Design of Low-Cost Axial-Flow Turbines for Very Low-Head Micro-Hydropower Plants

In the Amazon, nearly one million people remain without reliable access to electricity. Moreover, the rural electricity grid is a mostly single-phase, ground-return type, with poor energy quality and high expenses. This study examines very low-head micro-hydropower (MHP) sites in the Amazon, emphasizing the integration of multiple axial-flow turbines. It includes an analysis of flow duration curves and key curves, both upstream and downstream, to design an MHP plant with multiple units targeting maximized energy yield. The presence of multiple turbines is crucial due to the substantial annual flow variation in the Amazon rivers. One contribution of this work is its scalable framework for ultra-low-head and high flow variability in small rivers, which is applicable in similar hydrological configurations, such as those typical of the Amazon. The design applies the minimum pressure coefficient criterion to increase turbine efficiency. Computational Fluid Dynamics (CFD) simulations forecast turbine efficiency and flow behavior. The CFD model is validated using experimental data available in the literature on a similar turbine, which is similarly used in this study for cost reasons, with discrepancies under 5%, demonstrating robust predictions of turbine efficiency and head behavior as a function of flow. This study also explores the implications of including inlet guide vanes (IGVs). We use a case study of a small bridge in Vila do Janari, situated in the southeastern part of Pará state, where heads range from 1.4 to 2.4 m and turbine flow rates span from 0.23 to 0.92 m3/s. The optimal configuration shows the potential to generate 63 MWh/year.