DOE awarding $4.4M to advance hydropower manufacturing for “low-head” sites

2 December 2014

The US Department of Energy (DOE) is awarding a total of $4.4 million for two projects to support the use of advanced materials and manufacturing techniques in the development of new “low-head” hydropower technologies. Low-head sites, which operate with a change in elevation between 2 and 20 meters, include waterways at existing non-powered dams, canals, and conduits. According to Energy Department assessments, there is a technical resource potential of more than 50 gigawatts of potential capacity at these low-head sites.

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New, low-cost, integrated hydropower turbine and generator sets made with modern materials and manufacturing technologies will help power providers harness the full generating potential of these existing low-head sites and produce cost-competitive, renewable electricity.

• Eaton Corporation will develop a turbine and generator system that uses lightweight advanced materials and advanced manufacturing techniques such as laser-assisted welding, surface treatments, and processing. The turbine will be designed to deliver a constant source of energy despite changes in water flow by using a system that operates efficiently across a range of ebbs and flows. The Eaton Corporation will design, fabricate, and test its turbine at 1/10^th scale.

• Pennsylvania State University will develop and demonstrate a low-head hydropower turbine and generator system prototype that combines lightweight, corrosion-resistant metallic components that can be produced through an additive manufacturing process. A condition-based monitoring system will also facilitate improved operation and maintenance.

Together, these organizations will combine advanced materials and manufacturing techniques to maximize efficiency and improve the design, performance and durability of innovative hydropower manufacturing capabilities.