Pro-Pipe’s Insulated Drill Pipe (IDP) project is a pioneering initiative designed to enhance the efficiency of geothermal and high-temperature drilling by overcoming critical thermal management challenges. Developed in collaboration with manufacturing partners, the IDP employs advanced insulation materials applied to drill pipes. These novel materials minimize heat transfer, enabling significantly cooler circulating temperatures at the bottomhole assembly (BHA). This is essential for ensuring the survival and performance of downhole electronics in Enhanced Geothermal Systems (EGS) in Super Hot Rock (SHR).
The project began with rigorous thermodynamic simulations and material testing. This culminated in the creation of novel insulation materials optimized for thermal resistance, mechanical durability, and compatibility with standard repair and maintenance processes. Two field trials are planned to validate Pro-Pipe’s IDP’s performance and durability before scaling to commercial production. The first trial will evaluate the IDP’s efficiency under extreme bottomhole temperatures of 300°C, while the second will test its resilience to real-world abrasion and erosion.
Parallel with these trials, preparations for commercial-scale production will begin, with the goal of creating a complete 5,000-meter IDP string by 2027. This string will be used to drill an Enhanced Geothermal System (EGS) in Super Hot Dry Rock, enabling the extraction of supercritical water—a medium with an energy density seven times greater than traditional EGS systems. Alberta holds significant potential for EGS SHR systems, with over 388,500 MW of untapped geothermal generation capacity. According to the International Energy Agency, these next-generation systems could unlock 600 terawatts of global energy potential, exceeding current worldwide energy needs by more than eightfold.
Pro-Pipe, with the ERA’s support, plans to be the first to market with a 300°C solution.