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Warm ice at temperatures close to the pressure melting point is often encountered in deep ice-core drilling. The heat generated by rotary cutting can melt ice chips, which seriously threatens the safety of drilling if the chips refreeze on the drill bit or barrel. Lowering the cutting heat is an effective method to reduce the melting of ice chips. In this study, a general theoretical model was established based on heat transfer theory and the cutting mechanism to calculate and analyze the cutter temperature during the circulation of the drilling fluid. The model was validated by a series of experiments, which demonstrated reasonable agreement between the calculated data and experimental results, with a maximum error of <16%. The factors that contribute to the rise in the cutter temperature during warm ice drilling were investigated. Results suggest that the drilling fluid has excellent cooling performance, and its type and flow rate have minimal impact on the cutter temperature. To mitigate the cutter temperature rise, maximizing the rake angle and thermal conductivity of the cutter, while minimizing the rotation speed of the drill bit, cutting depth, cutter width and friction coefficient between the ice and cutter is recommended.

A new type of ice core drill bit, designed with a vane swirler, was developed for ice core drilling with air reverse circulation. An orthogonal experimental design method was employed to investigate the effects of the swirler structure parameters on the reverse circulation performance of the drill bit including helical angle, number of blades, blade length and blade central angle, etc. The entrainment ratio was used to evaluate the reverse circulation effectiveness of the drill bit. The results show that the helical angle is the dominant factor regardless of whether or not the flushing nozzles are part of the design of the drill bit. The number of blades is the least important factor for the drill bit designed with the flushing nozzles (referred to as drill bit I ), while the outlet area of the swirling slot is the least influential factor for the drill bit without flushing nozzles (referred to as drill bit П ). In addition, the appearance of the ice core has a certain effect on the air reverse circulation for both drill bits. Within the ranges of this study, the optimal structure of the drill bit was determined based on the range analysis of the orthogonal design.

Using an anti-icing coating to prevent ice accretion on the drill surface is a feasible solution to address the drilling difficulties in warm ice. In this study, four types of commercially available hydrophobic coating materials were tested to evaluate their water repellency and anti-icing properties, namely, a mixture of silica and fluorocarbon resin with polytrifluoroethylene, modified Teflon, silica-based emulsion and an acrylic-based copolymer. Their water contact angles are ~107°, 101°, 114° and 95°, respectively. All these hydrophobic coatings can significantly reduce the strength of the ice adhesion within a temperature range of −10 to −30°C on a planar or curved surface. The coating of an acrylic-based copolymer, in particular, can reduce the average tensile strength and the shear strength of the ice adhesion by 87.08 and 97.11% on planar surfaces at −30°C, and by 98.06 and 96.15% on a curved surface, respectively. The main challenge in the practical application of these coatings is their durability. An acrylic-based copolymer coating will lose its water repellency performance after 140 cycles of abrasion. The shear strength of ice adhered on curved surfaces coated with this material will approach that achieved on uncoated surfaces after 11 cycles of icing and de-icing tests.

A new, modified version of the cable-suspended Ice and Bedrock Electromechanical Drill (IBED) was designed for drilling in firn, ice, debris-rich ice and rock. The upper part of the drill is almost the same for all drill variants and comprises four sections: cable termination, a slip-ring section, an antitorque system and an electronic pressure chamber. The lower part of the IBED comprises an auger core barrel, reamers, a core barrel for ice/debris-ice drilling and a conventional geological single-tube core barrel or custom-made double-tube core barrel. First, the short and full-scale field versions of the IBED were tested at an outdoor testing stand and a testing facility with a 12.5 m-deep ice well. Then, in the 2018–2019 summer season, the IBED was tested in the field at a site ~12 km south of Zhongshan Station, East Antarctica, and a ~6 cm bedrock core was recovered from a 198 m-deep borehole. A total of 18 d was required to penetrate the ice sheet. The retrieved core samples of blue ice, basal ice and bedrock provided valuable information regarding the Earth's paleo-environment.

Drilling to the bedrock of ice sheets and glaciers offers unique opportunities for examining the processes occurring in the bed. Basal and subglacial materials contain important paleoclimatic and paleoenvironmental records and provide a unique habitat for life; they offer significant information regarding the sediment deformation beneath glaciers and its effects on the subglacial hydraulic system and geology. The newly developed and tested Antarctic subglacial drilling rig (ASDR) is designed to recover ice and bedrock core samples from depths of up to 1400 m. All of the drilling equipment is installed inside a movable, sledge-mounted, temperature-controlled and wind-protected drilling shelter and workshop. To facilitate helicopter unloading of the research vessel, the shelter and workshop can be disassembled, with individual parts weighing <2–3 tons. The entire ASDR system weighs ~55 tons, including transport packaging. The ASDR is designed to be transported to the chosen site via snow vehicles and would be ready for drilling operations within 2–3 d after arrival. The ASDR was tested during the 2018–2019 summer season near Zhongshan Station, East Antarctica. At the test site, 2-week drilling operations resulted in a borehole that reached bedrock at a depth of 198 m.

A reverse circulation Down-The-Hole (DTH) hammer drill bit in Casing-while-Drilling (CwD) processes is designed and applied to drilling under complicated formation. The drill bit is a special retractable drill bit with an exclusive reverse circulation gas channel. Using numerical simulations and experiments, the influence of the gas channel structure parameters of the drill bit, including the inner jet nozzles, flushing nozzles, suction channel, and other parameters, on its reverse circulation performance is analyzed, and the optimal gas channel structure parameters of the drill bit are determined to improve the reverse circulation effect. The results show that the flushing nozzles and inner jet nozzles have an important influence on entrainment performance. The entrainment rate η decreases as the flushing nozzle diameter increases and decreases as the inner jet nozzle diameter increases. An increase in the suction channel diameter can improve the reverse circulation effect of the drill bit. The spiral slot drill bit is more conducive to air being sucked into the central channel in the form of spiral flow, so it can improve the entrainment performance. The entrainment rate η can reach 23.4% with the optimum structured drill bit.

Ice core drilling with air reverse circulation is a promising technology that uses high-speed airflow to transport the ice core from the bottom of the hole along the central passage of the drill pipe to the surface. Understanding how the ice core moves through the pipe is crucial for this technology in order to calculate the pneumatic parameters. In this paper, experimental study and the CFD dynamic mesh technique are used to analyze the ice core transport process and flow field characteristics. In order to prove the correctness of the dynamic mesh technique, the simulation results were verified with the experimental results, and it was found that all the simulation data were in agreement with the experimental data trend, and the maximum error was less than 10%. According to the study, once the ice core’s velocity reaches its maximum throughout the transport process, it does not change. The ice core’s maximum velocity increases with the diameter ratio and decreases with the length-to-diameter ratio, while eccentricity has no impact on the maximum velocity. When the air velocity reaches 21 m/s, the diameter ratio for the ice core with a length-to-diameter ratio of 2 increases from 0.80 to 0.92, and the maximum velocity increases from 8.92 m/s to 17.45 m/s. Data fitting demonstrates that the equation Vmax=−1.04V0 + 1.04Va describes the relationship between the ice core’s maximum velocity, Vmax, and air velocity, Va. Finally, we obtain the ice core’s suspension velocity model using CFD simulation to calculate the suspension velocity, V0.

A swirling drill bit designed with an integrated vane swirler was developed to improve reverse circulation in down-the-hole hammer drilling. Its entrainment effect and influential factors were investigated by CFD simulation and experimental tests. The numerical results exhibit reasonable agreement with the experimental data, with a maximum error of 13.68%. In addition, the structural parameters of the swirler were shown to have an important effect on the reverse circulation performance of the drill bit, including the helical angle and number of spiral blades, swirler outlet area, and the flushing nozzles. The optimal parameters for the swirling drill bit without flushing nozzles include a helical angle of 60°, four spiral blades, and the area ratio of 2, while it is about 30°, 3, and 3 for the drill bit with flushing nozzles. Moreover, the entrainment ratio of the drill bit without flushing nozzles can be improved by nearly two times compared with one with flushing nozzles under the same conditions.

Due to its high mechanical penetration rate and lack of pollution of the environment, air reverse circulation drilling is considered to be a promising method for ice drilling. The air reverse circulation is caused by the combination of the ejector and the flushing nozzles in the drill bit. In this paper, CFD software was used to simulate the influence of the structure of the swirler on the effect of air reverse circulation in the swirling drill bit, and a testing stand was established for the testing of air reverse circulation. The results show that for drill bits without flushing nozzles, the smaller the helical angle is, the larger the entrainment ratio will be, meanwhile the smaller the area ratio is, the larger the entrainment ratio will be. In contrast, for drill bits designed with flushing nozzles, the larger the helical angle is, the larger the entrainment ratio will be, and the larger the area ratio is, the larger the entrainment ratio will be. In addition, the presence of the ice core sharply reduces the effect of air reverse circulation. When the ice core’s height exceeds that of the outlet of the swirler, the reverse circulation effect is slightly improved.

Defoaming is a key technology for increasing the efficiency of foam drilling in petroleum engineering. To enhance the performance of a mechanical foam breaker in foam drilling, a novel aerodynamic foam breaker with two annular slits was investigated in this study. The computational fluid dynamics code of ANSYS Fluent was used to simulate the velocity and pressure distribution inside the foam breaker, and the optimum distance between the two annular slits was determined based on the simulation methods. Meanwhile, a series of experiments were conducted to test the actual performance of the foam breaker. The results demonstrate that various factors may affect the efficiency of the foam breaker, including the foam gas‐liquid ratio, basic liquid viscosity, and air supply method. A higher gas‐liquid ratio of the foam and air supply pressure result in a superior foam breaker performance. The viscosity of the foam liquid phase exhibits exactly the opposite behavior, meaning that the foam breaker more effectively destroys foam from a lower‐viscosity liquid. This study verifies the practicability of this novel aerodynamic foam breaker and discusses the effects of different parameters on the defoaming percentage, and this study can act as a reference and guidance for subsequent defoaming research. A novel aerodynamic foam breaker used for foam drilling is investigated in the present study. The effects of many factors on its performance are analyzed by a series of experiments. It is very effective to destroy foam with higher gas‐liquid ratio and lower liquid viscosity.