Small Hydro – Poster Presentations

Presentations are:

Hybridizing Non-Powered Dams: Boosting Techno-Economic Viability with Batteries and Solar PV, presented by Soumyadeep Nag, Idaho National Laboratory

An Integrated System Approach to Low-Head Hydro: LFAM Manufacturing, Debris Mitigation, and Field Validation, presented by Randal Mueller, Cadens LLC

Details about each presentation and the speakers are below:

Hybridizing Non-Powered Dams: Boosting Techno-Economic Viability with Batteries and Solar PV
Presented by Soumyadeep Nag, Idaho National Laboratory

Hydropower plays a vital role in U.S. grid resilience, offering flexibility, ancillary services, and black-start capabilities. However, thousands of non-powered dams (NPDs) remain untapped, representing over 4.1 GW of potential capacity. This is mainly because of the low financial viability of the NPD retrofit alone. This study investigates the techno-economic benefits of co-developing NPDs with battery energy storage systems (BESS) and solar photovoltaics (PV) as hybrid power plants, while exploring ways to synergize the characteristics of each resource.

Using a structured framework, this study integrates site selection, system modeling, and economic analysis to assess whether hybridization improves financial viability and operational performance. Modeling tools such as HydroGenerate, HydroHybrids, and HydroBoost were employed to estimate hydropower potential, optimize battery sizing, and optimize dispatch strategies, respectively. Three sites were chosen based on electricity market diversity, hydropower potential, and data availability. The three case studies, Oologah Dam (SPP), Cannonsville Dam (NYISO), and North Fork Dam (CAISO), illustrate the spatio-temporal complementarity of hydropower and solar resources under diverse market conditions. Metrics such as the levelized cost of energy (LCOE), internal rate of return (IRR), payback period, and net present value (NPV) have been used to compare economics across the different sites.

Results indicate that short-duration storage (30 to 60 minutes) offers the most favorable economic returns, while hybrid systems enhance revenue through energy arbitrage and ancillary services. Time-of-use power purchase agreements (PPAs) further improve project economics by leveraging storage flexibility during peak periods. Hybridization also supports grid reliability, reduces renewable curtailment, and promotes sustainable reservoir operations. Despite regulatory and interconnection challenges, co-developing NPDs with BESS and solar PV emerges as a cost-effective pathway to unlock latent hydropower potential, advance decarbonization goals, and strengthen energy resilience in the United States.

An Integrated System Approach to Low-Head Hydro: LFAM Manufacturing, Debris Mitigation, and Field Validation
Presented by Randal Mueller, Cadens LLC

Reducing Economic Barriers with LFAM: Small-capacity hydropower is often sidelined by the high cost of site-specific, custom components. Cadens, in collaboration with Oak Ridge National Laboratory (ORNL), is utilizing Large Format Additive Manufacturing (LFAM) to produce low-volume, fully functional turbine components. This approach shifts the paradigm from expensive traditional casting to cost-effective, flexible customization with rapid-iteration 3D printing. Our work validates the durability of polymer composite materials in high-stress aquatic environments, demonstrated by our testbed in SE Wisconsin, which has operated for over 6 years with zero failures in structural LFAM components (intake adaptor, draft tube).

Solving the "Debris Bottleneck": Debris accumulation is the leading cause of downtime and high O&M costs for small-capacity hydro. Our research focuses on automated debris passage systems integrated directly into the turbine, designed to dislodge organic and inorganic fouling and pass it through the system. This internal passage approach is essential because standard trash racks often fail to stop thin or flexible debris like willow leaves and milfoil. Our current iterative design process focuses on balancing high hydraulic efficiency (targeting a baseline of 85% turbine efficiency at very low head) with the mechanical necessity of self-clearing geometries.

Surface Management and Winter Resilience: To complement internal passage, we utilize bubble curtains (aerators) for debris and intake management. Our experiential testing confirms that bubble curtains are an exceptionally energy-efficient tool for de-icing. By keeping the surface water open at the trash rack during long sub-zero stretches, even in back-to-back negative temperatures, we maintain consistent flow and prevent ice-bridging more effectively than mechanical de-icers. We have successfully addressed field challenges like pneumatic line freezing using targeted heat-tape applications, ensuring 24/7 reliability in extreme winter conditions. We are currently evaluating optimal curtain placement and angles to maintain effectiveness as flow rates increase.

Advanced Manufacturing and Performance Validation: Our technology is grounded in real-world endurance; our testbed in SE Wisconsin has operated for over 6 years with zero failures in structural LFAM components. While we leverage LFAM for large conveyance components like intake adapters and draft tubes, our latest collaboration with ORNL focuses on high-precision manufacturing for the power-dense components. As a dedicated testbed facility, we utilize generator-coupled systems and active load-bank regulation to validate these methods under continuous load. This data serves as a critical foundation for optimizing the trade-offs between mechanical resilience and hydraulic efficiency in small-capacity systems.

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