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At least 19 records

RePED 250: A Revolutionary, High Drilling Rate, High-T Geothermal Drilling System and Companion Power Electronics (Final Report)

Geothermal drilling in the United States is drastically slower and more costly than Oil and Gas drilling, primarily due to the additional challenges in geothermal wells: hard rock types and high temperatures. The Repetitive Pulsed Electric Drill (250 degrees C) (RePED-250), developed by Tetra Corporation has the potential to change this with a novel electro-crushing technology. RePED-250 releases pulses of electricity through the rock, which causes it to break in tension, instead of compression like conventional rotary drilling. The tensile strength of hard rocks like granite is only ~5% of their compressive strength, requiring less energy, time, and wear on the bit than conventional drilling. The RePED drill bit has no moving parts, uses drilling mud to remove rock fragments, and standard drill pipe, enabling a direct transition from conventional drilling systems. The objective of this project is to move RePED technology towards commercial readiness for high-temperature geothermal applications. This involves: 1) Creating high-temperature, high power electronic components for the RePED drill capable of operating at the high temperatures of a geothermal well. The target is a 250 degrees C ambient environment. Specifically, capacitors, high voltage switches, and a downhole generator capable of generating the necessary power. 2) Demonstrating RePED's effectiveness drilling through hard rock (granite) and examining its pathway to commercialization and effect on the US geothermal market. Work on this project has led to significant improvement over the state-of-the-art for all the examined electronics, through design, modeling, and testing of these novel components, though some additional development is still needed to deploy these high-temperature parts in a geothermal well. Besides their use in RePED-250, each component has applications in other industries where the stability of electronics at high-temperature is needed. To address the second barrier to commercialization, a 9" hole was drilled through a sample block of granite, demonstrating the tool's effectiveness in hard rock. The team investigated RePED-250's effect on well cost, and the geothermal industry, through various models described in the report.

15 GEOTHERMAL ENERGY↗

RePED 250: A Revolutionary, High Drilling Rate, High-T Geothermal Drilling System and Companion Power Electronics

Geothermal drilling in the United States is drastically slower and more costly than Oil and Gas (O&G) drilling, primarily due to the additional challenges in geothermal wells: hard rock types and high temperatures. The Repetitive Pulsed Electric Drill (250°C) (RePED-250), developed by Tetra Corporation has the potential to change this with a novel electro-crushing technology. RePED-250 releases pulses of electricity through the rock, which causes it to break in tension, instead of compression like conventional rotary drilling. The tensile strength of hard rocks like granite is only ~5% of their compressive strength, requiring less energy, time, and wear on the bit compared to conventional drilling. The RePED drill bit has no moving parts, uses drilling mud to remove rock fragments, and uses standard drill pipe, enabling a direct transition from conventional drilling systems. The objective of this project is to move RePED technology towards commercial readiness for high-temperature geothermal applications. This involves: 1) Creating high-temperature, high power electronic components for the RePED drill capable of operating at the high temperatures of a geothermal well. The target is a 250°C ambient environment. Specifically, capacitors, high voltage switches, and a downhole generator capable of generating the necessary power. 2) Demonstrating RePED’s effectiveness drilling through hard rock (granite) and examining its pathway to commercialization and effect on the US geothermal market. Work on this project has led to significant improvement over the state-of-the-art for all the examined electronics, through design, modeling, and testing of these novel components, though some additional development is still needed to deploy these high-temperature parts in a geothermal well. Besides their use in RePED-250, each component has applications in other industries where the stability of electronics at high-temperature is needed. To address the second barrier to commercialization, a 9” hole was drilled through a sample block of granite, demonstrating the tool’s effectiveness in hard rock. The team investigated RePED-250’s effect on well cost and the geothermal industry, through various techno-economic models described in the report.

15 GEOTHERMAL ENERGY↗

Toward Drilling the Perfect Geothermal Well: An International Research Coordination Network for Geothermal Drilling Optimization Supported by Deep Machine Learning and Cloud Based Data Aggregation

The EDGE project, supported by the U.S. Department of Energy Geothermal Technologies Office under award DE-EE0008793, established a data-driven framework for improving the efficiency, cost-effectiveness, and reliability of geothermal well drilling. The project focused on developing scalable data infrastructure, advanced machine learning and probabilistic models, and integrated analytics tools to support continuous drilling optimization. A central objective was to reduce geothermal drilling costs by up to seventy percent while minimizing the risk of well failure through predictive diagnostics and adaptive planning. Over the project period, a comprehensive data repository was designed and deployed, incorporating records from over one hundred geothermal wells across varied geological settings. This repository supported both structured and unstructured data and adhered to FAIR data principles, enabling provenance tracking, quality control, and standardized metadata. The project introduced automated ingestion pipelines and a cloud-hosted platform that facilitated access to raw, processed, and derived datasets. This infrastructure served as the foundation for model development and analysis. Machine learning workflows were developed to predict key drilling metrics including rate of penetration, non-productive time, and total drilling costs. Self-organizing maps and dimensionality reduction methods were used to uncover operational patterns and outliers, while supervised learning algorithms such as random forests and deep neural networks were applied to forecast performance outcomes. The models were validated on heterogeneous datasets from both U.S. and Icelandic fields, demonstrating variable but significant predictive accuracy. The results indicated that finer temporal resolution, inclusion of lithological data, and consistency in operational annotations could substantially improve model performance. The project also implemented process mining techniques to reconstruct state-transition models from drilling event logs. These models enabled the identification of deviations from optimal workflows and provided insights into recurring failure modes. Analysis of non-productive time highlighted the impact of equipment failures, geological challenges, and human factors, offering opportunities for targeted mitigation strategies. The EDGE Dashboard was developed as a web-based expert system integrating data visualization, model outputs, and user-driven queries. It provided an accessible interface for operators to explore historical data, evaluate predicted outcomes, and compare drilling scenarios. Initial feedback from project partners suggested that the dashboard could serve as a foundation for more advanced advisory and optimization tools. Overall, the EDGE project demonstrated the feasibility and value of applying modern data science techniques to geothermal drilling. It delivered a set of interoperable tools and models that can support more efficient, lower-risk well development. The findings point toward a viable path for transitioning from advisory analytics to semi-autonomous drilling systems, contingent on continued collaboration, expanded datasets, and field validation. The project results have immediate relevance for drilling operations, data management practices, and future geothermal R&D efforts aimed at achieving reliable, cost-competitive geothermal energy at scale.

15 GEOTHERMAL ENERGY↗

RePED 250: A Revolutionary, High-Drilling Rate, High-T Geothermal Drilling System and Companion Power Electronics

Project partner, Tetra has demonstrated developed an electro-crushing technology, a repetitive, pulsed electric drill (RePED), capable of crushing hard rock in tension and at high speeds. In this project, NREL, TPL, and Tetra are upgrading the RePED drilling system for operation in 250 degree C environments, and demonstrating its effectiveness drilling hard rock. The RePED drilling system is being designed to function with most of the elements of a conventional drilling system (e.g., drill pipe, steering tools, measurement-while-drilling (MWD) systems, mud systems), so no specialized rigs or drill pipe are required.

geothermal↗

Downhole Sensing and Event-Driven Sensor Fusion for Depth-of-Cut Based Autonomous Fault Response and Drilling Optimization

Achieving robust and efficient drilling is a critical part of reducing the cost of geothermal energy exploration and extraction. Drilling performance is often evaluated using one or more of three key metrics: depth of cut (DOC), rate of penetration (ROP), and mechanical specific energy (MSE). All three of these quantities are related to each other. DOC refers to the depth a bit penetrates into rock during drilling. This is an important quantity for estimating bit behavior. ROP is the simply the DOC multiplied by the rotational rate, and represents how quickly the drill bit is advancing through the ground. ROP is often the parameter used for drilling control and optimization. Finally, MSE provides insight into drilling efficiency and rock type. MSE calculations rely on ROP, drilling force, and drilling torque. Surface-based sensors at the top of the drill are often used to measure all these quantities. However, top-hole measurements can deviate substantially from the behavior at the bit due to lag, vibrations, and friction. Therefore, relying only on top-hole information can lead to suboptimal drilling control. In this work, we describe recent progress towards estimating ROP, DOC, and MSE using down-hole sensing. We assume down-hole measurements of torque, weight-on-bit (WOB). Our hypothesis is that these measurements can provide more rapid and accurate measures of drilling performance. We show how a multi-layer perceptron (MLP) machine learning algorithm can provide rapid and accurate performance when evaluated on experimental data taken from Sandia’s Hard Rock Drilling Facility. In addition, we implement our algorithms on an embedded system intended to emulate a bottom-hole-assembly for sensing and estimation. Our experimental results show that DOC can be estimated accurately and in real-time. These estimates when combined with measurements for rotary speed, torque, and force can provide improved estimates for ROP and MSE. These results have the potential to enable better drilling assessment, improved control, and extended component lifetimes.

15 GEOTHERMAL ENERGY↗

Evaluation of Drilling Performance at The Geysers with Machine Learning Methods Using Geologic Data

A recent well, GDC-36, was drilled in The Geysers Geothermal Field served in a Department of Energy-industry to demonstrate improved drilling performance with polycrystalline diamond compact (PDC) bits. Both PDC and roller cone drill bits were used to drill this well. Key challenges encountered during drilling included lost circulation in the mud-drilled section, and bit damage interfacial severity in the deeper, air-drilled section. The objective of this study is to evaluate the drilling performance in relation to the local geological characteristics using machine learning methods. By applying K-clustering to the sonic log data, we were able to identify areas correlated with measured lost circulation. Also, the boundaries defined by clustering of the mineralogical and lithological data from the mud logs correlate well with interfacial severity during drilling. A random forest model was employed to build correlation between drilling data and rock strength. The confined compressive strength (CCS) of the rock in the training of the machine learning model was inferred from the dipole sonic log. The R-squared of the testing data is 0.78, and the RMSE (Root Mean Squared Error) is 0.06. The trained model was used to forecast rock strength for the section where sonic log data are not available. CCS could also be inferred from mud logs provided the relationship between mineralogy and rock strength is established through core testing data.

15 GEOTHERMAL ENERGY↗

Utah FORGE: Well 16B(78)-32 Drilling Data

This drilling data for Utah FORGE well 16B(78)-32 include a well survey, core summary, mud and mud temperature logs, daily reports of the drilling process, and additional data from the Pason oil and gas company. Well 16B(78)-32 serves as the production well for reservoir creation, fluid circulation, and demonstration of heat extraction for the FORGE project. It has been drilled as a doublet approximately 300 feet parallel to and above the injection well 16A(78)-32. The proposed total depth was 10,658 feet, which was exceeded. Spudding began on April 26th, 2023. As of June 20th, 2023, the total depth measured 10,947 feet and the vertical depth measured 8,357 feet. Drilling included the trial use of insulated drill pipe (IDP) from Eavor Technologies, which was considered a success. IDP restricts counter-current heat transfer between drilling fluid inside the drill string and hotter returning fluid in the annulus, thereby ensuring the bottomhole assembly (BHA) remains submerged in cool fluid. Eavor rented 350 joints of IDP to FORGE which were run in two consecutive BHAs at the well. The results of this trial are included here.

15 GEOTHERMAL ENERGY↗

Evaluation of Physics-Based Limiter Redesign Drilling and Alternative Bit Design at The Geysers

As part of a U.S. DOE Geothermal Technologies Office funding opportunity, Geysers Power Company, LLC, an indirect subsidiary of Calpine Corporation, partnered with Sandia National Labs, EGI at the University of Utah, and Texas A&M University to demonstrate increased drilling performance at The Geysers Geothermal Field. The performance target in the drilling demonstrations is at least a 25% improvement in rates of penetration with increased time on bottom for each bit. The project will leverage advances in oil and gas drilling technologies including PDC bits, along with the physics-based limiter redesign techniques championed in drilling demonstrations conducted at the Utah FORGE geothermal site. The planned drilling demonstrations are being conducted as part of an existing drilling campaign intended to enhance reservoir utilization. The wells are typically drilled to the top of the reservoir with mud and then air-drilled to total depth (TD) through fractured zones at temperatures ≥ 450°F. A major goal of the project is to assess the effectiveness of implementing mechanical specific energy (MSE) and drilling dysfunction diagnosis and remediation in these challenging environments, as well as alternate bit technologies. The first demonstration well has been completed, with a total of 15 PDC bit runs in the 17.5”, 12.25” and 8.5” sections. Initial analysis shows ROP gains in all three hole sections, especially in the 17.5” and 12.25” sections, compared with conventional roller cone bit runs in the demonstration well and offset wells. However in the 8.5” hole, wear and damage to the PDC bits resulted in relatively short bit runs. Analysis is underway to take advantage of the positive results and remediate the challenges.

15 GEOTHERMAL ENERGY↗

Use of Rig Parameter Data in Bit Constraint Models for Improved Drilling Performance at The Geysers

Surface parameter measurements are routinely used during deep well construction to monitor and guide drilling conditions for improved performance and reduced costs. However, these measurements are of reduced value without a standard to aid in evaluation and decision making. A method is demonstrated whereby drill bit constraint models are used to interpret drilling response parameters. Drill rig parameter data for well GDC-36 at the Geysers Geothermal Field Power were acquired by Geysers Power Company and drilling contractor Kenai Drilling using Pason US DataHub and evaluated. Drilling parameters are evaluated using laboratory-validated rock reduction models for predicting the phenomenological response of drag bits (Detournay and Defourny, 1992) along with other model constraints in computational algorithms. The method is used to evaluate overall bit performance, monitor bit integrity, and detect the presence of drillstring vibrations and other conditions contributing to bit failure; comparisons are made to observations of bit wear and damage. The method will be applied in real-time to improve decision-making on subsequent wells and has applicability to development of advanced analytics on future geothermal wells using real-time electronic drilling recorder (EDR) data for improved performance and reduced drilling costs.

15 GEOTHERMAL ENERGY↗

Analysis of Rig Parameter Data Using Drilling Process Modeling Constraints, Volume 5: Utah FORGE Well 16B(78)-32

Drill rig parameter measurements are routinely used during deep well construction to monitor and guide drilling conditions for improved performance and reduced costs. While insightful into the drilling process, these measurements are of reduced value without a standard to aid in data evaluation and decision making. In the main body of this work (Volume 1), a method is demonstrated whereby rock reduction model constraints are used to interpret drilling response parameters; the method could be applied in real-time to improve decision-making in the field and to further discern technology performance during post-drilling evaluations. Drilling parameters are evaluated using laboratory-validated rock reduction models for predicting the phenomenological response of drag bits (Detournay and Defourny, 1992) in computational algorithms. The method presented has applicability to development of advanced analytics on future geothermal wells using real-time electronic data recording for improved performance and reduced drilling costs. A drilling cost model is also used to show the tradeoff between rate of penetration and bit life and the influence on interval drilling costs. Details of the bit specifications and performance are cataloged in an independent volume, documented under separate cover, for each of the four wells, and include Volume 2: Utah FORGE 16A(78)-32; Volume 3: Utah FORGE 56-32; Volume 4: Utah FORGE 78B-32 and Volume 5: Utah FORGE 16B(78)-32.

15 GEOTHERMAL ENERGY↗

Analysis of Rig Parameter Data Using Drilling Process Modeling Constraints, Volume 4: Utah FORGE Well 78B-32

Drill rig parameter measurements are routinely used during deep well construction to monitor and guide drilling conditions for improved performance and reduced costs. While insightful into the drilling process, these measurements are of reduced value without a standard to aid in data evaluation and decision making. In the main body of this work (Volume 1), a method is demonstrated whereby rock reduction model constraints are used to interpret drilling response parameters; the method could be applied in real-time to improve decision-making in the field and to further discern technology performance during post-drilling evaluations. Drilling parameters are evaluated using laboratory-validated rock reduction models for predicting the phenomenological response of drag bits (Detournay and Defourny, 1992) in computational algorithms. The method presented has applicability to development of advanced analytics on future geothermal wells using real-time electronic data recording for improved performance and reduced drilling costs. A drilling cost model is also used to show the tradeoff between rate of penetration and bit life and the influence on interval drilling costs. Details of the bit specifications and performance are cataloged in an independent volume, documented under separate cover, for each of the four wells, and include Volume 2: Utah FORGE 16A(78)-32; Volume 3: Utah FORGE 56-32; Volume 4: Utah FORGE 78B-32 and Volume 5: Utah FORGE 16B(78)-32.

15 GEOTHERMAL ENERGY↗

Analysis of Rig Parameter Data Using Drilling Process Modeling Constraints, Volume 3: Utah FORGE Well 56-32

Drill rig parameter measurements are routinely used during deep well construction to monitor and guide drilling conditions for improved performance and reduced costs. While insightful into the drilling process, these measurements are of reduced value without a standard to aid in data evaluation and decision making. In the main body of this work (Volume 1), a method is demonstrated whereby rock reduction model constraints are used to interpret drilling response parameters; the method could be applied in real-time to improve decision-making in the field and to further discern technology performance during post-drilling evaluations. Drilling parameters are evaluated using laboratory-validated rock reduction models for predicting the phenomenological response of drag bits (Detournay and Defourny, 1992) in computational algorithms. The method presented has applicability to development of advanced analytics on future geothermal wells using real-time electronic data recording for improved performance and reduced drilling costs. A drilling cost model is also used to show the tradeoff between rate of penetration and bit life and the influence on interval drilling costs. Details of the bit specifications and performance are cataloged in an independent volume, documented under separate cover, for each of the four wells, and include Volume 2: Utah FORGE 16A(78)-32; Volume 3: Utah FORGE 56-32; Volume 4: Utah FORGE 78B-32 and Volume 5: Utah FORGE 16B(78)-32.

15 GEOTHERMAL ENERGY↗

Analysis of Rig Parameter Data Using Drilling Process Modeling Constraints, Volume 1: Summary of Utah FORGE Wells 16A(78)-32, 56-32, 78B-32 and 16B(78)-32

Drill rig parameter measurements are routinely used during deep well construction to monitor and guide drilling conditions for improved performance and reduced costs. While insightful into the drilling process, these measurements are of reduced value without a standard to aid in data evaluation and decision making. In the main body of this work (Volume 1), a method is demonstrated whereby rock reduction model constraints are used to interpret drilling response parameters; the method could be applied in real-time to improve decision-making in the field and to further discern technology performance during post-drilling evaluations. Drilling parameters are evaluated using laboratory-validated rock reduction models for predicting the phenomenological response of drag bits (Detournay and Defourny, 1992) in computational algorithms. The method presented has applicability to development of advanced analytics on future geothermal wells using real-time electronic data recording for improved performance and reduced drilling costs. A drilling cost model is also used to show the tradeoff between rate of penetration and bit life and the influence on interval drilling costs. Details of the bit specifications and performance are cataloged in an independent volume, documented under separate cover, for each of the four wells, and include Volume 2: Utah FORGE 16A(78)-32; Volume 3: Utah FORGE 56-32; Volume 4: Utah FORGE 78B-32 and Volume 5: Utah FORGE 16B(78)-32.

15 GEOTHERMAL ENERGY↗

lllinois Storage Corridor CarbonSAFE Phase III: Pre-drilling Site Assessment: Prairie State Generating Company

The Illinois Storage Corridor project will drill a stratigraphic test well as part of the Illinois Storage Corridor CarbonSAFE Phase 3 project near the Prairie State Generating Company coal-fired power plant near Marissa, Illinois. The pre-drilling site evaluation has considered the primary target reservoirs, the Potosi Dolomite and St. Peter Sandstone, and primary seal, the Maquoketa Group. Data to be collected from the well include core, fluid samples, in situ well tests, geophysical logs intended to provide information on lithologic, geomechanical, and geophysical characteristics to determine the feasibility for the geologic sequestration of 50 million metric tons or more of injected carbon dioxide. The planned drilling site has been evaluated using available subsurface geologic data and analyses from the Illinois Basin. These data provide lithologic and structural information, shallow groundwater resource distribution, location of known nearby wellbores, and regional drilling characteristics. The data were used to generate geologic structure and isopach maps for the target reservoir and caprock strata and for prognosing the tops of major lithologic units to aid drilling and coring procedures. The regional analyses indicate that no known structural features are expected to negatively impact the target storage reservoir or caprock. No protected and sensitive areas, groundwater resources, or existing resource development are expected to be impacted by the proposed well drilling activities. The well is planned to be drilled to a total depth of approximately 5,600 feet (1,707 m) and terminate in the Precambrian. Cores (up to 5 intervals) will be collected from the Maquoketa Group, confining units above the St. Peter Sandstone, St. Peter Sandstone, confining units of the Potosi Dolomite and the Potosi Dolomite. Water samples will be attempted to be collected from the St. Peter Sandstone and Potosi Dolomite. Potential impact on drilling progress is a lost circulation zone in the Potosi Dolomite, which has been demonstrated to have intermittent cavernous porosity from karstification elsewhere in the Illinois Basin. This document also presents a preliminary coring and sampling program, proposed logging suite, and well testing program, all of which will be reviewed during drilling.

01 COAL, LIGNITE, AND PEAT↗

Downhole to surface communications platform for drilling applications

A drilling assembly for downhole to surface communications is provided. The drilling assembly includes a series of pipe segments coupled in fluid communication between a slip ring assembly and an end pipe portion. The slip ring assembly is coupled in data and fluid communication with the pipe segments. A surface communications link is in data communication with the drilling assembly via the slip ring assembly. An end pipe portion is coupled with the drilling assembly that includes an electronics assembly with electronic components for transferring data to the slip ring assembly via the drilling assembly. A drill bit is operably coupled with the end pipe portion for drilling a borehole. Each pipe segment includes an outer conductor portion, a hollow inner conductor portion, and a dielectric portion for electrical isolation between the outer conductor portion and the inner conductor portion.

Su, Jiann-Cherng↗

2025 Geothermal Drilling Cost Curves Update: Preprint

Drilling activities account for 30% to 57% of the cost to develop and install a geothermal plant. Therefore, an accurate representation of the cost to drill a well is paramount in techno-economic analysis to determine the feasibility of a geothermal power project. In 2022, the National Renewable Energy Laboratory (NREL) endeavored to revise the U.S. Department of Energy (DOE) GeoVision baseline drilling cost curves due to extensive improvement in drilling rates at the Utah Frontier Observatory Research in Geothermal Energy (FORGE) demonstration site. That effort did not culminate in the recommendation of new curves because the actual project costs did not match the reported performance improvements and were at or above the GeoVision baseline. The need for another iteration of this analysis has arisen from industry record drilling performance reported by recent commercial field-scale and demonstration projects, including Fervo Energy’s Cape Station, the Utah FORGE 16B(78)-32 demonstration and the Geysers Power Company’s GDC-36 demonstration. Therefore, in this work, we have estimated the resulting industry average rate of penetration (ROP) and bit life and applied these parameters as inputs to the Well Cost Simplified model used in the GeoVision analysis. The resulting revised cost curves show a significant decline from the GeoVision baseline. For vertical wells, the magnitude of cost decline ranges between 12% and 24% while for deviated wells, cost reductions between 18% and 26% are estimated. The revised cost curves are in good agreement with actual cost data and therefore, quantify the economic impact of the utilization of (and advances in) polycrystalline diamond compact (PDC) bit technology and the application of physics-based methodologies that optimize mechanical specific energy.

15 GEOTHERMAL ENERGY↗

Characterization of Oil and Gas Drill Cuttings for Critical Mineral Recovery and Reuse Potential as Soil Supplements

Expansion of unconventional oil and natural gas production over the last decade in the United States has resulted in record production of natural gas and oil in 2024. Millions of tons of drill cuttings generated from shale gas development are currently disposed of in landfills. Converting these cuttings into value product(s) such as critical minerals (CMs) and soil supplements, has the potential of reducing environmental impact of fossil fuel exploration. In this study we characterize the CM distribution and extractability from collected drill cuttings and core samples from major U.S. shale formations. A four-step sequential extraction, consisting of a sonicated soap step, sonicated EDTA step , mildly reducing agent, and a oxidizing agent, was developed to simultaneously extract CMs and convert the drill cuttings into soil supplements. Viability of converted drill cuttings as soil supplement was determined with a seedling growth experiment. Results show high concentrations of vanadium (V) (up to 1575 ppm, barite (up to 5 wt. %), and rare earth elements (REE) concentrations (up to 253 ppm). High extractability of selected critical minerals such as REE (19-50%) and Ba (10-58%) show promising results. Preliminary results show seedling growth in a mixture of converted drill cuttings with soil. These results show the potential for recovery of CMs from drill cuttings as an alternative domestic and the reduction of the environmental impact of fossil fuel production.

Barczok, Maximilian↗