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DOE OSTI2024

Wind Turbine Design Optimization for Hydrogen Production

To help meet the need for inexpensive green fuels, we are working on wind turbine design optimization specifically for hydrogen production. We have thus far achieved a 1.53% decrease in LCOH as compared to a turbine optimized for LCOE using the same code, design variables, and models. We accomplished this by optimizing some components of the wind turbine tower, rotor, and drivetrain design with hydrogen production and costs in the design loop.

hydrogen↗

DOE OSTI2024

In-Situ Blade Strain Measurements and Fatigue Analysis of a Cross-Flow Turbine Operating in a Tidal Flow

Cross-flow turbines (CFTs) are inherently unsteady devices with regards to operating principle and loading. By improving our understanding of the dynamic loading on these turbines, we hope to better inform CFT design, improve survivability, and reduce overall costs. The University of New Hampshire (UNH) and the National Renewable Energy Laboratory (NREL) collaborated on a project to instrument and test a four-bladed New Energy Corp. vertical axis cross-flow turbine in a real tidal flow. One blade from the 3.2 m diameter x 1.7 m height turbine was instrumented with eight full-bridge strain gauges along the span of the blade. The turbine was then deployed at the UNH-Atlantic Marine Energy Center (AMEC) Tidal Energy Test Site in Portsmouth, NH. Time-synchronized measurements of blade strain, inflow, thrust, rotational speed, and electrical output were obtained to characterize blade loading under various conditions. The blade strain was examined to assess the dynamic loading and conduct a fatigue analysis on the device.

blade strain↗

DOE OSTI2025

Contextualizing Non-Powered Dam Site Selection for Archimedes Screw Turbines: A Methodology for Responsible Archimedes Screw Turbine Conversion at Existing Dams

Non-powered dams represent 97% of dams in the United States and their energy generation potential has not been fully realized. The use of an Archimedes screw turbine to generate power at non-powered dams offers a dual benefit; producing electricity, and acting as downstream fish passage, helping to reconnect previously separated ecosystems. In this study, we assess the technical, environmental, social, and economic feasibility of generating power at non-powered U.S. dam sites using Archimedes screw turbines by integrating mechanical constraints, social impact metrics, proximity to infrastructure, and environmental sensitivity data. Results account for future precipitation predictions and show, between 2024 and 2050, the number of sites where Archimedes screw turbines are viable decreases by one site, but overall generation capacity increases due to increased flow rates across persisting locations. Our analysis identified 82 non-powered dam sites with a mean generation capacity of 49 kW that meet the mechanical requirements for Archimedes screw turbine technology in 2024. Our analysis presents a framework for considering social, environmental, and economic impacts of specific turbine technologies to convert non-powered dams to generate power.

Archimedes screw turbine↗

DOE OSTI2026

Computational Design to Advance AM Fabrication of High Gamma Prime Alloys for Hot Gas Path Components in Gas Turbine Engines: A Pathway to Enhanced Gas Turbine Efficiency and Energy Saving (Final CRADA Report)

Raising turbine inlet temperature is a key lever for improving industrial gas-turbine efficiency and power output, but it increases thermo-mechanical demands on hot-gas-path components. Additive manufacturing (AM), particularly laser powder bed fusion (L-PBF), enables complex internal cooling features in critical components such as turbine tip shoes that are difficult to produce by conventional casting. However, qualification of new high-temperature AM alloys and aggressive geometries is often limited by trial-and-error iteration of build parameters and post-build heat treatments, with cracking during stress relieving or hot isostatic pressing (HIP) being a recurring failure mode.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

Wind Turbine Materials Recycling Prize Phase 2 (Commercialization of Wind Turbine Blade Waste (WTBW)-Based, Lightweight, Cementitious Composite Materials): Cooperative Research and Development Final Report, CRADA Number CRD-24-31305

The National Laboratory of the Rockies (NLR) and AltiSora, LLC., will develop new lightweight cementitious composite material technologies that will utilize wind turbine blade waste as a raw material to; (1) allow a high value addition (2) at low cost, enabling (3) a significant waste consumption volume; while (4) consuming the entire wind turbine blade, without (5) creating any waste or emissions and to also (6) offer specific benefits to communities involved.

17 WIND ENERGY↗

DOE OSTI2026

An Intermediate-Scale Version of the Volturnus + Floating Offshore Wind Turbine Platform Concept in a Real Ocean Environment with an Operating Turbine off the Coast of Maine (Final Scientific/Technical Report)

This project was undertaken to advance the technical readiness and commercial viability of a next-generation, industrialized concrete floating foundation for offshore wind turbines called VolturnUS +. The design objective is to deliver a platform that is lower cost, faster to manufacture, simpler to deploy, and optimized for domestic supply chains and local workforce participation. To enable project financing and commercial adoption, an at-sea demonstration under representative operating conditions was required and therefore this project aimed to deploy a ¼-scale VolturnUS+ prototype offshore the Coast of Maine.

17 WIND ENERGY↗

DOE OSTI2025

Detailed Design and Cost Estimation of a 300 MWe Oxy-Fuel sCO2 Turbine

The detailed design of a 300 MWe, utility scale oxy-fuel turbine has been completed for purposed operation in the sCO2 direct fired Allam-Fetvedt cycle, targeting near-zero emissions and a 50% LHV system efficiency. The turbine and its supporting plant aim to offer a lower levelized cost of energy than a natural gas combined cycle plant employing carbon capture. The oxy-fuel turbine conditions include an inlet temperature of 1150°C and inlet pressure of 305 bar, representing temperatures near that of a gas turbine simultaneously with pressures near an ultra-supercritical steam turbine. The combustor housing and turbine designs were completed according to the ASME BPVC; the turbine case specifically incorporates a multi-body design with inner high-pressure barrel case and low-pressure (30 bar) horizontally split outer case of low-chromium steel material. Lateral rotordynamic evaluation demonstrated acceptable vibration response for a range of imbalance conditions per API standards. The cooling flow required in the six-stage turbine flowpath for 30,000 hr. blade and stator lifetime is predicted through thermal and structural modeling of the first stage. The provided cost estimate of the turbine is formed through a combination of scaled up-costs from procured 10 MWe scale sCO2 turbomachinery hardware, and vendor provided budgetary quotes of larger components including the turbine case requiring casting, welding, and final machining processes. The performance and cost estimation of the oxy-fuel turbine predicted for the completed detailed design provides important information towards future development needs for market penetration of utility scale direct fired sCO2 power cycles.

Marshall, Michael [Southwest Research Institute, S↗

DOE OSTI2025

The influence of wind veer and drivetrain flexibility on fatigue loading for large floating wind turbines

To reduce costs, offshore wind turbines are expected to be designed with significantly increased rotor diameters. Larger turbines become more flexible and span a larger portion of the atmospheric boundary layer. With these changes, the validity of traditional modeling assumptions should be investigated. This work challenges two common assumptions: (1) that the drivetrain can be considered rigid (except in torsion) and does not couple with the rotor and tower and 2) that wind directional change with height (veer) does not greatly influence the fatigue damage in the tower, blades and drivetrain. Two large semi-submersible floating wind turbines are considered: a 15 and a 22 MW reference turbine. Both use direct-drive generators. Aero-hydro-servo-elastic simulations are performed using OpenFAST, with drivetrain bending flexibility and main bearing response implemented in the coupled analysis. The turbines are subjected to a set of load cases at below-, near- and above-rated mean wind speeds, assembled based on the 3 km Norwegian reanalysis (NORA3) hourly wind and wave hindcast data for Utsira Nord, off the coast of Norway. In each load case, conditions with and without veer are simulated to evaluate the influence of veer on damage equivalent loads (DELs) of the turbine tower, blades and main bearings. Further, these load cases are applied to evaluate the influence of drivetrain flexibility on aero-elastic turbine response. The results indicate that, depending on the veer gradient, mean wind speed, operating regime and turbine size, veer can be very important for tower-top DELs and the fluctuations of main bearing radial loads, while main bearing and blade-root flapwise DELs are less affected. Considering these specific load cases and turbine models, drivetrain flexibility is found to significantly influence tower-top DELs of the largest turbine: the tower-top fore-aft and torsional damage equivalent moments of the 22 MW turbine are reduced by more than 20 % at near-rated wind speeds when the drivetrain is modeled as flexible.

17 WIND ENERGY↗

DOE OSTI2025

Contextualizing Wind Turbine Blade Waste: Comparison to Other Global Waste Streams

Worldwide wind energy generation capacity has grown rapidly over the past several decades, and wind turbines installed at the beginning of this wave of growth are approaching the end of their design lifetimes. As an increasing number of wind power plants reach their end of life, both decommissioning and repowering (i.e., dismantling or refurbishing existing turbines and commissioning new ones) will produce waste material from the retired wind turbines, foundations, and balance of plant. However, the amount and type of waste, particularly for wind blades, is often mischaracterized. Although wind turbine components are largely recyclable, the blades are typically made of fiberglass composites, which can present challenges for material recovery and reuse. Within the USA, the accumulation of wind turbine blades in landfills has raised questions about whether the continued expansion of wind energy is sustainable if it results in substantial future waste. This study compares the mass and volume of potential global wind blade waste to other waste streams. It also discusses the materials used to manufacture wind turbine blades and summarizes current options for material redesign, recycling (recovery and reuse), repurposing, and disposal of used blades. The analysis indicates that, although wind turbine blades could represent 14% of the composite market by 2027, the potential future mass and volume of wind turbine blade waste is relatively small compared to other industries. These findings suggest that although the development of scalable, economically viable, and environmentally sustainable methods for wind turbine manufacturing, repurposing, and recycling is important, it may make sense to take advantage of synergies among multiple industries in recycling composite waste, rather than focusing solely on wind turbine blades. From a global perspective, larger sustainability, recycling, and waste stream reduction impacts can be made in other industries, such as transportation and construction.

17 WIND ENERGY↗

DOE OSTI2026

Observations of marine animal interactions with a small tidal turbine

The risk of collisions between animals and operating tidal turbines remains a concern in the scientific and regulatory communities. A sensor package including optical cameras was deployed to monitor animal interactions with a small-scale (1 m 2 ) cross-flow tidal turbine. The turbine was deployed in Washington State, USA for 141 days at a site with peak flow speeds of 2.5 m/s. We analyze optical camera imagery spanning 109 days of turbine operation. The analyzed images contain 1044 observations of fish, fish schools, seabirds, or seals in the vicinity of the turbine. No instances of collision with seabirds or seals were observed. Seabirds were only observed during daylight hours and while the turbine was stationary. Both seals and fish were observed during both day and night and while the turbine was stationary and rotating. Four fish were observed colliding with the moving turbine and in all but one case the animals swam away following the collision. Over the same period of time, over fifty times more fish (224 individual fish and 5 fish schools) were observed passing the moving turbine without collision. Fish encounters were likely under counted due to the difficulty in discerning small fish from plant matter in the water column. These observations represent the first optical camera imagery showing fish, bird, and marine mammal interactions with a tidal turbine in North America. In addition to quantitative and qualitative discussion of the implications of our observations for collision risk, we discuss lessons learned on sampling schemes and deployment of machine learning for detection of animals to inform future data collection strategies in future monitoring campaigns.

16 TIDAL AND WAVE POWER↗

DOE OSTI2025

Comparison of wind farm control strategies under realistic offshore wind conditions: turbine quantities of interest

Abstract. Wind farm flow control is a strategy to increase the efficiency and therefore lower the levelized cost of energy of a wind farm. This is done using turbine settings such as the yaw angle, blade pitch angles, or generator torque to manipulate the flow behind the turbine, affecting downstream turbines in the farm. Two inherently different wind farm flow control methods have been identified in the literature: wake steering and wake mixing. This paper focuses on comparing the turbine quantities of interest between these methods for a simple two-turbine wind farm setup, while a companion article (Brown et al., 2025) focuses on the wake quantities of interest for a single wind turbine setup. Both papers use the same set of wind farm simulations based on high-fidelity large-eddy simulations (LESs) coupled with OpenFAST turbine models. First, precursor simulations are executed in order to match wind conditions measured with lidars in an offshore wind farm off the east coast of the USA. These measurements show general wind conditions that exhibit substantially higher vertical wind shear and veer than any of the LES studies performed with wind farm flow control strategies currently available in the literature. The precursors are used to evaluate the effectiveness of the control methods. In the LES, the wind veer leads to highly skewed wakes, which have considerable influence on the power uplift of wind farm flow control strategies. In addition to a baseline controller, four different control strategies, each of which uses either pitch or yaw control, are performed on the upstream turbine of a simple two-turbine wind farm. Assuming that the wind direction is known and constant over time, the simulations show that wake steering is generally the superior wind farm flow control strategy, considering both wind farm power production and turbine damage equivalent loads when substantial wind veer is present. This result is consistent over different wind speeds and wind directions. On the other hand, for similar wind conditions with lower veer, wake mixing was found to yield the highest power production, although at the expense of generally higher loads. This leads us to conclude that the effect of wind veer, which has so far not usually been considered, can not be neglected when determining the optimal wind farm flow control strategy.

17 WIND ENERGY↗

DOE OSTI2025

A Multi-Sensor Approach for Measuring Bird and Bat Collisions with Offshore Wind Turbines (Final Technical Report)

Collision of birds and bats with wind turbines is a conservation concern for both land-based and offshore wind projects. The fatality rates of birds and bats at land-based turbines are well documented. The measurement strategies on land focus on finding carcasses following collision, estimating the number of carcasses missed through searcher efficiency, carcass persistence trials and carcass fall distributions, and modeling statistically robust fatality rates. Few technologies have been developed to monitor offshore bird and bat collisions, and many that have been developed focused on detecting collisions with large birds. The few studies that have attempted to document collisions at offshore turbines do not account for smaller bodied animals or for collisions that might be missed, which prevents the calculation of statistically robust fatality rates. The overall goal of this report, A Multi-Sensor Approach for Measuring Bird and Bat Collisions with Offshore Wind Turbines (Project), was to develop an effective multi-sensor system for quantifying bird and bat collision rates, specifically for offshore wind facilities. The Project goal and resulting automated collision detection system was achieved through two major technological advancements: 1) refining The Netherlands Organisation for Applied Scientific Research’s (TNO’s) existing WT-Bird® vibration sensing system, that had successfully detected large bird collisions during daytime, to allow for improved detection of smaller birds and bats during both daytime and nighttime hours and 2) improving image processing systems and developing and integrating machine learning algorithms to automatically detect and classify small and large bird and bat collisions with offshore turbines. This final technical report (FTR) summarizes Methods , Results , Conclusions , and Lessons Learned during each of the five Tasks identified for this research and development effort. This FTR includes summaries of the following: Task 1. Initial Engineering Tests to Improve WT-Bird® Task 2. Installation of WT‐Bird® on a Utility-scale Turbine at the National Wind Technology Center – National Renewable Energy Laboratory Task 3. Field Tests and Refinement of the Object Detection System Task 4. Validation of WT-Bird® on a Land-based Turbine Task 5. Preparation for the Implementation of WT-Bird® on an Offshore Turbine. This research and development effort documented successful improvement of the WT Bird® collision detection system to detect small birds and bats, and WT-Bird® is the first collision detection system to validate results compared to land-based post-construction monitoring. The collision trials provide estimates of missed targets that can be used to estimate fatality rates, a significant improvement relative to other offshore collision monitoring systems. Advances were made in developing an edge-processing solution to reduce data storage requirements, which is important if the system is deployed for long periods of time at offshore turbines. The improved WT-Bird® system also provides an important option for wind operators on land or offshore who need to document specific details about when collisions occur, particularly efforts to further research on bat impact minimization, or when standard fatality searches are impractical (e.g. offshore) or inadequate (e.g. challenging locations on land).

17 WIND ENERGY↗

DOE OSTI2026

Grid and Wind Transient Ride Through Assessment of Type-5 Synchronous Wind Turbine

The integration of the inverter-based renewable energy resources is increasing and replacing conventional synchronous generators in the evolving bulk power system (BPS), impacting the system inertia along the way. Also, the limited over-current capability of power electronic converters continues to deteriorate the grid strength of the evolving power systems. Type-5 wind turbines have the potential to mitigate these problems because this configuration interfaces with the grid through a synchronous generator; hence, its operation and consequent grid impacts might mimic the conventional synchronous generator. The drivetrain of this type of turbines, however, is different from the more common Type-3 and Type-4 turbines. A hydraulic torque converter and gearbox with torque limiting feature are integral parts of a Type-5 wind turbine drivetrain, to isolate the wind speed variations at the wind turbine rotor from the grid connected generator side. This supports the synchronous operation of the generator. However, high fidelity models of Type-5 wind turbine drivetrain including these core components are not openly and widely available for grid integration and transient stability studies. Moreover, Type-5 turbines are not commonly deployed and hence its power generation and frequency stability characteristics are not widely publicized. This hinders appropriate assessment of Type-5 wind power plant's contribution to bulk grid resilience. This work provides transient stability assessment of a standalone Type-5 wind turbine. Normal operation and grid transient studies are performed to see the step load change and wind speed disturbance impacts on the Type-5 drivetrain and generation dispatch. Preliminary results show that Type-5 wind turbines can support load changes of between 0.6 p.u to 1.15 p.u. Beyond this point, the synchronization of the generator starts to deviate from its set point.

17 - WIND ENERGY↗

DOE OSTI2025

Wind Turbine Sound Setbacks and Supply Curves: Ordinances and Extrapolated Trends, 110 Hub Height, 130 Rotor Diameter

This dataset provides a comprehensive set of wind turbine sound setbacks from every residential structure in the contiguous United States (CONUS). A sound setback is defined as the minimum required distance between a residential structure and a hypothetical turbine installation site to ensure that modeled sound levels received at the residence do not exceed local sound ordinances, which are commonly expressed in A-weighted decibels (dBA). Therefore, sound setbacks are a local spatial assessment combining multiple factors, including the sound pressure curve as a function of the observer location (distance and direction) relative to the turbine, local sound regulations, and the geographical distribution of residential structures. The dataset is organized into multiple scenario-based products, detailed as follows: 1. Existing and extrapolated sound setbacks. An existing scenario characterizes sound setbacks only in states or counties that have implemented sound regulations as of 2022. The extrapolated scenarios extend a constant sound threshold to counties that lack explicit sound regulations, with thresholds ranging from 35 to 60 dBA, in 5-dBA increments reflecting the variation observed in current sound ordinances. 2. Sound setbacks in directional and worst scenarios. The directional scenario accounts for the distance and orientation of residential structures relative to a hypothetical turbine location, utilizing the turbine's sound emissions in that specific direction. In contrast, the worst scenario takes loudest sound level at each distance step from the turbine, irrespective of directional considerations, which aligns with current industry practice. 3. Supply curves for Open and Reference Access scenarios. This dataset includes supply curves generated by the reV model, which integrates each of the above sound setbacks into both Open and Reference siting scenarios. In addition, two Open and Reference baselines scenarios were included which do not consider sound setbacks for comparative analysis. All sound setback data are stored in TIF files, with partial maps of the data provided in PNG format. The values in the sound setback raster range from 0 to 1, representing the fraction of developable land within a 90 meter by 90 meter pixel due to sound ordinances. A value of 0 indicates areas where wind energy development is prohibited, while a value of 1 signifies areas fully permissible. The wind turbine parameters used in the sound modeling are based on the land-based turbine from International Energy Agency (IEA), featuring a rated electrical power of 3.4 MW, a rotor diameter of 130 meters, and a hub height of 110 meters. The atmospheric conditions, including wind speed/direction, turbulence, air temperature, relative humidity, and air pressure, that drive the sound generation are obtained from the WIND Toolkit dataset.

Array↗

DOE OSTI2025

Bats flying through a Y-maze are visually attracted to wind turbine surfaces

Wind energy’s rapid expansion has led to unintended consequences for wildlife, with migratory bats among the species most at risk. The behavioural mechanisms underlying collisions remain poorly understood, but one hypothesis is that bats are attracted to wind turbine structures. Vision is important to bat orientation and obstacle avoidance, yet it has been relatively understudied in the context of bat–turbine interactions. We hypothesize that light reflected off turbine surfaces could attract bats, acting as a sensory pollutant that may increase collision risk. To test whether reflective turbine surfaces elicit attraction, we flew 242 Lasiurus cinereus and 154 Lasionycteris noctivagans through Y-maze assays. Bats were at least twice as likely to fly towards white turbine blade sections compared to less reflective black ones. This attraction intensified when the alternative exit was a dark, empty flyway, with 74% of L. cinereus and 97% of L. noctivagans flying towards the white turbine blade. These findings provide evidence that visual sensory pollutants could underlie bat–turbine interactions, and if so, wind turbines could be ecological traps.

17 WIND ENERGY↗

DOE OSTI2025

Aeroelastic Validation of the Sandia Offshore Wind Energy Simulator (OWENS) for Vertical-Axis Wind Turbines

Vertical-axis wind turbines (VAWTs) have been the subject of research and development for nearly a century. However, this turbine architecture has fallen in and out of favor on multiple occasions. Beginning in the late 1970s, the U.S. Department of Energy sponsored an extensive experimental program through Sandia National Laboratories which produced a mass of experimental data from several highly instrumented turbines. Turbines designed, built, and tested include the 2 meter, 5 meter, 17 meter, and 34 meter and their respective configurations. This program kicked off a commercial collaboration and resulted in the FloWind turbines. The FloWind turbines had several notable design changes from the experimental turbines that, in conjunction with a general lack of understanding regarding predicting fatigue at the time, led to the majority of the turbines failing prematurely during the late 80s.

17 WIND ENERGY↗

DOE OSTI2026

Comparison of juvenile white sturgeon blade strike survival through a conventional and a novel hydropower turbine

Hydropower is a globally important renewable energy source with profound impacts on aquatic organisms, including direct injury and mortality to fish that move through hydropower facilities. While it is expected that the characteristics of turbine design and operation influence the type, frequency, and magnitude of injuries suffered by entrained fish, few direct comparisons exist to illustrate differences in fish survival outcomes for conventional and novel turbine designs. This study evaluated blade strike-associated injury and mortality rates for juvenile white sturgeon (Acipenser transmontanus) passed through a model-scale turbine equipped with a runner having conventional blade profiles (thin, straight leading edges) and the same turbine equipped with a runner designed for improved fish survival (thick, slanted leading edges). In both trials, head and turbine runner rotational speeds were matched to produce five blade peripheral speeds between 15.0 and 27.6 m/s. High-speed video was captured for all turbine passage events. Fish were assessed for injuries following passage, and mortalities were assessed immediately after passage and after 48 h. Conventional runner passage resulted in 42% to 78% survival after 48 h, with approximately one-third of all tested fish killed by severing. Under the same test conditions, immediate and 48 h survival rates through the novel runner were 100% except at the highest speed condition (95.6% survival at 48 h). These results clearly indicate that turbine design has a profound effect on fish survival, and suggest that thoughtful redesign of hydropower equipment could significantly ameliorate the risks of blade strike mortality.

13 HYDRO ENERGY↗

DOE OSTI2025

Experimental Validation of a High-Temperature Test Facility for Future Additive Manufactured Supercritical Carbon Dioxide Turbine Testing

For next-generation power plants to achieve high cycle efficiencies consistent with the Department of Energy's 65% efficiency target, turbomachinery capable of operating within high-temperature power cycles must be demonstrated. Pairing additively manufactured superalloy turbines with the supercritical carbon dioxide (sCO 2 ) power cycle could enable turbine inlet temperatures approaching 1300 °C while providing flexibility in turbine cooling strategies. Development of test facilities to characterize and validate such systems is crucial. In this study, a turbine test facility capable of achieving inlet conditions of 800 °C, 11 MPa, and 0.43 kg/s while accommodating complex auxiliary cooling flow requirements has been designed and constructed to support future testing of a Haynes 282 additively manufactured 30 kW turbine-generator system with advanced cooling channels. This facility enables characterization of aerodynamic performance, leakage, and windage losses. Details of the facility's construction and operation are presented, along with experimental validation tests using an orifice as an expansion device in place of the turbine. These tests confirm that the facility can reach the required conditions, distinguish regions of achievable steady and pseudo-steady conditions, and identify the heater power required for each point in the upcoming turbine campaign. The campaign confirmed that ISO 5167-2 can reliably predict orifice mass flow rates in extreme supercritical carbon dioxide conditions with deviations of 0.5–7.5%.

42 ENGINEERING↗