Method and system for forming a non-circular borehole

Abstract: System and methods for creating shaped, non-circular boreholes in rocks especially for use with geothermal heat pump applications and for increasing wellbore support in applications such as horizontal oil and gas drilling are described. The systems and methods when applied to geothermal heat pumps create an elliptical shaped hole that is optimized for placing heat transfer tubes with a minimum of grout used. The significantly reduced cross-sectional area of the elliptical borehole also increases the overall drilling rate in rock and especially in hard rocks. In horizontal hard-rock drilling, creation of a horizontal non-circular borehole or modification of a circular borehole to a non-circular geometry is used to stabilize the borehole prior to casing insertion, and may also allow the use of lower mud pressures improving drilling rates. The system uses a non-contacting drilling system which in one embodiment uses a supersonic flame jet drilling system with a movable nozzle that swings between pivot points. In a second embodiment the elliptical shaped hole is created by an abrasive fluid or particle bearing-fluid or air jet drill that moves between pivot points. In another embodiment a non-contacting drill can use dual parallel nutating nozzles that create a pair of overlapping circular holes. The non-circular shaped hole is created by either the high temperature flame or water-particle jet or chemically active fluid jet as it removes rock material by erosion, dissolution and or thermal spalling. Modifications of circular boreholes to a generally elliptical shape can also be done using milling or jetting techniques. (end of abstract)