of energy dissipation. The additional energy dissipation compared with LHFM mainly comes from the viscous fluid flow in the rough fracture process zone and is larger for a larger ratio between the in-situ stress and the material peak cohesive stress. We finally discuss HF experiments performed on two impermeable rocks under different confinement and injection conditions. We notably develop an inversion technique to reconstruct the fracture front geometry using diffracted waves recorded via an array of 32 sources and 32 receivers. We find that transmitted waves attenuate before the arrival of the fracture front estimated from diffracted waves, indicating the existence of a fracture process zone of centimeters extent. This fracture process zone is found to be comparable with the fracture extent, thus implying an important artifact of laboratory HF experiments performed in quasi-brittle rocks on finite-size centimeter-decimeter samples.

EPFL2021

Finite element modeling and experimental study of brittle fracture in tempered martensitic steels for thermonuclear fusion applications

Pablo Federico Mueller

In this work we have studied brittle fracture in high-chromium reduced activation tempered martensitic steels foreseen as structural materials for thermonuclear fusion reactors. Developing the adequate materials that can withstand the severe irradiation conditions of the burning plasma in a future fusion reactor is one of the major challenges to be solved in order to make profit from the great advantages of thermonuclear fusion as an energy source. High-chromium tempered martensitic steels such as F82H and the most advanced version Eurofer97 are among the main candidate materials for structural applications in future fusion power plants due to low irradiation-induced swelling, good mechanical and thermal properties, and reasonably fast radioactive decay. The most concerning drawback of these kind of steels is irradiation embrittlement, which is manifested by a ductile-to-brittle transition temperature shift to higher temperatures after irradiation whose amplitude depends on the irradiation conditions (temperature, neutron flux, neutron fluence, etc). The aim of this work was to study and model brittle fracture in the ductile-brittle transition region of this kind of steels in the as-received unirradiated conditions. It is necessary to be able to transfer laboratory specimen fracture data to real components and structures in order to assess the performance of these steels in the different operating and transient conditions they could find during the operation life of a fusion reactor. In order to do so, the specimen geometry effects and specimen size effects on measured fracture toughness need to be properly understood, taken into account and predicted with an appropriate model. In particular, specimen size effect on measured toughness is a major concern for the nuclear materials research community owing to the limited irradiation volume in current and planed materials irradiation facilities. The main results of this PhD work are summarized below. The microstructure of Eurofer97 and F82H has been characterized and compared by means of optical microscopy, scanning electron microscopy, transmission electron microscopy and energy-dispersive X-ray spectroscopy in order to identify microstructural features that could play a role in the measured fracture toughness. Both steels have similar but slightly different chemical composition and final heat-treatments but the prior austenitic grain size measured in F82H is approximately 8 times larger than in Eurofer97. It was shown that the alloying element Tantalum, added to stabilize the austenite grain size, played a different role in both steels. After a careful analysis of the particles present in both steels, it was found that Tantalum in Eurofer97 formed carbides of an average size around 100 nanometers. In contrast in F82H it did not form small carbides but formed big oxide inclusions with a size up to 30 µm. These large particles do not effectively pin the grain boundaries. The different behavior of Tantalum in these steels is believed to be mainly a consequence of the larger content of Oxygen present and the smaller amount of Aluminum in F82H compared to Eurofer97. The Master-Curve ASTM-E1921 standard is a method initially developed to determine the ductile-to-brittle transition reference temperature, T0, in fission reactor ferritic steels from a small number of experiments. In this work the applicability of the Master-Curve method to reduced activation tempered martensitic steels such as Eurofer97 and F82H was studied in detail. Fracture tests with pre-cracked sub-sized compact tension specimens (three different sizes, 0.18T, 0.35T and 0.87T of Eurofer97) were carried out in the temperature range [-196 °C, -40 °C]. The toughness-temperature behavior and scatter were shown to deviate from the ASTM-E1921 standard predictions near the lower shelf. Using the method of maximum likelihood, the athermal component of the Master-Curve was calculated to better fit our fracture toughness data from the lower to the middle transition region. We showed that these Master-Curve adjustments are necessary to make the T0 values obtained near the lower shelf with 0.35T size C(T) specimens consistent with those obtained in the middle transition region with 0.87T C(T) specimens. The ASTM-E1921 specimen size limitations, setting the maximum toughness measurable with a given specimen size, were found to be too lenient for this kind of steels. This problem was especially evident in fracture toughness data of Eurofer97 and F82H obtained in the upper transition temperature range with two different specimen sizes. Thus a more stringent specimen size requirement was proposed to avoid inconsistent transition temperature determinations. A promising local fracture model with the potential of predicting cleavage fracture toughness was studied. Finite element simulations were undertaken for compact specimens, notched specimens and tensile specimens of Eurofer97 steel tested from 20 °C down to -197 °C. Three and two dimensional as well as axisymmetric simulations were run in order to calculate the stress and strain fields at the onset of brittle fracture. For each tested temperature, the calculated load-displacement curves were found to reproduce very well those of the experiments. A local approach fracture criterion was studied. This criterion states that when the maximum principal stress is larger than a critical stress within a critical volume ahead of the crack tip, notch or neck, cleavage is triggered leading to macroscopic fracture of the specimen. It was shown that this model is able to predict the minimum fracture load of the notched specimens with the same values of critical stress and critical volume that were calibrated to predict the lower bound of fracture in compact specimens. This local approach model was also successfully used to predict the strong size effect observed experimentally in pre-cracked compact tension specimens in the upper transition region. The critical fracture stress determined in the standard tensile specimens was found higher than that of the fracture specimens. It was suggested that this difference stems from a significant difference in the stress state between the different specimens (triaxiality). Finally, the comparison between the overall fracture behavior in the transition between F82H and Eurofer97 steels indicated that these two materials are quite similar. A difference in the reference temperature T0 of about 20 °C was found, with a nominal value of -100 °C and -80 °C for F82H and Eurofer97 respectively. However, some excessive scatter in the toughness data was found in F82H with more data points than expected lying below the 1% tolerance bound; this was not observed in Eurofer97. From an engineering point of view, the entire fracture databases of these two steels are encompassed practically by the same lower tolerance bound.

EPFL2009