As the OptiDrill project approaches its conclusion, we are excited to launch the project ending ‘Beneath the Surface’ blog series, where consortium partners share their perspectives, challenges, learnings, and insights based on their roles in the project.

In this inaugural installment, we shed spotlight on Geolorn Limited and their contributions. We had the pleasure of speaking with Kevin J Mallin, Managing Director of Geolorn Limited, who shared valuable insights into the project. Kevin reflected on the company’s role, the challenges encountered, and the impact of their efforts in advancing geothermal drilling processes through this transformative initiative.

The OptiDrill project represents a bold step forward in geothermal drilling, integrating AI and sensor technologies to optimise operations and reduce risks. At its core, this project brings together industry leaders and experts to push the boundaries of drilling technology.
Geolorn Limited, a key partner in this endeavour, has leveraged its extensive experience in drilling and exploration to contribute to the project’s commercial viability. Their practical approach bridges research outcomes with real-world applications, ensuring OptiDrill’s innovations are ready for industry adoption.

OptiDrill D&C: Considering your role in commercialisation, what kind of market research or feedback have you received regarding OptiDrill’s technologies? Do you feel the market is ready to adopt such innovations in geothermal drilling?
Kevin J Mallin: Geolorn is widely involved with multiple drilling projects, from relatively shallow wells (~200m) to very deep ones (>5,000m), all of which come with varying drilling-associated risks. Operators and contractors are constantly on the lookout for technologies that can reduce costs, either by cutting drilling time or minimising inefficiencies when geological conditions deviate from pre-drill predictions.
The OptiDrill system’s ability to provide real-time analysis of downhole conditions and predict lithological changes has generated significant interest. Operators particularly value its potential for seamless integration with existing rig systems, such as MWD (Measurement While Drilling) and LWD (Logging While Drilling). Both shallow and deep drilling markets are ready to adopt innovations that improve their bottom line, and if the OptiDrill system works as promised, they will certainly use it.

OptiDrill D&C: Looking back, how would you describe the overall progress your team made on OptiDrill? Were there phases where you achieved key breakthroughs or moments when progress stalled?
Kevin J Mallin: Like any research and innovation project, OptiDrill has had its fair share of setbacks and breakthroughs. Engaging with customers and stakeholders about the project has been a long-running process; we also had delays towards the project that made the engagement a bit challenging.
On the technical side, the topside data gathering and analysis system has shown promise. However, integrating this with deep-hole testing and downhole sensor strings remains a challenge. The environment in such tests will differ significantly from the I-BOGS tests and limited field trials conducted in Bochum. While a plan is in place to address these challenges even after the project ends.

OptiDrill D&C: What specific methodologies or approaches did your team find most effective for completing your tasks within the project? Were there any new methods or tools introduced that particularly contributed to your success?
Kevin J Mallin: Our approach has always been to ensure products work effectively in real-world scenarios. Once a system is functional, we can quickly move towards commercialisation. However, it’s essential that the system works fully, not partially.
There were no new methods or tools introduced to aid this process. It all came down to delivering the promised functionality and ensuring it met industry needs.

OptiDrill D&C: Reflecting on your involvement in the project, are there any specific milestones or phases where you saw significant breakthroughs or improvements in your work?
Kevin J Mallin: One of the key achievements has been the development of algorithms capable of predicting lithological changes. Significant progress has also been made in designing sensors that can function in harsh downhole environments. However, conducting deep well field tests to validate these technologies remains an important next step.

OptiDrill D&C: In your role, what specific methods or technologies (e.g., AI, ML, novel sensors) did your team find most effective in driving progress?
Kevin J Mallin: Encouraging people to focus on practical solutions that work in the drilling industry has been crucial. There’s no point in having the best sensors or data analysis if it doesn’t help with the core task of breaking rock to create a well.

OptiDrill D&C: What do you consider to be the most significant achievement or milestone your team reached during the project?
Kevin J Mallin: Transforming legacy data into a format that AI systems can process has been a major milestone. This capability has significantly advanced the project and enhanced its overall impact.

OptiDrill D&C: What were the key challenges in implementing OptiDrill’s technologies in the field? How did you overcome them?
Kevin J Mallin: Implementation challenges remain, and we’re not yet at a stage where the system is field-ready. The main obstacle has been achieving a robust system that drilling companies can trust to deliver results without financial or material risk.

OptiDrill D&C: How do you think the innovations developed within OptiDrill, particularly the AI-driven advisory system, will impact the geothermal industry? What specific benefits or changes do you foresee in drilling operations?
Kevin J Mallin: Geothermal energy is increasingly becoming a cornerstone in the global shift away from greenhouse gas (GHG)-emitting systems, particularly for applications such as space heating, cooling, and baseload electricity generation. However, almost all geothermal systems rely on drilling boreholes—ranging from shallow to highly challenging depths—where risks and uncertainties become more difficult to evaluate. This complexity often creates barriers to investment, despite the significant benefits a successful geothermal system can offer.
Risk assessment in drilling varies widely and is often tied to incomplete knowledge or uncertainty about outcomes. Over time, repeated exposure to similar situations reduces risk levels exponentially. Today, data plays a critical role in assessing and ranking risk profiles. However, even a single negative incident can disrupt these profiles, underscoring the need for comprehensive data collection and analysis to create more reliable risk assessments.
The drilling of wells, whether for geothermal or other purposes, follows this trend. The OptiDrill System addresses these challenges by leveraging the vast volumes of data generated during drilling. By analysing both legacy and real-time drilling data, OptiDrill provides teams with a rapid advisory system that helps reduce downtime, improve efficiency, and prevent hazardous incidents. While accessing such data remains a challenge, OptiDrill’s proactive approach demonstrates the immense potential of data-driven solutions in transforming geothermal drilling operations.

OptiDrill D&C: What technological innovations or breakthroughs, developed through OptiDrill, do you believe will have the most lasting impact on the geothermal drilling industry in the future?
Kevin J Mallin: OptiDrill’s most significant breakthrough is its ability to reduce lost drilling time caused by poor decision-making. This innovation has the potential to save operators both time and resources, addressing a critical pain point in geothermal drilling operations.

OptiDrill D&C: What are the main takeaways or lessons your team has gained from participating in the OptiDrill project?
Kevin J Mallin: One key lesson is understanding how non-drilling technologies, such as AI (artificial intelligence) and ML (machine learning), can be effectively applied to drilling systems. This integration has opened up new possibilities for improving efficiency and decision-making in the field.

OptiDrill D&C: Are there any findings or insights you think would benefit the wider drilling industry?
Kevin J Mallin: The drilling industry is highly adaptable and agnostic to the type of operation. Whether the goal is geothermal or another purpose, operators will drill the well as required. The OptiDrill system’s versatility allows it to be seamlessly integrated into any well operation, provided it can handle the challenges of the downhole environment.

OptiDrill D&C: Beyond geothermal drilling, do you see potential applications for the OptiDrill technologies or methodologies in other areas of energy exploration or drilling operations?
Kevin J Mallin: Absolutely! Geothermal drilling is just one small part of the overall drilling industry. The OptiDrill system can be adapted for any well operation, provided it can handle the downhole environment. Its capabilities, particularly in real-time decision-making and risk reduction, make it valuable for broader energy exploration efforts.

Interviewee Profile: Kevin Mallin

Kevin J Mallin, Managing Director of Geolorn Limited, has over 40 years of experience in resource exploration and drilling across geothermal, mineral, and oil and gas sectors. He has held leadership roles in leading organisations such as Atlas Copco and Ingersoll Rand, as well as founding specialist drilling companies like Bluewater. Kevin has also led international collaborations in deep geothermal developments and is known for his practical, results-driven approach to advancing drilling technologies. Outside of work, Kevin is an accomplished climber and geology enthusiast.

Connect with Kevin: Connect on LinkedIn ; Connect through Email

OptiDrill project is funded by the European Union’s Horizon 2020 Research and Innovation Action under grant agreement No. 101006964