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COST SAVING POTENTIAL IN SMALL WIND USING NEW TOWER MATERIALS AND MANUFACTURING PROCESSES

V. Berkhout, P. KühnFraunhofer Institute for Wind Energy and Energy System Technology (IWES)

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Motivation

We are very close to the ‘tipping point’ where production volumes would skyrocket, causing production costs to plummet.

source: AWEA, 2002

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Outline

World market analysis in 1 kW to 5 kW segment

Manufacturers

Component prices of a generic small wind turbine

Cost potentials

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World market size for SWT from 1 kW to 5 kW

World market size for 1 kW – 5 kW: approx. 22.000 Units

sources: AWEA, BWEA, REEEP

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Small wind manufacturingBetween one piece production and line assembly

source: Heyde Windtechnik / Grüne Elbe-Weisseritz / www.flickr.com source: www.hyenergy.com.cn

source: www.effsun.comsource: AWEA / www.flickr.com

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Small wind components prices

0 €

1000 €

2000 €

3000 €

4000 €

5000 €

1.8 m FRPblades

2.5 kW PM-generator

bearing 17m monopolesteel tower

controllerand inverter

Com

pone

nt p

rice

Component

overhead, salesand profit

indirect costs

direct costs

material

alternativetechnologies

manuallaminationprocess

nobearingfl anges

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Cutting tower costs with new materials

Fibre reinforced plastics being applied as tower material

Centrifugal casting process

Fatigue testing necessary

Cost savings depend on less material use and spread to steel prices

source: Anemergonics / Paul Migliore in Veers (2011)

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Cutting small wind logistic costs

source: Blittersdorf, AllEarthRenewables

blade length [m] 1.9 2.2 2.9 5.8rotor diameter [m] 3.8 4.4 5.8 11.6rotor area [m²] 10.8 15.2 26.4 105.7capacity at 3.5 m²/kW [kW] 3.1 4.3 7.5 3o.2

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Conclusion and Outlook

Estimated world market size of 22.000 turbines in 1 kW – 5 kW

segment

Less than ten manufacturer produce more than 1.000 units per year

Significant production cost cuts in blade manufacturing achieved

Major component value comes from tower and power electronics

New materials for small wind towers to be expected

Focus on the tower and logistics for further cost reduction

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