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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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