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Field evaluation of remote wind sensing technologies: Shore-based and buoy mounted LIDAR systems

In developing a national energy strategy, the United States has a number of objectives, including increasing economic growth, improving environmental quality, and enhancing national energy security. Wind power contributes to these objectives through the deployment of clean, affordable and reliable domestic energy. To achieve U.S. wind generation objectives, the Wind and Water Power Program within the Department of Energy’s (DOE) Office of Energy Efficiency and Renewable Energy (EERE) instituted the U.S. Offshore Wind: Removing Market Barriers Program in FY 2011. Accurate and comprehensive information on offshore wind resource characteristics across a range of spatial and temporal scales is one market barrier that needs to be addressed through advanced research in remote sensing technologies. There is a pressing need for reliable offshore wind-speed measurements to assess the availability of the potential wind energy resource in terms of power production and to identify any frequently occurring spatial variability in the offshore wind resource that may impact the operational reliability and lifetime of wind turbines and their components and to provide a verification program to validate the “bankability” of the output of these alternative technologies for use by finance institutions for the financing of offshore wind farm construction. The application of emerging remote sensing technologies is viewed as a means to cost-effectively meet the data needs of the offshore wind industry. In particular, scanning and buoy mounted LIDAR have been proposed as a means to obtain accurate offshore wind data at multiple locations without the high cost and regulatory hurdles associated with the construction of offshore meteorological towers. However; before these remote sensing technologies can be accepted the validity of the measured data must be evaluated to ensure their accuracy. The proposed research will establish a unique coastal ocean test-bed in the Mid-Atlantic for the evaluation of LIDAR-based wind measurement systems to validate the accuracy of remotely measured wind data in marine applications. Specifically, the test-bed will be utilized to systematically evaluate the capability of emerging scanning LIDAR and buoy mounted vertically profiling LIDAR by: (1) Evaluating a fixed scanning LIDAR against land-based 50 and 60 meter high meteorological masts fitted with research quality cup-vane and/or sonic anemometers; (2) Evaluating a buoy mounted vertically profiling LIDAR fixed on land and floating in a sheltered bay against a co-located 60 meter high meteorological mast fitted with a research quality cup-vane and/or sonic anemometers and the fixed scanning LIDAR; and (3) Offshore field evaluation of both LIDAR platforms through a comparison of the fixed scanning LIDAR data and data obtained by the buoy mounted LIDAR located 10 miles offshore. The proposed research will systematically validate Light Detection and Ranging (LIDAR) based wind measurement systems and assess the temporal and spatial variability of the offshore wind resource in the Mid-Atlantic east of New Jersey. The goal of the proposed project is to address the technical and commercial challenges of the offshore wind energy industry by validating and assessing cost-effective, over ocean wind resource characterization technologies. The objective is to systematically evaluate the capability of both scanning and vertically profiling LIDARs to accurately measure 3D wind fields through comparison with fixed met masts and intercomparison among LIDAR platforms. Once validated, data collected by both buoy mounted vertically profiling LIDARs and shore-based, pulsed horizontally scanning LIDARs can be used to accurately assess offshore wind resources and to quantify the spatial and temporal variability in the offshore wind fields. One of the fundamental research questions to be addressed in phase 1 is the assessment of various measurement and data processing schemes to retrieve accurate wind vectors in the marine environment over large sampling ranges (10 to 12 km) and varying atmospheric aerosol levels. Atmospheric conditions and aerosol content within the coastal ocean region of the Mid-Atlantic seaboard of the US can vary significantly over short time periods in response to frontal passages and extratropical and tropical low pressure system passage offshore of the coast. Since aerosols provide the scattering medium for the determination of LIDAR Doppler shifts in the atmosphere the accuracy and range of LIDAR derived velocity measurements as a function of variation in aerosol content in the marine environment is a key research question to be addressed. In phase 1, it is desired to capture as much variation in atmospheric conditions and aerosol content as possible. To this end, collocated measurements of LIDAR and standard anemometer wind fields will be captured by the project PIs over all four seasons and during specific events (e.g., coastal low pressure system passage) in year 1. Additionally, since the meteorological masts are permanent structures, additional events can be captured over the three year duration of the field research project. All research instruments are owned by Fishermen’s Energy and made available to the PIs though a lease agreement as part of the DOE grant. Energy Fishermen’s Energy will be responsible for the operation and maintenance of the scanning LIDAR and met mast anemometers. On a daily basis, environmental data and systems performance indicators will be transmitted from each measurement station to the Fishermen’s project team consisting of both in-house personnel and equipment manufacturer engineers. Data sets include compiled LIDAR files as well as data sets from ancillary sensors. Diagnostic parameters to be monitored include standard deviations of measured values, battery levels and charging systems output, and the operational status. Once data have been confirmed as complete and reliable, files will be transferred to the Garrad Hassan (a subcontractor to Fishermen’s Energy) for incorporation in to the validation database, which is accessible to other scientific team members. Data collection times and durations will be determined by the PI and Co-PIs in consultation with instrument engineers to ensure the capture of data representative of the expected range of mid-Atlantic atmospheric conditions (e.g., temperature, moisture, coastal low pressure systems, tropical systems, rain, snow, fog). The collection and processing of the data is a function of site specific measurement requirements (Kelley et.al. 2007; Hannon et.al. 2008). To determine the optimal profiles of wind speed and direction from the LIDAR radial velocities as a function of azimuth angle, rigorous estimates of the bias and random error of each radial velocity estimate are required. Lockheed Martin Coherent Technologies, Inc., under contract with Fishermen’s Energy, will provide analyses of raw and processed data using various scan patterns to determine optimal performance settings for the pulsed scanning LIDAR. Once optimized, appropriate processing and analyses techniques will be evaluated by Garrad Hassan for use in validating the accuracy of the LIDAR wind field measurements against the standard anemometer measurements from the meteorological masts. The most attractive capability of the scanning LIDAR is the ability to provide high spatial resolution observations in a three-dimensional volume which provides superior statistical accuracy due to the large number of samples obtained. Each radial scan provides measurements in 100 range gates over a distance of 10 to 12 km at an update rate of 5 to 10 Hz and rotation of 2.5° per second. Each rotation at a fixed azimuth requires 2.4 minutes. Depending on the number of azimuths desired a complete scan can take up to 10 minutes or longer to complete. Once collected the radial velocities are processed to produce vector wind velocity estimates based on a set of data distributed in angle and range around points of interest, typically a standard grid within the radial wind map. To calculate wind vectors over a limited spatial area of interest for the comparison of data with other measurement platforms a localized least-squares approach has been applied by Hannon et.al. (2008) and a Variation Assimilation (VAR) processing technique has been applied by Chan and al Assimilation (VAR) processing technique has been applied by Chan and Shao (2006). Additionally, Kelley et.al. (2007) applied a “stare” technique that fixed a scanning LIDAR in both azimuth and elevation angles to measure over collocated sampling volumes of the LIDAR and a 3D sonic anemometer mounted to a fixed mast. Although the stare technique is limited to wind directions aligned with the sampling radial of the LIDAR, it does provide a direct comparison of sampling volumes. Each of the processing techniques described above (and possibly others) will be evaluated to determine the validity of the LIDAR derived wind fields in the marine environment. Numerical methods such as linear regression and comparison of probability density functions of wind fields measured by each instrument platform will be used to assess the processing techniques. Linear regression has the advantage of directly evaluating corresponding pairs of wind data measured by each instrument and can lend insight into deviations and bias between instruments as a function of wind speed. Assessment of the coherency between the probability density function of the wind measured by each instrument provides insight into processes that may not be accurately resolved by each instrument at specific frequencies. Once processed and assessed the most appropriate technique will be utilized to provide valid wind measurements from the pulsed scanning LIDAR. A detailed analysis of the measurement data from the LIDAR and the three meteorological towers and comparison of the coastal wind characteristics from the different systems will be performed by the CO_PI at NREL. This analysis will evaluate how the WT LIDAR performance and measurement of the wind characteristics vary with distance from the LIDAR and by atmospheric conditions; using the tower measurements at different distances (4.8, 9.6, and 19 km) from the LIDAR as a reference. The comparative analysis will include, to the extent possible, evaluation of parameters such as wind speed and direction distributions, wind shear, turbulence intensity and their variations by atmospheric conditions, month or season, and time of day.

17 WIND ENERGY↗

Field Validation of Thermoelectric Generation System at Holcim Cement Plant in Alpena, Michigan

Executive Summary Project Background The Industrial Technology Validation (ITV) program aims to identify and demonstrate the performance of new, emerging, and underutilized energy-saving technologies in the industrial sector to help inform decisions to help accelerate their commercialization and deployment, as well as to help make industries more competitive. This ITV demonstration evaluated a thermoelectric generation (TEG) technology at a cement plant, aiming to reduce energy demand in the cement industry. A median cement plant consumes 5.73 million British thermal units per ton of clinker production (resulting in 0.838 metric tons of carbon dioxide [CO₂] emissions per ton of clinker) (Boyd and Zhang 2011, EPA 2021), equivalent to approximately 6.9 trillion British thermal units (TBtu) per year in energy consumption at a cement plant producing 3,300 tons of clinker per day.¹ Collaborating with Holcim, Advanced Thermovoltaic Systems (ATS) developed and deployed a pilot-scale thermoelectric power system to efficiently capture and convert waste heat to electricity. The system leverages the Seebeck effect to convert temperature differences on two sides of semiconductor cartridges into electrical power (ScienceDirect, n.d.). This generation is realized with minimal moving parts compared to existing waste-heat-to-generation solutions and allows capture from heat sources with temperatures as low as 150°C. This project aimed to validate a scalable solution applicable for capturing medium-temperature waste heat, including ambient losses from other high-temperature processes, and high-temperature sources less suitable for other waste-heat-to-power solutions. By recovering this otherwise wasted heat, this project intends to validate improvements to overall process efficiency through reduction in purchased electricity, thereby reducing operational costs while enhancing resiliency and competitiveness. Description and Scope This study evaluated the performance of a TEG system from ATS as a solution to convert waste heat into useful power at a Holcim cement plant in Alpena, Michigan. This plant is a fully integrated cement plant that has been operating since 1907. The facility operates continuously (24/7/365) with approximately 250 employees and five long dry kilns, yielding a total production capacity of 7,852 tons of cement per day (EPA 2023). Currently, the Alpena plant uses waste heat boilers to convert waste heat from the exhaust of each kiln into steam, which drives steam turbine generators. The ATS TEG is being evaluated for its potential to supplement the steam turbines by capturing the remaining lower grade heat. This technology is also being considered for other Holcim plants where steam turbines are not a viable option. ATS installed a pilot-scale TEG unit with an array of 582 individual thermoelectric semiconductor cartridges, of which 573 were operational. The cartridges are sandwiched between 48 hot plates and 49 cold plates. Each cartridge is designed to generate 20 watts (W) of gross power at a hot-side temperature of 240°C and cold-side temperature of 20°C. As such, the total gross generation capacity of the installed system is 11.5 kilowatts (kW) at design conditions. The system configuration for the evaluation was designed to prioritize convenience of installation and minimize disruption to production at the site, while ensuring that the heat required can be obtained for evaluating the TEG system at various operational conditions. To accomplish this, a portion of the steam supplied to Alpena’s steam turbine generation system was diverted to be used as the heat source for the TEG system, while water was supplied to the cold side of the system from nearby Lake Huron. This configuration was designed for the evaluation of the pilot-scale system to assess the performance at different conditions. A commercial-scale system will likely vary from the pilot system depending on typical configurations, including both scale and application. Future commercial applications of the ATS system would involve integrating the system into the exhaust from kiln preheaters, clinker coolers, or radiant heat capture from kiln shells for the heat source. For the cold source, a range of cooling solutions can be considered, including a mechanical cooling system, depending on the location and the application. To increase the generation capacity for commercial applications, the technology provider is working toward developing a commercial-scale TEG system, which would combine multiple TEG units (each similar in design to the pilot system) together. The scope of this evaluation includes the pilot-scale TEG system and all impacted equipment including pumps, controllers, and power handling equipment. Study Objectives The evaluation's goal was to assess the potential of the ATS TEG system to generate useful electrical power by capturing waste heat from cement production kilns. The objectives of this study are to evaluate and verify the following claims made by ATS regarding the pilot-scale system installed at the Holcim Alpena plant. The following design parameters and claims are also outlined in Table ES- 1 and Table ES- 2: • Gross Power: The thermoelectric system converts heat into power to create gross power, the total measured power generated by the system. The 573 active cartridge pilot-scale system is expected to generate 11.5 kW of gross power at the designed hot-side temperature of 240°C and cold-side temperature of 20°C. Power production is dependent on the temperature difference between the heat source (ultimately from the waste heat) and cold temperature supply source. • Net Power: The net power is the total usable power provided to the site by the TEG system after deducting parasitic power loads from the gross generated power. Supplementary equipment is required to operate the TEG system including pumps, controllers, and, in certain anticipated applications, mechanical cooling, which introduce parasitic loads to system operation. After deducting the parasitic loads from the gross power generation, ATS anticipates achieving a net power generation of 7.5 kW from the pilot-scale system. • Thermal Efficiency: The thermal efficiency is the percent of the total heat transferred to the TEG system that is converted to gross power. Historically, TEGs have a thermal efficiency of 2%–5% (DOE 2008). Prior industrial-scale TEG systems, such as the E1 TEG offered by Alphabet Energy, operated at an efficiency of 2.5% (Lamonica, 2014). ATS anticipates achieving an average efficiency of 4.8% or higher in converting heat energy to usable electricity. • Cartridge Performance: The TEG system comprises 573 active individual semiconductor cartridges, each of which generates a portion of the total power. Cartridge optimization and selection is an important design consideration for potential future TEG system design performance. Therefore, understanding the distribution of gross power and efficiency within the pilot system is vital to understanding what is achievable. At a design hot-side temperature of 240°C and cold-side temperature of 20°C, ATS anticipates a cartridge performance of 20 W of gross power per cartridge at an efficiency of 4.8% per cartridge. In addition to evaluating the claimed performance of the TEG pilot-scale unit, the study estimated the potential annual impacts of a scaled-up commercial system used to capture kiln waste heat over annual operations. The evaluation estimated the gross and net annual electric generation achievable by capturing heat from the two proposed tap-in points: the kiln exhaust and the clinker cooler exhaust; see Section 2.1 for details. Two use cases were examined: • Holcim Alpena: The Holcim Alpena site consists of long dry kilns with superheater boilers, which differs from the rest of Holcim’s cement plant portfolio and results in lower waste heat temperatures. The study estimates gross and net annual generation using the superheater boiler exhaust and clinker cooler exhaust, based on 2023 operational data. • Typical Installation: Common cement plants have preheater kilns with higher exhaust temperatures than Holcim Alpena across a range of production rates. The study estimates gross and net annual generation using the preheater exhaust and clinker cooler exhaust, with a sensitivity analysis to account for the typical range of preheater exhaust temperatures, clinker cooler exhaust temperatures, and clinker production rates. Methodology The evaluation methodology followed a measurement and verification (M&V) strategy based on the International Performance Measurement and Verification Protocol Option B through comprehensive measurements and analyses of the affected systems. Evaluation data was collected from March 9 to March 11, 2024, the test period of the pilot TEG system. During the test period, in coordination with the ITV team, the ATS team adjusted system operations to capture the range of variability expected for each of the variables pertinent to performance of the system. The methodology consisted of two parts: evaluating the performance of the pilot unit's TEG system and estimating the annual TEG impact in terms of gross and net power based on a given waste heat profile. First, the evaluation of the thermoelectric generation performance of the pilot unit relative to the claims was performed by analyzing the collected test data. Gross power of the pilot TEG system was directly measured. Net power was determined by deducting the measured parasitic power from the gross power. The gross power generation was compared to heat transferred to the system by the working fluid (which was heated by steam generated from the kiln waste heat) to calculate the thermal efficiency achieved by the system. Performance of individual semiconductor cartridges within the pilot array was also assessed in terms of measured gross cartridge power and calculated cartridge thermal efficiency. The second part of the evaluation estimated the annual TEG impacts in terms of gross power and net power (calculated from the difference between gross power and parasitic power). This analysis comprised development of mathematical regression models for gross power and parasitic power, with assessment of each model’s goodness-of-fit characteristics to ensure satisfaction of statistical requirements. The models predicted the gross power generation, the parasitic load based on the temperature difference between the hot working fluid and the cold-side fluid (cold water from Lake Huron) entering the system, the volumetric flow rate of the cold-side fluid at the inlet, and the volumetric flow rate of the hot working fluid at the inlet. The annual impact analysis considered a theoretical commercial-scale system sized to capture the available waste heat at a cement plant, consisting of linked pilot-scale units that receive heat from a theoretical gas-to-working-fluid heat exchanger. To estimate annual impacts at the Alpena plant, the gross power and parasitic power regression models were applied to the arrays in the theoretical commercial-scale system. The heat supplied to the unit was calculated based on the kiln run time, annual production, kiln exhaust waste heat, and clinker cooler waste heat derived from 2023 Holcim Alpena kiln operational data. Net power impacts were calculated by deducting the resulting parasitic power from the estimated gross power. Inputs for the model were generated from a combination of hourly data, assumed design considerations for TEG system scale-up from the pilot-scale unit, and assumptions regarding TEG system operations. This analysis was then used as the basis for estimating annual impacts of typical TEG installation at cement plants, by applying sensitivity analyses to key kiln operational characteristics including kiln preheater exhaust temperatures, cooler clinker exhaust temperatures, and plant daily production rates across a range of expected values. Project Results/Findings Table ES- 2 and Table ES- 2 provide a summary of the operating conditions and evaluation results compared to the stated claims from the technology provider. Key takeaways include: • Gross Power: The peak gross power achieved during the testing period was 10.0 kW, compared to the 11.5 kW expected for 573 active cartridges. The claimed gross power was associated with a target hot side of 240°C; however, the system only received a maximum hot-side mean plate temperature of 212°C during the testing period. • Net Power: The pilot-scale unit exceeded the claims for net power, achieving a peak of 7.7 kW net compared to a claim of 7.5 kW. One factor contributing to the higher achieved net power is the relatively high water pressure available through Lake Huron. The pilot TEG system did not require cold-side pumps during the test, whereas most installations would. This reduced the parasitic loads on the system, ultimately contributing to higher net power relative to the gross power. • Thermal Efficiency: The pilot-scale unit outperformed the claimed efficiency, achieving a peak system efficiency of 5.0% thermal efficiency compared to the stated 4.8%. • Cartridge Performance: To compare cartridge performance against claims, the study focused on the third day of testing, which aimed for conditions closest to the design specifications, with a hot side of 240°C and cold-side exit temperature of 6.4°–30°C. On this day, the mean gross power observed in the cartridges within the TEG array was 18.1 W/cartridge, and the peak performance was 34.7 W/cartridge. The estimated mean cartridge efficiency was 5.2%, and the estimated efficiency at peak gross cartridge power was 10%. The regression models developed for gross power generation and parasitic loads were used to estimate the generation impact for given heat input to the TEG from the working fluid (captured from the waste heat) and from the cold loop (Lake Huron) on an hourly basis for a year of operation. Based on this analysis, installation of a commercial-scale TEG system at the Holcim cement plant in Alpena, Michigan, with a waste heat exchanger of 0.85 effectiveness, would generate up to 391 kW of net power, translating to between 920,000 and 1,800,000 kilowatt-hours (kWh) in net electricity per year. Based on typical grid emissions for Alpena, this would avoid estimated net emissions by 752 metric tons of CO₂ annually.² The sensitivity analysis estimated that typical TEG system installations at cement plants could generate an average of 56–1,040 kW of net power, or between 488,000 and 9,110,000 kWh of net energy. This generation potential is most significantly affected by plant production rates and also influenced by preheater and clinker cooler exhaust temperatures. Applying the national average emission rate, typical commercial-scale installations at Holcim plants are projected to avoid between 182 and 3,401 metric tons of CO₂ annually per site. Table ES- 3 shows a summary of the estimated annual impacts.³ While parasitic loads are significant and vary by application, this analysis assumed the use of heating loop pumps and access to Lake Huron as a cold sink. This setup assumed no need for cooling loop pumps due to the available water pressure at the test site. Applications that require cooling towers or additional equipment are likely to experience higher parasitic loads. Therefore, the study’s estimates are most applicable to scenarios with similar parasitic load configurations—namely, access to a high-pressure cold sink. Applicability to other locations may be limited, as differing conditions could necessitate additional pumps and cooling systems, potentially impacting performance significantly.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗