Crossflow turbines represent a valuable choice for energy recovery in aqueducts, due to their constructive simplicity and good efficiency under variable head jump conditions. Several experimental and numerical studies concerning the optimal design of crossflow hydraulic turbines have already been proposed, but all of them assume that structural safety is fully compatible with the sought after geometry. We show first, with reference to a specific study case, that the geometry of the most efficient impeller would lead shortly, using blades with a traditional circular profile made with standard material, to their mechanical failure. A methodology for fully coupled fluid dynamic and mechanical optimization of the blade cross-section is then proposed. The methodology assumes a linear variation of the curvature of the blade external surface, along with an iterative use of two-dimensional (2D) computational fluid dynamic (CFD) and 3D structural finite element method (FEM) simulations. The proposed methodology was applied to the design of a power recovery system (PRS) turbine already installed in an operating water transport network and was finally validated with a fully 3D CFD simulation coupled with a 3D FEM structural analysis of the entire impeller.

Cross-flow turbines have recently been proposed for energy recovery in aqueducts when the outlet pressure is greater than zero, owing to their constructive simplicity and good efficiency within a large range of flow rates and head drops. In the case of high head drop (higher than 150 m) and relatively small discharge (lower than 0.2 m 3 /s), the traditional design of these turbines leads to very small widths of the nozzle and the runner; as a consequence, friction losses grow dramatically and efficiency drops down to very low values. Standard Pelton turbines require zero outlet pressure and cannot be used as alternatives. A new counter-pressure hydraulic turbine for high head and low flow rate, called the High Power Recovery System (H-PRS) is proposed. H-PRS presents a different geometry to reduce friction losses inside the nozzle and the runner by widening the two external walls. Several curved baffles are proposed to guide the fluid particles inside the nozzle and to guarantee the right velocity direction at the inlet surface of the runner. Computational Fluid Dynamics (CFD) 3D transient analyses are carried out to measure H-PRS efficiency for different operating conditions and to compute its characteristic curve for different positions of the regulating flap.

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In the last few decades, hydropower production has been moving toward a new paradigm of low and diffused power density production of energy with small and mini-hydro plants, which usually do not require significant water storage. In the case of nominal power lower than 20 kW and ultra-low head H (H < 5 m), Archimedes screw or Kaplan type turbines are usually chosen due to their efficiency, which is higher than 0.85. A new cross-flow type turbine called Ultra-low Power Recovery System (UL-PRS) is proposed and its geometry and design criteria are validated in a wide range of operating conditions through 2D numerical analysis computed using the ANSYS Fluent solver. The new proposed solution is much simpler than the previously mentioned competitors; its outlet flow has a horizontal direction and attains similar efficiency. The costs of the UL-PRS turbine are compared with the costs of one Kaplan and one cross-flow turbine (CFT) in the case study of the main water treatment plant of the city of Palermo in Italy. In this case, the UL-PRS efficiency is estimated using a URANS 3D numerical analysis computed with the CFX solver.

Hydraulic turbines for energy recovery in wastewater treatment plants, with relatively large discharges values and small head jumps, are usually screw Archimedes or Kaplan types. In the specific case of a small head jump (about 3 m) underlying a rectangular weir in the major Palermo (Italy) water treatment plant, a traditional Kaplan solution is compared with two other new proposals: a Hydrostatic Pressure Machine (HPM) located at the upstream channel and a cross-flow turbine (CFT) located in a specific underground room downstream of the same channel. The fluid mechanical formulations of the flow through these turbines are analyzed and the characteristic parameters are stated. Numerical analysis was carried out for the validation of the HPM design criteria. The efficiency at the design point of the CFT and HPM are estimated using the ANSYS CFX solver for resolution of 3D URANS analysis. The strong and weak points of the three devices are compared. Finally, a viability analysis is developed based on several economic indicators. This innovative study with a theoretical formulation of the most suitable turbomachine characterization, the potential energy estimation based on hydraulic energy recovery in a real case study of a wastewater treatment plant and the comparison of the three different low-head turbines, enhancing the main advantages, is of utmost importance towards the net-zero water sector decarbonization.