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All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Pathways to cost competitive and viable lithium production from Salton Sea geothermal brines

Lithium supply chains remain heavily concentrated in hard rock and brine resources, creating significant supply risks. Geothermal brines represent an underutilized alternative, yet commercial progress is hindered by the absence of facility-scale cost assessments. Here, we present a techno-economic analysis of large-scale lithium extraction from Salton Sea geothermal brines, drawing on primary company disclosures, process patents, and brine resource modeling. Caused by varying lithium and impurity concentrations, brine dilution over time, and process configurations (e.g., production via carbonation and conversion vs. electrolysis), we find that large-scale production costs may reach ~10,000 United States dollars per ton, but increase up to 22,000 United States dollars per ton with higher certainty of brine modeling, raising concerns about economic competitiveness to conventional low-cost sources. Finally, a project feasibility-focused scenario analyses shows that leveraging brine pre-treatment by-product sales could lower long-term lithium break-even prices by ~5,000 United States dollars per ton, whereas capital cost optimization of 20% could further reduce lithium break-even prices by 10%.

Wesselkaemper, Jannis↗
DOE OSTI2024

The brine of the times

New processes directly extract lithium from dilute sources. The accelerating global push to reduce carbon emissions is driving substantial demand for clean energy technologies and the materials on which they depend. Nations are vying for critical minerals, such as lithium, cobalt, and rare earth elements), to produce electric vehicles, energy storage devices, and other low-carbon technologies. Tremendous attention focuses on lithium, which is primarily sourced from either hard rock called spodumene or natural brines—solutions containing lithium and other salts found in continental deposits, for example. However, mining lithium often involves energy-intensive, laborious processes. On pages 1438 and 1444 of this issue, Li et al. and Song et al., respectively, report efficient ways to extract lithium from dilute brine. In conclusion, these advances open up opportunities for sustainable extraction from unexploited dilute brines.

Darling, Seth B.↗
DOE OSTI2022

EGS Collab Experiment 2: Continuous Broadband Seismic Waveform Data

Two broadband seismometers were installed on the 4100 level and recorded for the duration of EGS Collab Experiment #2. Inspired by published data from similar instruments installed in the Aspo Hard Rock Lab, these long-period instruments aimed to measure the tilting of the drift in response to the injection of fluid into the testbed. One instrument was installed underneath the wellheads in Site A (aka the "battery" alcove) and the other was installed along the east wall of the drift, south of Site B. Due to the feet of gravel (ballast) laid along the floor of the drift, we were unable to anchor the sensors directly to the rock. As a result, the coupling of the sensors to the experiment rock volume is likely poor. In addition, there are a number of noise sources that complicate the interpretation of the data. For example, sensor BBB is installed adjacent (within 3 ft) to the rail line that runs towards the Ross shaft. Trains (motors) run along this line almost daily and produce a large signal in these data. Careful extraction of periods of interest, as well as filtering for specific signals, is necessary. The sensors are Nanometrics Trillium Compact Posthole seismometers, sensitive down to 120 seconds period. They were installed as close to the drift wall and as deep as we could manually excavate (only about 1 ft or so). The holes were leveled with sand and the sensors were placed on a paver before backfilling with sand. The hole was then covered by a bucket filled with insulation to improve the sensor's isolation from daily temperature variations, which are minor but present due to drift ventilation from the surface. Data were recorded on Nanometrics Centaur digitizers at 100 Hz. The full response information is available in the StationXML file provided here, or by querying the sensors through the IRIS DMC (see links below). These instruments were provided free of charge through the IRIS PASSCAL instrument center. The network code is XP and the station codes are BBA and BBB. The waveform data can be queried through the IRIS FDSN server using any method the user likes. One convenient option is to use the Obspy python package: https://docs.obspy.org/packages/obspy.clients.fdsn.html

15 GEOTHERMAL ENERGY↗
DOE OSTI2023

Utah FORGE: Reports on Northwestern Nevada Well Doublet Drilling and Testing by Fervo Energy

These reports review Fervo Energy's construction of a commercial enhanced geothermal system (EGS). Fervo has qualified full functionality of the system through production testing at commercially relevant operating conditions. The project site is located in a nearfield setting adjacent to an operating geothermal power station in north-central Nevada and is designed to deliver an uplift in high-temperature geothermal flow rates to increase the power capacity at the facility. The project involved drilling a first-of-a-kind EGS horizontal doublet well system consisting of an injection and production well pair within a high-temperature hard-rock geothermal formation. The lithology of the target reservoir is characterized as a mixed metasedimentary and igneous formation, comprised of phyllite, quartzite, diorite, and granodiorite, representative of the geology across the most prospective geothermal areas throughout the western US. This work included a 16-stage plug-and-perforate stimulation treatment which was the first of its kind in a high-temperature mixed metasedimentary and granitic formation in a fully horizontal doublet geothermal well.

15 GEOTHERMAL ENERGY↗
DOE OSTI2021

Exploring the Effects of Emplacement Conditions on Explosion P/S Ratios across Local to Regional Distances

High-frequency (~> 2 Hz) seismic P/S amplitude ratios are well-established as a discriminant to distinguish between natural earthquakes and underground explosions at regional distances (~200–1500 km). As research shifts toward identifying lower-yield events, work has begun to investigate the potential of this discriminant for use at local distances (<200 km), in which initial results raise questions about its effectiveness. Here, we utilize data from several chemical explosion experiment series at the Nevada National Security Site in southern Nevada in the United States to study explosion Pg/Lg ratios across the range of local to regional distances. Additionall, the experiments are conducted over differing emplacement conditions, with contrasting geologies and a variety of yields and depths of burial, including surface explosions. We first establish the similarities of Pg/Lg ratios from chemical explosions to those from historic nuclear tests and conclude that, as previous data have suggested, chemical explosion ratios are good proxies for nuclear tests. We then examine Pg/Lg ratios from the new experiment series as functions of distance, yield, depth of burial, and scaled depth of burial (SDOB). At far-local and regional distances, we observe consistently higher ratios from hard-rock explosions compared to ones in a weaker dry alluvium medium, consistent with prior regional distance results. No other trends with yield, depth of burial, or SDOB are strongly evident. Scatter in the observed ratios is very high, particularly at the shortest event-to-station distances, suggesting that small-scale path effects play a significant role. On average, the local distance explosion Pg/Lg ratios show remarkable consistency across all the variations in emplacement. Explosion source models will need to reproduce these results.

58 GEOSCIENCES↗
DOE OSTI2022

Auto Indexer for Percussive Hammers Final Report

Geothermal energy has been underutilized in the U.S., primarily due to the high cost of drilling in the harsh environments encountered during the development of geothermal resources. Drilling depths can approach 5,000 m with temperatures reaching 170 C. In situ geothermal fluids are up to ten times more saline than seawater and highly corrosive, and hard rock formations often exceed 240 MPa compressive strength. This combination of extreme conditions pushes the limits of most conventional drilling equipment. Furthermore, enhanced geothermal systems are expected to reach depths of 10,000 m and temperatures more than 300 °C. To address these drilling challenges, Sandia developed a proof-of-concept tool called the auto indexer under an annual operating plan task funded by the Geothermal Technologies Program (GTP) of the U.S. Department of Energy Geothermal Technologies Office. The auto indexer is a relatively simple, elastomer-free motor that was shown previously to be compatible with pneumatic hammers in bench-top testing. Pneumatic hammers can improve penetration rates and potentially reduce drilling costs when deployed in appropriate conditions. The current effort, also funded by DOE GTP, increased the technology readiness level of the auto indexer, producing a scaled prototype for drilling larger diameter boreholes using pneumatic hammers. The results presented herein include design details, modeling and simulation results, and testing results, as well as background on percussive hammers and downhole rotation.

15 GEOTHERMAL ENERGY↗
DOE OSTI2022

Real-Time Drilling Optimization System for Improved Overall Rate of Penetration and Reduced Cost Per Foot in Geothermal Drilling

The key to success in geothermal drilling is economic feasibility, and a major cost in the development of geothermal resources is the actual drilling of the wells. In this project, a real-time drilling optimization system for geothermal drilling was developed. The system couples three individual components while drilling. The first component is a drill stem vibration analysis model, the second is Mechanical Specific Energy (MSE) analyses, and the third is a detailed PDC Rate of Penetration (ROP) drill bit model for optimum RPM and WOB combinations. The benefit of the coupled system is that the range of WOB and RPM could be selected to avoid drill stem vibrations. Secondly, MSE is used as an efficiency measure and the detailed PDC drill bit model ensures the drill bit does not endure temperatures that exceed the temperature at which the PDC cutters experience accelerated wear. The new detailed PDC bit model is based on rock/bit interaction that physically tracks the PDC cutter wear flats as the bit drills ahead giving the capability to calculate the temperature being generated underneath the worn cutters to better advise on operational parameters to avoid accelerated cutter wear and failure and to ensure that operational parameters are applied so that overall ROP is maximized. By combining the drill stem vibrations and the detailed PDC bit cutter wear and “safe” non-accelerated cutter wear temperature and optimum ranges of operating parameters, it results in higher ROP and lower cost drilling. Single cutter PDC testing performed in different lithologies at Sandia was utilized to verify the PDC cutter forces and depth of cut for new and worn cutters. Based on single cutter PDC temperature modeling, verification using single cutter data from the testing done by National Oilwell Varco (NOV) was performed. Sandia’s Hard-Rock Drilling Facility (HRDF) was utilized to test different drill bit configurations with different cutter designs and wear status with different induced modes of vibration to obtain the critical bit RPM/WOB ranges resulting in ineffective drilling and low ROP. The collected test data were further used to verify and calibrate the full hole PDC ROP model that was developed based on single cutter interaction data. A full coupled drill stem vibration model was formulated and verified with geothermal field data from the Chocolate Mountain Aerial Gunnery Range (CMAGR). A graphical user interface (GUI) was developed using Tkinter library in the computer programming language Python, which integrates all the developed models in one system. The developed system consists mainly of the PDC ROP model, PDC bit wear model, PDC cutter temperature model, Mechanical Specific Energy (MSE) model, and drillstring vibration model integrated into one system. The developed system can be used for both, post well analysis and real-time optimization using different criteria such as ROP maximization or MSE minimization. The software uses Differential Evolution Algorithm (DEA) to find optimum values for operational parameters based on last foot drilled while avoiding the drillstring vibration and cutter temperature critical operating parameters.

15 GEOTHERMAL ENERGY↗
DOE OSTI2023

Local-Scale Framework for Techno-Economic Analysis of Subsurface Hydrogen Storage

The energy sector is evolving toward increased reliance on renewable energy technologies to meet state, national, and organization decarbonization goals. This trend is creating challenges and opportunities with meeting current and future energy demand under the variable supply conditions that most renewables provide. Hydrogen (H 2 ) is a promising energy carrier that may meet the need for both on-demand and long-duration storage to maintain energy security and resilience. Underground hydrogen storage (UHS) is a method of storing H 2 in subsurface geological systems, such as depleted hydrocarbon reservoirs, salt caverns, saline aquifers, hard rock, and other engineered systems. UHS has the potential to store large quantities of H 2 over time, providing a reliable source of energy while minimizing surface footprints at a lower investment cost compared to surface storage. Earlier work estimated that, if converted and retrofitted, existing underground natural gas storage (UGS) facilities in the U.S. can store approximately 327 TWh, or 9.8 million metric tons, of pure H 2 . However, a shift to pure H 2 would decrease the collective working-gas energy of the UGS facilities by approximately 75% due to physical and chemical differences between natural gas and hydrogen. The same work also suggests that almost 75% of the existing UGS facilities in the U.S. could maintain current energy demand buffering using a blend of only 20% H 2 to 80% natural gas, by volume at surface conditions. If we can take advantage of the suite of mature technologies of existing UGS facilities and natural gas utility systems to accelerate the transition to a hydrogen economy in the U.S., a 20% H 2 blend could lead to a 6-7% reduction of greenhouse gas emissions for energy delivered through natural gas utility systems.

03 NATURAL GAS↗
DOE OSTI2024

RePED 250: Manufacturing and Market Analysis of High-Temperature Alternators

The novel repetitive pulsed electric drill 250 (RePED 250) has the potential to greatly lower the costs and drilling times of geothermal projects. This tool discharges electric pulses through hard rock formations, shattering the rock in tension and allowing it to be quickly removed. One hurdle in bringing this technology to market is the RePED 250 downhole alternator. This component is essential for supplying power to the electronic drilling tool. There are currently no downhole tools on the market that meet the RePED 250 alternator's high temperature and power requirements. This report focuses on the path to commercialization for this novel alternator technology being developed as part of the RePED 250 project. One aim of this work is to identify the geothermal market size for the RePED 250 alternator, as well as other potential markets for this technology outside of geothermal. The geothermal market is very small, with only approximately 13 wells drilled in the United States each year. The worldwide market is several times this size and growing each year. The ability of the RePED 250 technology to drastically reduce the cost of geothermal projects may also lead to an increase in this market size. Technology developed for the high-temperature, high-power RePED 250 alternator can also be used to create high-temperature and high-power motors. These motors and alternators will have potential applications in oil and gas drilling, a $300 billion dollar industry in the United States alone, as well as in more distant industries such as aircraft, weapon systems, space exploration, and electric vehicles. Other aspects of the RePED 250 alternator's path to commercialization are also analyzed, including the supply chain for production materials and potential manufacturing methods. The supply chain and manufacturing practices for low-temperature motors and alternators are well established and require relatively minor changes for the high-temperature and high-power RePED 250 alternator. Sourcing for high-temperature materials has been identified, as well as potential supply chain risks. These most notably include electrical steel and high-temperature samarium cobalt (SmCo) magnets. Overall, these risks are not expected to be significant at the likely manufacturing scale required for the RePED 250.

15 GEOTHERMAL ENERGY↗
DOE OSTI2023

Sandia and Ditch Witch Technology Commercialization Fund Integral Motor and Percussive Hammer

This report captures the results of development and testing of a integral downhole motor and percussive hammer used for drilling in near-surface hard rock formations. The work was funded through the DOE Office of Technology Transitions Technology Commercialization Fund. It was a collaboration between Sandia National Labs and The Charles Machine Works (aka Ditch Witch). In the collaboration, Sandia developed a pneumatic motor derived from an indexing tool used in other drilling applications, and Ditch Witch developed the bearing pack tied to the output shaft of the motor as well as the angled beacon housing used for directional control.

15 GEOTHERMAL ENERGY↗
DOE OSTI2024

Aspects of Spodumene Lithium Extraction Techniques

Lithium (Li), a leading cathode material in rechargeable Li-ion batteries, is vital to modern energy storage technology, establishing it as one of the most impactful and strategical elements. Given the surge in the electric car market, it is crucial to improve lithium recovery from its rich mineral deposits using the most effective extraction technique. In recent years, both industry and academia have shown significant interest in Li recovery from various Li-bearing minerals. Of these, only extraction from spodumene has established a reliable industrial production of Li salts. The current approaches for cracking of the naturally occurring, stable α-spodumene structure into a more open structure—β-spodumene—involve the so-called decrepitation process that takes place at extreme temperatures of ~1100 °C. This conversion is necessary, as β-spodumene is more susceptible to chemical attacks facilitating Li extraction. In the last several decades, many techniques have been demonstrated and patented to process hard-rock mineral spodumene. The objective of this review is to present a thorough analysis of significant findings and the enhancement of process flowsheets over time that can be useful for both research endeavors and industrial process improvements. The review focuses on the following techniques: acid methods, alkali methods, carbonate roasting/autoclaving methods, sulfuric acid roasting/autoclaving methods, chlorinating methods, and mechanochemical activation. Recently, microwaves (MWs), as an energy source, have been employed to transform α-spodumene into β-spodumene. Considering its energy-efficient and short-duration aspects, the review discusses the interaction mechanism of MWs with solids, MW-assisted decrepitation, and Li extraction efficiencies. Finally, the merits and/or disadvantages, challenges, and prospects of the processes are summarized.

25 ENERGY STORAGE↗
NASA NTRS1969

Sampling.

Bulk, selective particulate and hard rock samplers for landed extraterrestrial geological and biological instruments performing on-site analysis

Hotz, G. M.↗
NASA NTRS1971

Lunar-Surface Closeup Stereoscopic Photography on the Sea of Tranquility (Apollo 11 Landing Site)

Analysis of returned lunar samples provides limited information about lunar geology. To obtain information about in-place lunar material, a closeup stereoscopic camera capable of photographing small-scale surface features was built and was used at the Apollo 11 landing site. Stereoscopic photographs were taken of surface areas relative to the lunar module, and the surfaces photographed were analyzed. The photographs are classified into five groups: soil disturbed by astronaut activities, generally undisturbed soil, loose aggregate surface material, crater bottoms with prominent glass deposits, and hard rock deposits. Glass deposits in the returned samples are described for comparison with the features observed in the photographs. The stereoscopic photographs were of outstanding quality and show the nature of lunar-surface material in detail. Lunar topography was reconstructed from the photographs with an analytical plotter. The photography results indicate that the closeup composition and genesis of lunar soil at the Apollo 11 landing site.

Greenwood, W. R.↗
NASA NTRS1974

Biodetection grinder

Grinder, which employs shearing action with minimum energy input, obtains desired particle sizes in materials ranging from soft plastics to hard rocks. Modified version of this grinder might be used in hospitals and biological laboratories involved with bacteriological research and testing.

Beyerle, F. J.↗
NASA NTRS1973

Biodetection grinder

A biodetection grinder for sampling aerospace materials for microorganisms without killing them was constructed. The device employs a shearing action to generate controllable sized particles with a minimum of energy input. Tests were conducted on materials ranging from soft plastics to hard rocks.

Beyerle, F. J.↗
NASA NTRS1978

A design for a 1984 Mars rover

A Mars rover is planned for the mid-1980's as a follow-up to the Viking program, and as a prelude to a return-to-earth mission of Martian samples in the late eighties or early nineties. An overall view of the rover's configuration is presented with a summary of basic design parameters. Six subsystems are outlined: computing, with a 10 to the 8th bit bubble memory; mobility, designed for a journey of 100 km in 2 earth years; science sample acquisition, including a soil auger and hard rock drill; power, supplied by an RTG and stored in batteries; telecommunication, with 50 K bit UHF transmission relayed through an orbiter; and visual imaging, employing two television cameras, each with an 800 x 800 pixel charge coupled device. Scientific research goals include information about Martian seismic characteristics, magnetic field, surface heat flow, chemical composition, geology along a transverse, and meteorology. Attention is given to the necessity of rover autonomy from earth commands.

Dobrotin, B. M.↗
NASA NTRS1987

Concept for Underground Disposal of Nuclear Waste

Packaged waste placed in empty oil-shale mines. Concept for disposal of nuclear waste economically synergistic with earlier proposal concerning backfilling of oil-shale mines. New disposal concept superior to earlier schemes for disposal in hard-rock and salt mines because less uncertainty about ability of oil-shale mine to contain waste safely for millenium.

Bowyer, J. M.↗
NASA NTRS1993

Fractal dimensions of rampart impact craters on Mars

Ejecta blanket morphologies of Martian rampart craters may yield important clues to the atmospheric densities during impact, and the nature of target materials (e.g., hard rock, fine-grained sediments, presence of volatiles). In general, the morphologies of such craters suggest emplacement by a fluidized, ground hugging flow instead of ballistic emplacement by dry ejecta. We have quantitatively characterized the shape of the margins of the ejecta blankets of 15 rampart craters using fractal geometry. Our preliminary results suggest that the craters are fractals and are self-similar over scales of approximately 0.1 km to 30 km. Fractal dimensions (a measure of the extent to which a line fills a plane) range from 1.06 to 1.31. No correlations of fractal dimension with target type, elevation, or crater size were observed, though the data base is small. The range in fractal dimension and lack of correlation may be due to a complex interplay of target properties (grain size, volatile content), atmospheric pressure, and crater size. The mere fact that the ejecta margins are fractals, however, indicates that viscosity and yield strength of the ejecta were at least as low as those of basalts, because silicic lava flows are not generally fractals.

Ching, Delwyn↗