Smart Modulation for Control Systems with High Regulation Capabilities for Cooling Systems Optimisation and Carbon Footprint Reduction in Industry

Nowadays, every large enterprise is concerned about reducing CO2 emissions. Along with legislation, management, packaging, and transportation decisions, optimising the operation of automated systems in the industry is important. Overheating processes or large cooling systems of one machine during product assembly may seem minor but at the industry level it is quite significant. Either an optimisation of cooling systems or an intelligent machine control which will prevent heat strokes and allow the transition to passive cooling of the whole system is an important issue for improving machine tools efficiency and contributing therefore to CO2 reduction in the industry sector. This research is a transitional phase from the creation of a control system to solve the problems of resonance in the control of systems with parallel piezo kinematics, which were designed to automate the iterative process of non-circular drilling with a precise shape and the subsequent research on the implementation of smart control to optimise the cooling of industrial machines. The total dynamics of the example system in this research is unknown and consists of the dynamics of electrical converters, piezo kinematics, and mechanics. The control signal of this system is generated by the model of the system state with assumptions and simplifications in combination with machine learning techniques considering the previous errors of the transient characteristics with the possibility of re-drilling without damaging the workpiece and with possibility of further trainings to eliminate the iterative process in general. Algorithms for further training at different resonances with a drilling depth change for cylinders of internal combustion engines are offered. These algorithms are proposed for accurate transmission of the input signal amplitude even in resonant situations, power optimisation, increase the system efficiency, as well as reducing the carbon footprint when used in industry in specific applications.

Improving the rheological properties of water-based calcium bentonite drilling fluids using water-soluble polymers in high temperature applications

Most of bentonite used in modern drilling engineering is physically and chemically modified calcium bentonite. However, with the increase of drilling depth, the bottom hole temperature may reach 180 °C, thus a large amount of calcium bentonite used in the drilling fluid will be unstable. This paper covers three kinds of calcium bentonite with poor rheological properties at high temperature, such as apparent viscosity is greater than 45 mPa·s or less than 10 mPa·s, API filtration loss is greater than 25 mL/30 min, which are diluted type, shear thickening type and low-shear type, these defects will make the rheological properties of drilling fluid worse. The difference is attributed to bentonite mineral composition, such as montmorillonite with good hydration expansion performance. By adding three kinds of heat-resistant water-soluble copolymers Na-HPAN (hydrolyzed polyacrylonitrile sodium), PAS (polycarboxylate salt) and SMP (sulfomethyl phenolic resin), the rheological properties of calcium bentonite drilling fluids can be significantly improved. For example, the addition of 0.1 wt% Na-HPAN and 0.1 wt% PAS increased the apparent viscosity of the XZJ calcium bentonite suspension from 4.5 to 19.5 mPa·s at 180 °C, and the filtration loss also decreased from 20.2 to 17.8 mL.

Theoretical Study and Experiment Validation on Drilling Cutting Weight during the Whole Process of Drilling

In mining engineering, coal and gas outburst is extremely dangerous dynamic disaster, which will cause serious casualties and property losses. As a method to predict coal burst, the drilling cutting method has been widely used in coal mines. The drilling cutting weight is an important index of the drilling cutting method. In theoretical calculation, scholars usually assume that the coal is isotropic and homogeneous before drilling to deduce the formula of drilling cutting weight. However, in actual mining engineering, drilling cutting is usually carried out in the plastic coal body in front of the working face. Therefore, in the present study, the theoretical formula of the drilling cutting weight in the plastic coal mass is deduced, as well as in the elastic coal mass. The results show that the drilling cutting weight calculated based on the deduced formula increases with the increase of drilling depth in the plastic coal mass, which is consistent with the field measurement results. The fragmentation degrees of coal around the drilling hole are also considered by introducing cohesion, which changes linearly along the radial direction of the drilling hole. The results show that the smaller the cohesion, the greater the drilling cutting weight. The calculation formula for drilling cutting in elastic coal mass is also given. The dilatancy effect of coal around the drilling hole is also considered by introducing expansion coefficient n, which changes linearly along the radial direction of the drilling hole. There is a good match between the theoretical calculation results and the laboratory test results. The obtained results are helpful for the prediction and prevention of coal burst.

Review of the Heat Flow Mapping in Polish Sedimentary Basin across Different Tectonic Terrains

Heat flow patterns variability related to the age of the consolidated, and differences in, sedimentary thickness of the sedimentary succession are important constraints upon the thermal state of the sedimentary fill and its geothermal energy potential. Heat flow in the Permian basin of central Europe varies from a low of 40 mWm−2 in the Precambrian Platform to 80 mWm−2 in the Paleozoic basement platform influencing temperature for geothermal potential drilling depth. Continuity of thermal patterns and compatibility of heat flow Q across the Permian basin across the Polish–German basin was known from heat flow data ever since the first heat flow map of Europe in 1979. Both Polish and German heat flow determinations used lab-measured thermal conductivity on cores. This is not the case for the recent heat flow map of Poland published in 2009 widely referenced in Polish geological literature. Significant differences in heat flow magnitude exist between many historical heat flow maps of Poland over the 1970s–1990s and recent 21st century patterns. We find that the differences in heat flow values of some 20–30 mWm−2 in Western Poland exist between heat flow maps using thermal conductivity models using well log interpreted mineral and porosity content and assigned world averages of rock and fluid thermal conductivity versus those measured on cores. These differences in heat flow are discussed in the context of resulting mantle heat flow and the Lithosphere-Asthenosphere Boundary depth modelled differences and possible overestimates of deep thermal conditions for enhanced geothermal energy prospects in Poland.

The rock breaking capability analyses of sonic drilling

Sonic drilling technology uses the longitudinal vibration of a drill string to realize fast and effective drilling. By setting the top and bottom boundary conditions of the drill string during drilling, a dynamic model of flexible sonic string percussive drilling is established in this article. At a certain drilling depth, with the excitation frequencies as the control parameters, the maximum impact force and rock breaking energy utilization rate are used to evaluate the rock breaking capability of the sonic drilling system under the linear bit–rock model. A surface diagram of the maximum breaking force reached within the working frequencies and at varying drilling depths is obtained. The curve graph of the rock breaking energy utilization rate varying with drilling depth under the first six orders of resonance is also calculated. Analysing the influence of changing drilling parameters on the rock breaking capability of sonic drilling systems can provide theoretical guidance for the actual drilling process.

Investigation of Geochemical Sections in Exploratory Boreholes of Mesgaran Copper Deposit in Iran

Mesgaran copper deposit is located in Sarbisheh city of South Khorasan province of Iran. To investigate the geochemical changes of the elements with increasing depth in the deposit, geochemical sections for important minerals related to mineralization in the area including copper, lead, zinc and cobalt were drawn for 9 exploratory boreholes. In these sections, the trend of changes of different elements versus depth is shown and the resulting diagrams were drawn for different boreholes. As a result, there is a significant relationship between the elements. With increasing the drilling depth, the amount of copper decreased and the amount of copper in each section was determined according to its cause. Keywords: Geochemistry, Copper deposit, Exploratory borehole, geochemical section.

Impact of Natural Polymer (Xanthan Gum) and Bentonite Clay on the Development of Oil-In-Water (O/W) Emulsion Drilling Fluids

Drilling fluid plays the same role in oil and gas well drilling as the blood in human body. A new type of oil-in-water (o/w) emulsion drilling fluid has been developed using diesel oil as dispersed phase, brine water as continuous phase, xanthan gum as viscosity modifier and clay as emulsion stabilizer and filtration controlling agent. Initially, standard recommended techniques were opted to detect the rheological properties of the emulsions. The fluids have also shown stable properties upto 70°C after aging for 24 h. As drilling fluids encounter a lot of variation in temperature and pressure as drilling depth increases, hence the stability of such fluids becomes an imperative parameter. Furthermore, emulsion itself is a heterogeneous fragile system so the stability was investigated using shear stress-shear rate rheology measurements. Emulsions have shown strong shear-thinning (pseudoplastic) behaviour which is considered an advantageous property for the drilling fluids. Experiments conducted to determine the dynamic rheology of the emulsions have shown the elastic behaviour towards emulsion breakdown processes. The fluids have also shown physical stability after 30 days at ambient conditions. Inter-facial variables such as zaeta potential, inter-racial tension (IFT) and contact angle measurements were conducted to examine their role in stability characterization.

Vibration Behavior during Underground Drilling Based on an Innovative Measurement Method and the Application

Pressure relief drilling is one of the most common techniques to reduce the impact of rock burst, but the useful dynamic phenomena in the drilling process are ignored due to the lack of corresponding technical methods. Based on the fact, an innovative measurement method for vibration signals during the drilling construction by pneumatic drill rig is presented in this study. The acquisition and analysis of vibration signals show that the vibration information can reflect the drilling depth, the amplitude of different depth can reflect the pressure, and the vibration events of different depths can reflect the pressure relief effect. The method proposed in the study is of great significance to the supervision of the relief work quantity, the disclosure of the pressure situation, and the evaluation of the pressure relief effect.

Assessment of cylindricity and roughness tolerances of holes drilled in marble using multiple regression and artificial intelligence

The Calacatta-Carrara marble is widely used due to its excellent physico-chemical characteristics and attractive aspect. However, the sensitivity of this materiel, when performing delicate manufacturing operations, presents for the engineers a hard challenge to overcome. This issue is mainly encountered with complex shapes of parts, for which it is difficult to preserve surface integrity and avoid geometric defects. The paper aims at finding out optimal drilling parameters of cutting in the Calacatta-Carrara white marble material, in order to minimize the holes cylindricity (HC) and surface roughness (HR) using six controlled operating factors, namely, the rotation speed ( N), the feed speed ( F), the drill bit diameter (BD), the drill bit height (BH), the number of pecking cycles ( P), and the drilling depth (DD). The experimental design uses a [Formula: see text] fractional factorial plan that is replicated once for cost consideration. The optimization process, that is, minimum cylindricity and roughness tolerances, is carried out using the Gray Relational Analysis (GRA) technique. Numerical modeling of machining parameters is performed using Multi-Layer Perceptron Artificial Neural Network (MLP ANN) and Multiple Regression Model (MR) to predict surface quality. For the sake of completeness these two models were compared in terms of fitness and predictability. The models were assessed statistically using the correlation coefficient. Results showed that either solution predicts a roughness tolerance which is in good agreement with the test data (both R-sq.(adj.) and R-sq.(pred.) >94%). However, the holes cylindricity tolerance response was shown to be superior with MLP-ANN model (R-sq.(adj.) 50.64% and R-sq.(pred.) 48.67%). The GRA analysis shows that minimum cylindricity and roughness are met when N and F are set high, BD and BH low, P high and DD low.