As part of its mission to optimize the efficiency and sustainability of geothermal power systems, the Geyser initiative launched by Enel Green Power in Italy turned to additive manufacturing of power plant components.

3D printers provided replacement parts for geothermal power plants. Source: Enel Green PowerA 3D printer system equipped with laser metal deposition technology at the company’s Santa Barbara metallurgy laboratories in Cavriglia was used to repair a geothermal power plant impeller. The aging, worn component used to extract non-condensable gases from vapor at the end of the expansion process in a turbine was refurbished with the aid of 3D models, laser scans and powdered 17-4 PH stainless steel fed to the printer.

The project demonstrated that new impellers can be cost-effectively manufactured while keeping discarded equipment out of landfills. As four out of six impellers require replacement or repair annually in Enel’s geothermal power systems, the additive manufacturing is estimated to offer the company annual savings of €70,000.