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DOE OSTI2021

Chapter 2: Global Value Chain and Manufacturing Analysis on Geothermal Power Plant Turbines

The global geothermal power market has shown significant growth since the last decade and is expected to reach a total installed capacity of 18.4 gigawatts electric (GWe) by the end of 2021 (GEA, 2016). The global geothermal power plant turbine market is dominated by a small number of manufacturers. Between 2005 and 2015, 82% of the geothermal steam turbines were manufactured in Japan, and 74% of the geothermal binary cycle turboexpanders were manufactured in Israel. During this period, the United States played an important role in the global trade flow of fully assembled turbine units and turbine parts, with a high volume of imports and exports. Another significant growth area was in Italian turbine/turboexpander manufacturers, who have increased their market share in the last couple of years. One other important change in the manufacturing market was in Turkey, where the bonus on feed-in-tariff (FIT) for domestic hardware components boosted the national manufacturing sector between 2010 and 2020. When planning geothermal power projects, developers customize their power plant size to fit the available geothermal resource capacity. The turbine is designed and sized to optimize the efficiency and utilization of resource and revenue production. The rest of the power plant components such as heat exchangers (HX), water-cooled cooling towers (WCCT), or air-cooled condensers (ACC) are then chosen to complement the turbine size and design. These one-off manufacturing custom design turbines have relatively higher manufacturing set-up costs, longer lead times, and higher capital costs than the standard design turbines manufactured in larger volumes. However, turbines produced in standard increments and in larger manufacturing volumes could result in lower costs per turbine, but potentially lower efficiency. Based on pipeline projects and resource assessments, there is significant potential value in creating standard turbine sizes that could offer an economic advantage, as is done for modular microturbines.

40 EE - Geothermal Technologies Office (EE-4G)↗

DOE OSTI2023

Design of a Geothermal Power Plant With Solar Thermal Topping Cycle

Geothermal power plants are a reliable source of low-carbon power generation. However, modern electricity markets comprise relatively large proportions of variable renewable energy generation that may require power plants to flexibly dispatch energy. The power output, efficiency, and dispatch flexibility of a geothermal plant can be enhanced by integrating solar thermal energy into the system, as well as possibly compensating against ambient temperature variations. Concentrating solar thermal (CST) can generate temperatures much higher than conventional geothermal systems. Using a solar topping cycle is one way to efficiently convert high-temperature solar heat to electricity while also cascading lower-temperature heat to the geothermal power cycle, thereby increasing its power output and possibly its efficiency. A hybrid power cycle design is proposed and simulated using SimTech IPSEpro process modeling software. The design configuration depends on the expected temperature of the geothermal resource and the quantity of solar heat added at the design point. These design considerations are described and expected performance is calculated. The solar heat addition varies throughout the day and year; therefore, off-design models are necessary to assess the impact of solar availability (and ambient temperature) on the power plant performance. Off-design models are developed and combined with hourly weather data to facilitate an evaluation of annual system performance.

concentrating solar power↗

DOE OSTI2023

Design of a Geothermal Power Plant With Solar Thermal Topping Cycle: Preprint

Geothermal power plants are a reliable source of low-carbon power generation. However, modern electricity markets comprise relatively large proportions of variable renewable energy generation that may require power plants to dispatch energy flexibly. The power output, efficiency, and dispatch flexibility of a geothermal plant can be enhanced by integrating solar thermal energy into the system, as well as possibly compensating against ambient temperature variations. Concentrating Solar Thermal (CST) can generate temperatures much higher than conventional geothermal systems. Using a solar topping cycle is one way to efficiently convert high-temperature solar heat to electricity while also adding lower-temperature heat to the geothermal power cycle, thereby increasing its power output and possibly its efficiency. A hybrid power cycle design is proposed and is simulated using SimTech IPSEpro process modelling software. The design configuration depends upon the expected temperature of the geothermal resource and the quantity of solar heat added at the design point. These design considerations are described and expected performance is calculated. The solar heat addition varies throughout the day and year, therefore off-design models are necessary to assess the impact of solar availability (and ambient temperature) on the power plant performance. Off-design models are developed and combined with hourly weather data to facilitate an evaluation of annual system performance.

concentrating solar power↗

DOE OSTI2024

Efficient data-driven models for prediction and optimization of geothermal power plant operations

Increasing the capacity of geothermal energy as a renewable resource calls for development and deployment of efficient control and optimization technologies for geothermal power plants. A data-driven prediction and optimization model is presented as a cost-effective and efficient alternative to physics-based approach. The model predicts power output and operational cost by propagating the influence of control and disturbance variables within an artificial neural network (ANN). Numerical experiments with simulated and field data from a real geothermal power plant are first used to demonstrate the prediction performance of the ANN model. The model is then adopted to maximize the net predicted power production by automatically adjusting the working fluid circulation rate. The optimization performance of the model in evaluated using a thermodynamic flowsheet simulation model. The workflow is applied to model and control the effect of ambient temperature on an air-cooled binary cycle power plant, which is complex and costly to perform using a physics-based predictive model. As a result, the performance of the method is demonstrated by applying it to both simulated and field datasets from a binary cycle geothermal power plant.

15 GEOTHERMAL ENERGY↗

DOE OSTI2022

Data Curation for Machine Learning Applied to Geothermal Power Plant Operational Data for GOOML: Geothermal Operational Optimization with Machine Learning: Preprint

Geothermal Operational Optimization with Machine Learning (GOOML) is a transferable and extensible component-based geothermal asset modeling framework that considers complex steamfield relationships and identifies optimization prospects using a data-driven approach to physics-guided, data-centric machine learning. This framework has been used to develop digital twins that provide steamfield operators with operational environments to analyze and understand historical and forecasted power production, explore new steamfield configuration possibilities, and seek optimal asset management in real world applications. To create, test, and apply the GOOML framework, diverse time-series datasets spanning multiple years were sourced from various geothermal power plant components within several complex real-world geothermal operations. These operations are based in the United States and New Zealand and include a variety of technologies, end-uses and configurations, collectively covering nearly all relevant operating conditions for modern geothermal fields. Datasets were acquired from multiple sources to ensure that machine learning experiments generalized properly to various operating conditions. It was found that the data varied in quality, format, and completeness. To ensure consistency between the various datasets, a standardized data curation process was developed to reliably streamline data preparation. This paper will discuss best practices as learned from the GOOML data curation process which takes the following steps: 1) acquisition of large quantities of data from power plant operators, 2) digestion of data to gain an initial understanding of what is included, 3) data transformation, which includes converting the data into a standardized machine-readable format so that they can be visualized, quality checked, and cleaned, 4) quality assurance and quality control, involving identification of significant data gaps and apparent anomalies through mapping of data features to real world componentry via the GOOML historical model, followed by discussion with modelers and power plant operators to identify additional data needs and to resolve issues, 5) use in machine learning algorithms, and 6) repetition of steps one through five until all data needs are met and data are deemed suitable for producing trustworthy modeling results which may be disseminated, ideally along with the curated dataset. This iterative process is focused on improving the quality of the data rather than tuning machine learning model parameters and supports a shift towards data-centric AI as a means to improving real-world applicability of geothermal machine learning projects.

access↗

NASA NTRS1974

Investment and operating costs of binary cycle geothermal power plants

Typical investment and operating costs for geothermal power plants employing binary cycle technology and utilizing the heat energy in liquid-dominated reservoirs are discussed. These costs are developed as a function of reservoir temperature. The factors involved in optimizing plant design are discussed. A relationship between the value of electrical energy and the value of the heat energy in the reservoir is suggested.

Holt, B.↗

DOE OSTI2022

Latent-Space Dynamics for Prediction and Fault Detection in Geothermal Power Plant Operations

This paper presents a latent-space dynamic neural network (LSDNN) model for the multi-step-ahead prediction and fault detection of a geothermal power plant’s operation. The model was trained to learn the dynamics of the power generation process from multivariate time-series data and the effects of exogenous variables, such as control adjustment and ambient temperature. In the LSDNN model, an encoder–decoder architecture was designed to capture cross-correlation among different measured variables. In addition, a latent space dynamic structure was proposed to propagate the dynamics in the latent space to enable prediction. The prediction power of the LSDNN was utilized for monitoring a geothermal power plant and detecting abnormal events. The model was integrated with principal component analysis (PCA)-based process monitoring techniques to develop a fault-detection procedure. The performance of the proposed LSDNN model and fault detection approach was demonstrated using field data collected from a geothermal power plant.

15 GEOTHERMAL ENERGY↗

NASA NTRS1974

The hydrogen sulfide emissions abatement program at the Geysers Geothermal Power Plant

The scope of the hydrogen sulfide (H2S) abatement program at The Geysers Geothermal Power Plant and the measures currently under way to reduce these emissions are discussed. The Geysers steam averages 223 ppm H2S by weight and after passing through the turbines leaves the plant both through the gas ejector system and by air-stripping in the cooling towers. The sulfide dissolved in the cooling water is controlled by the use of an oxidation catalyst such as an iron salt. The H2S in the low Btu ejector off gases may be burned to sulfur dioxide and scrubbed directly into the circulating water and reinjected into the steam field with the excess condensate. Details are included concerning the disposal of the impure sulfur, design requirements for retrofitting existing plants and modified plant operating procedures. Discussion of future research aimed at improving the H2S abatement system is also included.

Allen, G. W.↗

DOE OSTI2024

Techno-Economic Analysis of Greenfield Geothermal Hybrid Power Plants using a Solar or Natural Gas Steam Topping Cycle

The relatively low generation costs associated with wind, solar photovoltaic (PV), and natural-gas power plants make it challenging for geothermal power plants to produce and sell the power that has the reliability and sustainability characteristics that are greatly needed in U.S. power markets. This is especially true for geothermal resources with low-to-medium temperatures, which results in relatively low-thermal efficiency and generation costs that are higher than those for wind, solar PV, and natural gas. This analysis evaluates solar thermal- and natural-gas combustion waste heat recovery-based topping cycle hybridization of geothermal binary power plants. This approach provides several benefits that may allow geothermal power plants to generate power at more competitive costs. First, the addition of solar thermal energy or natural-gas combustion waste heat input to a geothermal power plant provides additional heat input that can be converted to electrical power. Second, the temperature level of the heat obtained from concentrating solar collectors or natural-gas combustion exhaust is higher than that of geothermal heat, which provides opportunities for improving the efficiency of the conversion of thermal energy to electrical power. Third, the ease with which solar thermal systems integrate with energy storage and the flexibility of natural gas means power generation can occur during peak demand periods. The hybrid cycles are compared to equivalently sized, co-located, independent geothermal, concentrating solar, and/or natural-gas power plants. The hybrid cycle tends to produce slightly more power than the standalone plants combined. However, the hybrid plant Levelized Cost of Energy (LCOE) is slightly higher than the LCOE of the combined standalone power plants for each of the case study locations investigated. Using the steam-topping cycle, organic Rankine cycle (ORC)-bottoming cycle hybrid plant design to combine a solar thermal resource and low- temperature geothermal resource (<120 degrees C) leads to a hybrid plant with a lower LCOE than a standalone geothermal-only system. Thus, hybrid plants may enable the economic development of geothermal resources in locations with low geothermal resource temperatures. However, in areas with higher geothermal resource temperatures (>120 degrees C), the geothermal-only plant has a lower LCOE than the hybrid cycle and thus could be developed without the need for solar heat addition. iv A geothermal-natural-gas reciprocating engine hybrid plant was evaluated for an Elk Hills, California case study location. The Elk Hills case study analysis indicates that when the natural-gas engine operates for more than 12 hours per day the hybrid plant can produce power at an LCOE lower than a standalone geothermal plant, and comparable to that of the standalone natural-gas reciprocating engine, while also reducing the carbon intensity of the power generated relative to the standalone natural-gas engine. This may represent a scenario in which the hybrid plant provides an opportunity for the deployment of a low-temperature geothermal resource that otherwise may have an LCOE too high to develop and operate as a standalone resource, while also reducing the carbon intensity of natural-gas generation sources. A "triple-hybrid" plant that combines natural gas, solar thermal, thermal energy storage, and geothermal was also investigated. A natural-gas combustion turbine (NGCT) is added to the geothermal-solar hybrid such that the hot exhaust gas from the gas turbine provides an alternative source of heat to the steam turbine of the hybrid cycle. Analysis results suggest that the triple-hybrid plant has a significantly higher energy generation and revenue than a standalone NGCT or the original geothermal-solar hybrid. The triple-hybrid design benefits most from using a smaller solar field so that the solar energy can be dispatched at the most valuable times available. The triple-hybrid plant also has a lower LCOE than the standalone NGCT. The triple-hybrid plant was evaluated making simple assumptions about the dispatch profile of the gas cycle, and more nuanced and realistic dispatching schedules should be analyzed in future work.

15 GEOTHERMAL ENERGY↗

DOE OSTI2024

Techno-Economic Analysis of Greenfield Geothermal Hybrid Power Plants using a Solar or Natural Gas Steam Topping Cycle

The relatively low generation costs associated with wind, solar PV, and natural gas power plants make it challenging for geothermal power plants to produce and sell the power that has the reliability and sustainability characteristics that are greatly needed in US power markets. This is especially true for geothermal resources with low to medium temperatures, which results in relatively low thermal efficiency and generation costs that are higher than those for wind, solar PV, and natural gas. This analysis evaluates solar thermal- and natural gas combustion waste heat recovery-based topping cycle hybridization of geothermal binary power plants. This approach provides several benefits that may allow geothermal power plants to generate power at more competitive costs. First, the addition of solar thermal energy or natural gas combustion waste heat input to a geothermal power plant provides additional heat input that can be converted to electrical power. Second, the temperature level of the heat obtained from concentrating solar collectors or natural gas combustion exhaust is higher than that of geothermal heat, which provides opportunities for improving the efficiency of the conversion of thermal energy to electrical power. Third, the ease with which solar thermal systems integrate with energy storage and the flexibility of natural gas means power generation can occur during peak demand periods.

14 SOLAR ENERGY↗

DOE OSTI2020

Integration of a Concentrating Solar Steam Topping Turbine to an Existing Geothermal Binary Power Plant (CRADA CRD-17-700 Final Report)

U.S. Geothermal Inc. is a publicly traded leading renewable energy company focused on the development, production, and sale of electricity from geothermal energy with operating generation facilities at Raft River, Idaho; San Emidio, Nevada; and Neal Hot Springs, Oregon. (U.S. Geothermal was acquired by Ormat Technologies, Inc. since the execution of this project). This project will evaluate the integration of a concentrating solar steam topping cycle with a geothermal bottoming binary cycle. This hybrid plant configuration will enable high efficiency conversion of the solar heat to electrical power, while simultaneously increasing the power output of the bottoming cycle. Such a design has the potential to reduce the cost of electrical power from concentrating solar power (CSP) and geothermal plants, and a viable design could be deployed at existing geothermal plants that have experienced resource productivity decline as well as in greenfield projects. This analysis will examine US Geothermal’s Raft River power plant for implementation of this concept. INL and NREL have previously collaborated in the analysis of geo-solar hybrid power plants. These two labs will again work together to model the solar field, steam-topping, and geothermal bottoming cycles in order to investigate the performance of the proposed cycle. This analysis will provide US Geothermal with technical information including equipment specifications and estimated power generation necessary to advance the concept toward implementation. A successful project outcome has two parts: One would be for US Geothermal to have a process flow diagram (heat and mass balance), and performance parameters for the major pieces of equipment. US Geothermal could then use this information evaluate the techno-economic feasibility of the hybrid power cycle, and serve as the basis for subsequent detailed equipment design, purchase, and installation of the cycle. The second would be for the developed solution to be published by DOE for use by other geothermal developers both to retrofit underperforming plants and to lower the LCOE of new developments.

15 GEOTHERMAL ENERGY↗

DOE OSTI2023

Hybrid Natural Gas Geothermal Combined Cycle Power Plant Analysis

Low temperature geothermal resources, including those associated with oil and gas production, are an underutilized source of low carbon energy. The present work investigates coupling of low-temperature geothermal resources with concentrating solar and/or natural gas energy sources to increase the number of locations at which power generation from low temperature geothermal resources would be technically and economically viable. Stand-alone and hybrid geothermal power cycles are simulated using SimTech IPSEpro process modeling software. Design point strategies for a hybrid power cycle that may operate with either a single heat source or two simultaneous heat input sources are considered. Additionally, off-design power plant operation is investigated to consider the impacts of the heat source availability and ambient temperature variations. The off-design analysis utilizes a modeling tool that predicts power plant performance at each time step as a function of topping cycle heat input (from gas or solar), bottoming cycle heat input (from geothermal), and ambient temperature. Addition of a steam topping cycle to an organic Rankine cycle geothermal power plant provides opportunities to increase the efficiency and power output relative to a stand-alone geothermal power plant. Additionally, use of the waste heat from gas turbine power generation in a geothermal bottoming cycle provides opportunities to increase the amount of power generation associated with each unit of carbon dioxide emitted. This paper will describe the hybrid plant configuration evaluated, discuss the predicted power cycle performance, and compare with stand-alone natural gas and geothermal power generation cases. The power cycle investigated is expected to be applicable for use with conventional hydrothermal resources as well as with geologic thermal energy storage applications and/or enhanced geothermal systems. The steam topping cycle could use a concentrated solar heat source for fully renewable hybrid plant configuration. A plant initially constructed with a natural gas topping cycle heat source could be converted to a solar heat source part way though the power cycle operational life to achieve life cycle carbon emission reductions.

concentrating solar power↗

DOE OSTI2021

A New Modeling Framework for Geothermal Operational Optimization with Machine Learning (GOOML)

Geothermal power plants are excellent resources for providing low carbon electricity generation with high reliability. However, many geothermal power plants could realize significant improvements in operational efficiency from the application of improved modeling software. Increased integration of digital twins into geothermal operations will not only enable engineers to better understand the complex interplay of components in larger systems but will also enable enhanced exploration of the operational space with the recent advances in artificial intelligence (AI) and machine learning (ML) tools. Such innovations in geothermal operational analysis have been deterred by several challenges, most notably, the challenge in applying idealized thermodynamic models to imperfect as-built systems with constant degradation of nominal performance. This paper presents GOOML: a new framework for Geothermal Operational Optimization with Machine Learning. By taking a hybrid data-driven thermodynamics approach, GOOML is able to accurately model the real-world performance characteristics of as-built geothermal systems. Further, GOOML can be readily integrated into the larger AI and ML ecosystem for true state-of-the-art optimization. This modeling framework has already been applied to several geothermal power plants and has provided reasonably accurate results in all cases. Therefore, we expect that the GOOML framework can be applied to any geothermal power plant around the world.

15 GEOTHERMAL ENERGY↗

DOE OSTI2020

Geothermal Flexibility Characteristics

This spreadsheet identifies various flexibility characteristics for flash and binary geothermal power plants which could potentially facilitate provision of grid services beyond bulk power generation. Characteristics are differentiated between resource characteristics such as metal concentration and plant characteristics such as flow rates of pumps used in flash vs. binary plants.

15 GEOTHERMAL ENERGY↗

DOE OSTI2020

Hawaii Play Fairway Analysis: Noble Gas Raw Data for Hawaii, Maui, Oahu, Kauai, and Lanai islands

Noble gas raw data for the Hawaiian islands of Big Island, Maui, Oahu, Lanai, and Kauai. Based on results from prior phases of the Hawaii Play Fairway Analysis, this project targeted 66 wells on the islands of Hawaii, Maui, Lanai, Oahu, and Kauai for sampling of dissolved noble gases, trace metals, common ions, and the stable isotopes 2H and 18O. Ultimately, 23 of the 66 well targets were sampled. Noble gas data from this study is supplemented with data shared by the United States Geologic Survey for the summit of Kilauea, and by the geothermal energy company Ormat Technologies Inc. for their geothermal power plant Puna Geothermal Venture on the Lower East Rift of Kilauea, and for their exploration of Kona and Hualalai on Hawaii, as well as the Southwest Rift of Haleakala on Maui. The noble gas helium is used as an indicator of geothermal heat when excess 3He and/or 4He is present when compared to the atmospheric ratio of those isotopes (R/Ra). R/Ra is minimally affected by dilution and transport, allowing even those wells not perfectly situated over a geothermal system to indicate a geothermal anomaly. R/Ra anomalies are present on every island in this study. There is a strong correlation between R/Ra anomalies and proximity to rift zones and calderas. The Hawaii Play Fairway project was funded by the U.S. Department of Energy Geothermal Technologies Office (award DE-EE0006729). For more information, see Colin Ferguson's Master of Science thesis "Exploration for Blind Geothermal Resources in the State of Hawaii Utilizing Dissolved Noble Gasses in Well Waters."

15 GEOTHERMAL ENERGY↗

DOE OSTI2023

Geothermal Energy Stack-It

The Geothermal Energy Stack-It is an educational tool that can be used to describe how geothermal power plants work. Each square is numbered with a different layer of technology. Cut out each square and place them into the stacking correct order, starting with 1 and ending with 6 to see how each part comes together to form the geothermal power plant and power up homes and businesses!

educational materials↗

DOE OSTI2023

Historical Pattern Analysis of Global Geothermal Power Capacity Development: Preprint

Between 1913 and 1958, Italy was the only country with an operational geothermal power plant until New Zealand installed its first plant in 1958. At present, 24 countries are involved in the geothermal power market, and they have a combined installed capacity of 16,127 GW. This study analyzes the historical patterns of geothermal power capacity in the world and in individual countries to investigate the ideal global geothermal development pattern by examining the annual cumulative capacity (ACC) and the annual capacity addition (ACA) graphs of the historical development of geothermal power capacity in 24 countries. First, the global patterns are analyzed using these graphs in five periods (1945-1957, 1958-1976, 1977-1991, 1992-2002, and 2003-2020) that are marked by a series of characteristics of ACA peaks separated by two major troughs. Then, five characteristic patterns are developed in five periods globally. These patterns correspond to the early-stage linear, the first acceleration, the first steady-state linear, the second acceleration, and the second steady-state linear developments. A positive relationship exists between global patterns and the 5-year shifted oil-price curve: two major factors influenced global development: 1) increasing oil prices and increasing awareness of global climate change, and 2) global development of geothermal power. Last, we investigate these patterns in each country. The top ten countries, which comprise 93.3% of the world's total installed capacity are separated into five groups based on the availability and characteristics of patterns globally developed in five periods. Group-1 (the United States) has an installed capacity of 3,794 MW, Group-2 (Mexico and Philippines) 963-1935 MW, Group-3 (New Zealand, Italy, Iceland, and Japan) 601-1,037 MW, and Group-4 (Indonesia, Kenya, and Turkiye) 944-2,356 MW. The remaining 14 countries (6.7%), which are called Group 5, are still in an immature stage and have installed capacities of 7-262 MW and are not involved in pattern analysis. Overall, geothermal power in the world is in its third stage of development, which had its peak development after 1977. A fourth development peak may be expected to occur after this through business-as-usual cases. The biggest barrier to the development of the global geothermal power market is the risk associated with exploration and drilling. If risk mitigation systems and funds are employed, the growth of geothermal power production projects could accelerate.

GEOTHERMAL ENERGY↗

DOE OSTI2023

Historical Pattern Analysis of Global Geothermal Power Capacity Development

GEOTHERMAL ENERGY↗