Flagship project: Green energy on the Kentucky River

The Kentucky River features 14 historic locks and dams originally constructed between 1836 and 1917. Once used for transporting raw materials like coal and iron via shipping, most of the locks ceased operations about 30 years ago. Today, these structures provide an ideal foundation for modern, environmentally friendly energy generation. 

The Lock 14 project builds upon prior experience in utilizing existing hydraulic structures for renewable energy. A prime example is Lock 12, where the same project developer commissioned Kentucky’s first new small hydropower plant in 94 years in May 2021. This spearhead project demonstrated that decommissioned locks offer a valuable basis for sustainable energy production.

With more efficient technology and an optimized construction approach, Lock 14 is setting new standards. The fully submerged machinery is designed to withstand even the extreme flooding of the Kentucky River, which frequently experiences water levels over 10 meters above the normal gage. Furthermore, construction takes place within the decommissioned lock chamber, eliminating the need for costly and complex cofferdams and excavation pits, which are typically required for hydropower plants.

Voith was contracted to supply turbine technology for the project. With its extensive experience in small hydropower plant development, Voith has provided a tailored solution for the site with its innovative StreamDiver technology.

The plant’s design is based on a concept that remains confined within the existing lock chamber and is fully submerged. Large debris is diverted from the plant by a flood-resistant floating log-boom positioned upstream of the intake structure and guiding debris to the fixed crest dam. Within the lock chamber, the upstream water level is regulated by an inflatable rubber weir, which can be lowered to flush the horizontal, submerged trash rack. The turbine units themselves are positioned below the trash rack.

Initial planning for Lock 14 began in 2019, construction started in 2022, and the project was commissioned in spring 2025. Voith is responsible for supplying the turbines, turbine valves, and power cables, as well as overseeing installation and com-missioning of those.

In addition to flood resilience, the standardization of the concept is a major advantage: since the lock chambers along the Kentucky River have uniform widths, the design can be efficiently replicated for other locks. This facilitates planning and licensing for future hydropower projects.

Lock 14 features an innovative design that enhances power generation efficiency while reducing construction efforts. Compared to the first project, Voith experts guided the developer towards a new design concept that allows 30% more energy to be generated within the same lock chamber dimensions.

• Horizontal Installation: Unlike Lock 12, which used vertical turbines, Lock 14 features a horizontal configuration. This design reduces concrete requirements by approximately 40%, significantly lowering construction costs and time while ensuring efficient and sustainable power generation.
• Oil-Free Technology: The maintenance-friendly, water-lubricated, and oil-and grease-free StreamDiver turbines minimize environmental impact and enable nearly silent electricity generation, as they are fully submerged.

Innovative turbine-generator combination: The plant will be equipped with a total of six Voith StreamDiver turbines, including four StreamDiver units with a runner diameter of 1,490 mm, directly coupled with a 642 kW permanent magnet generator, and two StreamDiver units with a runner diameter of 895 mm, directly coupled with a 222 kW permanent magnet generator. The six horizontal StreamDiver turbines will achieve a total capacity of 3 MW. The combination of different turbine sizes allows for optimal adaptation to the river’s flow curve in 14 regulation steps despite unregulated turbines.

Lock 14 is more than just a hydropower project – it demonstrates how unused historic locks and dams can be transformed into modern, sustainable energy sources. “Choosing Voith’s StreamDiver technology was a crucial step for us in efficiently integrating renewable energy into existing infrastructure. Thanks to Voith’s early involvement, the project was optimally aligned and implemented efficiently. The easy installation and minimal environmental impact convinced us. Additionally, Voith not only provided innovative solutions but also ensured that the concept could be easily replicated, supporting long-term sustainable energy generation.“ – [David Brown Kinloch, President Appalachian Hydro Associates]

The uniform width of the lock chambers along the Kentucky River ensures a high level of design repeatability. As a result, this concept can be efficiently replicated for other locks and directly incorporated into the execution of already planned hydropower projects along the Kentucky River.

One of the project’s primary objectives was to minimize environmental impact. In addition to the innovative, oil- and grease-free turbine technology, further measures were implemented, including specialized fish protection systems with fine, horizontal trash racks and optimized water flow management to preserve the ecological balance of the Kentucky River. At the same time, Lock 14 underscores a strong commitment to social responsibility: revenues from electricity generation will directly support educational programs for underprivileged students at Berea College, promoting equal opportunities. Since its commissioning in May 2025, Lock 14 has been making a significant contribution to a sustainable energy future. The concept has the potential to serve as a model for many future projects across North America, further advancing the use of historic hydraulic structures for clima-te-friendly energy generation.