A DSU showing two types of Hollow Shafts, a purple Swinging
Windows Shaft and a red Sail Shaft. The structure also shows the green steel
Wire Mesh, yellow steel Angle Plates and red Sail and yellow ball-bearings
Ball-Bearings:
A BSW with 10m x 10m wide Spinning Frames will require 800
ball-bearings with 25mm inner diameter. As stated previously, each DSU has two
shafts. A Swinging Windows Shaft (purple color) will carry the Swinging Window
via two ball-bearings while the other shaft, the Sail Shaft (red color) will
carry the Sail, also by using two ball-bearings. The two images below represent
the kind of ball-bearings that can be used to build a DSU.
Steel Wire Mesh:
Each DSU will be
fitted with a Steel Wire Mesh, 190cm long, 95cm wide and either 4mm or 5mm
thick. The Steel Wire Mesh is designed to prevent the Sail from blowing over to
the other side of the DSU. The Swinging Window is carried on the DSU shaft,
shown below in purple, by two ball-bearings (seen in yellow).
Below are pictures of
Steel Wire Mesh that can be used to make Swinging Windows.
Sail:
Each DSU will require a Sail made of light and durable synthetic
or natural material. The Sail will be 190cm long and 95cm
wide. The
Sail must be light enough for the blowing wind to move it and pass freely
through the Swinging Window during the inactive phase, the phase where the wind
is not blocked by the Sail. During the active phase, during which the wind is
being blocked by the Sail and causing the Spinning Frame to spin, the Sail will
prevent the wind from passing through the gaps of the Swinging Windows”.
The Sail is mounted on the Sail Shaft, shown in
red on page 24, via two ball-bearings.
Bolts:
The BSW with 10m x 10m wide Spinning Frames and 200 DSUs
will require the following number of bolts:
8400 bolts,
30mm long and 18mm in diameter
3200 bolts will
be used to assemble the DSUs
5200 bolts
will be used to connect the 200 DSUs together to
form the 4 Spinning Frames.
Wires:
100 strong steel wires, with hooks
at each end, will be needed to tightly connect the Spinning Frames to each other. A group of 25 wires will be used to
connect together successive Spinning Frames. Thus, all four Spinning Frames
will be strongly connected together producing one solid and strong rigid system
where each Spinning Frame will support the other Spinning Frames during windy
conditions.
Using the 100 steel wires will
prevent the frames from wobbling; the net result is a solid, well-connected
rigid steel structure.
Summary of parts used to manufacture a BSW
with 10m x 10m wide Spinning Frames and
200 DSUs:
1. 800 Angle Plates 2m long (Type A)
2. 800 Angle Plates 1m long (Type B)
3. 400
Angle Plates 0.4m long (Type C)
4. 400
Angle Plates 0.3m long (Type D)
5. 800 Ball-bearings
6. 200 Steel Wire Mesh
7. 200 Sails
8. 400 Hollow Shafts 2m long
9. 3200 Bolts, to assemble the 200 DSU
10.
5200
Bolts to connect the 200 DSUs to 4 frames
11.
100
Strong steel wires with hocks at both ends
12.
500kW
250RPM 50 Hz 3 phase Vertical PMG Generator
13.
Central
Post
Generator:
The 10m x 10m BSW prototype will use 500kW 250RPM
50 Hz Vertical 3 phase PMG Generator for Vertical Wind Turbine. A quoted price of $53,600 US
dollars has been obtained from a Chinese supplier. Needless to say, prices of generators
will vary, whether they are Chinese, German, US or Japanese made.
To integrate the generator with the BSW, the following
items will be needed.
1-
One small pulley with four groves for the generator.
2-
One large pulley with four groves to be mounted on the
lower casing of the Central Post.
3-
Sizes of pulleys will depend on the generator; 6 inches
pulley for the generator and 12 inches pulley for the BSW.
4-
Strong belts, 22mm wide. Length of belts will be determined
later, when the generator is fixed on the BSW.
5-
A strong seating platform for the generator extending from
the Central Post with a sliding system to tighten the belts. This seating
arrangement will be 2m above ground level.
The Central Post:
An important note:
During the prototype phase, to avoid
time-consuming stress and expensive engineering efforts, the BSW’s Central Post, designed to carry
the four 10m x 10m wide Spinning Frames,
should not specifically be manufactured to
perform this job. This component
can always be manufactured later on since its role and function during the prototype phase is not very critical.
Therefore, for economic reasons and to
speed up the
prototype phase, a ready-made construction tower
crane, should either be built in a workshop or
purchased from local suppliers.
The image
above shows how the four 10m x 10m wide Spinning Frames (carrying rectangular red-colored
DSUs) are hanged on four arms of a construction tower crane (purple) carried by
a rig similar to derricks used in the oil industry (green)
Despite what was stated above, that
for pragmatic and economic reasons, specifically engineered Central Post should
not be manufactured for the BSW in the prototype phase, here is a general
outline of how to manufacture the Central Post that can be used at later
stages.
Central Post:
To manufacture a Central Post of the BSW
we need, 14m long pipes of different
diameters.
1-
2m long pipes with 12 inches diameter
2-
2m long pipes with 10 inches pipe
diameter
3-
10m long pipes with 8 inches diameter
The Central Post will
be divided into 7 segments, or sections if you
will, each 2m long for ease of transportation.
From the ground upward:
1-
The diameter of the first segment will be 12
inches
2-
The diameter of the second segment will be 10
inches
3-
The diameter of the subsequent segments, i.e. the
third, fourth, fifth, sixth and seventh segments will be 8 inches in diameter.
Picture of Central Post segments with perforated flanges
Dimensions and components of Central Post:
1-
The steel Central Post is 10mm thick
2-
Flanges used with Central Post is 25mm.
3-
All flanges of the BSW’s Central Post have 10 holes
4-
The flange used with the foundation segment of the Central
Post has two sets of 10 holes with two different circumferences i.e. the
foundation flange will have 20 holes with 24mm bolts.
5-
The Central Post will require 80 bolts with 24mm diameter
6-
The Central Post will also require two 11 inches
ball-bearings
7-
2 nine inches ball-bearings
8-
An upper and lower casing will house a total of 4
ball-bearings, where the lower casing will house the two 11 inches
ball-bearings while the upper casing will house the two nine inches
ball-bearings
9-
Each casing has four sides where each side is 40cm wide and
50cm long
10-
Each side of the casing will have two rows of threaded
holes, the distance between the two rows is 30cm. Each row has 12 threaded
holes each is 24mm diameter and 30mm deep.
11-
The bottom side of the lower casing will have 12 threaded
holes each 24mm in diameter and 30mm deep. These 12 holes will be used to fix
the 12 inches pulley to the casing.
12-
8 Steel channels each 9m long, 3 inches wide and 8mm thick will be bolted on the two casings. These 8 channels
have as many holes as the frames.
13-
Two steel channels 9m long will be bolted on each side of
the two casings, one channel will be bolted on the first row and the other will
be bolted on the second row.
14-
Finally, there is a four-sided channel 9m long rotating on
the main post. Each frame will be fixed on one side which consists of two 9m
channel where the positions of all the holes will match exactly the positions
of the holes on the frames.
Foundation and stabilization requirement for BSW prototype
To securely protect the BSW against powerful windy conditions a strong and well-designed
steel and concrete foundation is
needed.
The depth of the concrete foundation will be 3m long and the length and width 2.5m and 2.5m
respectively. A copper extension at the top of the BSW will secure it against lightening.
How safe is the BSW in a powerful storm?
The sketch below shows two Spinning
Frames. The one on the right shows
the three Swinging Windows are partially blocking the wind with their three shaded rectangular flaps. The left Spinning Frame shows how it is allowing all
the air to pass freely through the
gaps of the Swinging Windows without blocking
it.
In normal wind conditions,
however, the three Flaps of the right
Swinging Windows of the right Spinning Frame will stick to the steel Wire Mesh of the Swinging Windows when it is impacted by air and will block the air from
passing through the gaps.
But in this case a powerful wind is
blowing and exerting an enormous
force, almost at hurricane level, on the three Swinging
Windows of the right Spinning Frame and forcing their Flaps to shift out of place and allow the bulk of the wind
to pass freely through the gaps of the Swinging
Windows; this is a built-in safety
mechanism designed to protect the BSW against
destruction in hurricane and gale winds. The stronger the blowing wind the larger the gaps allowing the air to pass freely through them.
Thus, it is critical to keep in mind
that the BSW has an ingenious built-in
safety mechanism to protect it against destruction.
When the wind speed is normal, the safety mechanism
will not be activated.
But when the speed of
wind increases above a certain level the gape starts to open and as the speed
of the wind increases the gap gets larger letting more wind to pass through
active sail, so the BSW will be safe in all wind speeds but at the same time it
generates power, while conventional wind turbines must stop at such high winds,
if it does not stop it will be destroyed, while the BSW will generate power and
work normally in such distractive wind speeds.
The Actuator initiating the
safety mechanism can either be mechanical, where a spring can
control the size of the gaps
on the active Spinning Frame, the Spinning Frame impacted by air, or it can
be a magnet controlled by a controller
capable of measuring the speed of wind and accordingly
open the corresponding appropriate gap size for the wind to pass freely though these gaps and thus protect the BSW in powerful storms. Plus keeping the BSW
generating power at high-speed winds where other wind turbines must stop.
This safety mechanism is designed to
reduce the active Spinning Frame’s
surface area impacted by the wind.
As the wind gets stronger and stronger
the area impacted by the powerful wind
will get smaller and smaller.
Accordingly, the BSW is capable of
generating power even in extreme windy
conditions, unlike conventional wind turbines which
must be stopped to avoid its inevitable destruction.
BSW power output
calculations:
The detailed
calculations below will shed ample light on the most
crucial question concerning the BSW;
how much power
will the BSW generate?
We shall use
the universally accepted and used formula to calculate
power output by wind turbines:
Power
output (P) = 0.5 x air density at sea level (1.23) x swept area x wind velocity cubed x efficiency (Cp)
P = 0.5 × 1.23 × 2RH × V3 x
Cp
Where:
P = Power output
0.5 = General efficiency of wind powered generators
1.23 =
Air density at sea level
R= In conventional wind turbine, R denotes the
radius of the rotating blades.
In the case of a BSW, R
denotes
the distance between the Spinning
Frame’s
end column and the BSW’s Central Post
H = Height of the vertical column of the active Spinning
Frame
V3 =
The speed of wind cubed
Cp
= The efficiency rating assigned to wind turbines
But before outlining
the power output calculations in some detail,
and in order to understand and appreciate how these calculations are done, it is absolutely critical to highlight
an Important feature of the BSW’s
Spinning Frame’s structure which
plays an important role in how to calculate the generated power.
A BSW may have
3, 4, 5, or 6 Spinning Frames designed to spin, block the blowing wind and generate power. Think of the BSW’s Spinning Frames as Microsoft Window’s Excel
sheet consisting of multiple columns
juxtaposition next to each other; a series of parallel
columns as if they are stitched together.
BSWs of
different sizes will have different number of columns.
The larger the BSW the greater number of columns.
For example:
A BSW with 10m x 10m wide Spinning
Frames will have 5 columns, each 10m
long.
A BSW with 20m x 20m wide Spinning
Frames will have 10 columns, each 20m long.
A BSW with 30m x 40m wide Spinning
Frames will have 30 columns, each 40m long.
And just like
the Excel sheet with multiple cells, each BSW column
will have multiple Double-Sided Units (DSUs). Each DSU is 1m long and 2m wide.
Different size
BSWs will have different number of DSUs.
A BSW with 10m
x 10m wide = 200 DSUs
A BSW with 20m
x 20m wide = 800 DSUs
A BSW with 30m
x 40m wide = 2,400 DSUs
Having briefly
explained the general structure of the
BSW’s Spinning Frames which is directly responsible for generating power, it is crucial to explain an important
feature of the Spinning Frame which
has an enormous and direct impact
on how much power is generated.
A direct
application and use of the aforementioned power output Formula will give us a Conservative Power Output Figure. On the other hand, taking into
consideration the unique structure
of the BSW’s Spinning Frame and how the columns
are arranged in parallel columns, the same BSW will yield much higher Actual Power Output Figure
For
example, we can show that:
1-
BSW with 10m x 10m wide Spinning Frame can generate 98.4KW or 388.8
KW
2-
A BSW with 20m x 20m wide Spinning Frame can
generate 295KW or 2MW
3-
A BSW with 30m x 40m wide Spinning Frame can generate
590KW or 7.6MW
·
But how can we explain this huge discrepancy in
power output by the same BSW? As you can notice that the power discrepancy in a
BSW with 10m x 10m wide Spinning Frame is huge, 98.4KW versus 388.8KW.
When
we used the power output formula (quoted above on page 40) to calculate the lower power output figure of 98.4KW we simply aggregated the power produced by all
five columns of the BSW i.e. we did
not consider each column separately nor
did we assign a unique and corresponding radius (R) to each individual column. Instead, we simply used one general figure as a radius for all 5 columns and
applied it to the entire Spinning
Frame despite the obvious fact that each column has a unique and different radius of its own and produces its own specific amount of power which is
directly corresponding to its unique
radius.
To
explain the above point in more details, in the 2RH section of the power output calculation we simply used
20m to denote the radius (R) of the
entire Spinning Frame, although each of the
five columns has different radius of its own which is its distance from the Central Post of
the BSW.
In
light of the above explanation, here is how we can get two sets of different power output figures to
reflect the above-mentioned
observation.
To
drive the above point home and make it absolutely crystal clear three examples will be provided to show how
we can get a low Conservative Power
Output Figure and a much higher
Actual Power Output Figure for the same BSW.
A: So,
let us begin with a BSW with 10m x 10m wide Spinning Frame, attached on 20m
arm.
Our calculations can show that this BSW can generate either 98.4KW or 388.8
KW. But how?
This
Spinning Frame has 5 parallel columns, each column is 2m wide and 10m long. Despite the fact that the Spinning Frame has 5 parallel columns situated at
different distances from the Central
Post, when we assume that all 5 columns have
the same radius of 20m, then these 5 parallel columns will collectively generate only 98.4KW.
We
can simplify this matter even further by assigning specific letters to the 5 columns, A, B, C, D and E. All
five lettered columns will have the
same radius value of 20m.
In
the conservative method to calculate power generation we
do not calculate the power generated
separately by each individual column.
Instead the Spinning Frame will be considered
as one integral Spinning Frame with 20m radius and
10m height. Thus:
Conservative
Power Output:
P = 0.5 × 1.23 × 2RH × V3 x
Cp
P
= 0.5 x 1.23 x (2 x 20 x 10) x 103 x 0.4 = 98.4KW
Now,
let us calculate the Actual power generated by the same BSW with 5 parallel columns. The power
output figure will be a lot bigger.
And the reason is that each of the 5 columns, A, B, C, D and E will generate its own unique amount of power corresponding directly to the value of its
radius.
Putting
it in a nutshell as a general theory:
“All other values of all 5 columns being equal, the value of their
radius will determine the amount of power they produce; the bigger the radius the larger
the amount of power output”
So
how do we do that?
Let
us remember that each of the 5 lettered columns has its own specific radius, reflecting its corresponding distance from the Central Post of the BSW. Remember that the
five parallel columns are positioned in
series.
So,
starting from the far-right end of the Spinning Frame and moving in a left direction towards the Central
Post:
Column A: is
20m away from the central Post of the BSW i.e. its radius is 20m
Column B: is
18m away from the Central Post of the BSW i.e. its radius is 18m
Column C: is
16m away from the Central Post of the BSW i.e. its radius is 16m
Column D: is 14m away
from the Central Post of the BSW
i.e. its radius is 14m
Column E: is
12m away from the Central Post of the BSW i.e. its radius is 12m
Now
we are in a position to calculate the power generated by each column, depending on its corresponding
radius.
Actual Power Output
Power
produced by column A =
0.5 x
1.23 x (2 x 20 x 10 x 103 x 0.4 = 98.4
KW
Power produced
by column B =
0.5 x
1.23 x (2 x 18 x 10) x 103 x 0.4
=88 KW
Power produced
by column C =
0.5 x
1.23 x (2 x 16 x 10) x 103 x 0.4
= 77.6 KW
Power produced
by column D =
0.5 x
1.23 x (2 x 14 x 10) x 103 x 0.4
= 67.2 KW
Power produced
by column E =
0.5 x
1.23 x (2 x 12 x 10) x 103 x 0.4
= 57.6 KW
Total power
output = 388.8 KW
By adding all
the power generated by all 5 columns the Actual (total)
power generated by the same BSW is 388.8 KW; four times the value of
the Conservative figure of 98.4 KW
B: In
our second example we shall consider a BSW with 20m x 20m Spinning Frames, attached
on 30m arm. The calculations below will show that this BSW can generate a Conservative
power output of 295.2KW or an Actual power output of 2041KW (2MW).
By applying
the same method, we previously applied in example
A, here is a summary of all the critical information needed to reach the two sets of power output figures, a low Conservative figure and a
high Actual figure representing the total power generated by all 10 columns combined:
1.
A BSW with 20m x 20m wide Spinning Frame has 10 columns
lettered A, B, C, D, E. F, G, H, I and J.
2.
Each column is 2m wide and 20m long
3. Starting from the far-right end of the Spinning
Frame and moving in a left
direction toward the Central Post of the BSW,
column A is the farthest from the Central Pole and column J is the closest; the radius values of the ten columns, from column A to
column J, are as follow: 30m, 28m,
26m, 24m, 22m, 20m, 18m, 16m, 14m and 12m.
Conservative
Power Output Figure:
In a Conservative
power output calculation, the radius of the
arm is 30m and its height 20m.
P = 0.5 x 1.23
x (2 x 30 x 20) x 103 x 0.4 = 295.2KW
Actual
Power Output Figure:
In an Actual
power output calculation, we shall calculate the power output of each column, a total of 10
columns. And because each column
produces different amount of power corresponding
directly to the value of its radius, we shall calculate
all ten power output values, add them up together and reach the Actual power produced by a BSW with
20m x 20m wide Spinning Frame
attached on 30m arm.
Power
produced by column A = 0.5 x 1.23 x (2 x 30 x 20) x 103 x 0.4 = 295KW
Power produced
by column B = 0.5 x 1.23 x (2 x 28 x 20) x
103 x 0.4 = 275KW
Power produced
by column C = 0.5 x 1.23 x (2 x 26 x 20) x 103 x 0.4 = 255KW
Power produced
by column D = 0.5 x 1.23 x (2 x 24 x 20) x 103 x 0.4 = 235KW
Power produced
by column E = 0.5 x 1.23 x (2 x 22 x 20) x
103 x 0.4 = 216KW
Power
produced by column F = 0.5 x 1.23 x (2 x 20 x 20 x
103 x 0.4 = 196KW
Power produced
by column G = 0.5 x 1.23 x (2 x 18 x 20) x 103 x 0.4 = 176KW
Power produced
by column H = 0.5 x 1.23 x (2 x 16 x 20) x 103 x 0.4 =
157KW
Power produced
by column I = 0.5 x 1.23 x (2 x 14 x 20) x
103 x 0.4 = 137KW
Power produced by column J = 0.5 x 1.23 x (2 x 12 x 20) x
103 x 0.4 = 99KW
Total Power =
2041KW (2MW)
C:
In our third and final example we
shall consider a BSW with 30m x 40m wide Spinning Frame attached on 40m arm.
Our calculations will show that as Conservative
calculations this BSW can generate 590KW and as an Actual calculation will generate 7661KW
or 7.6MW
By applying
the same method which we’ve applied in the previous
two examples, here is a summary of all the critical information needed to reach the two sets of power output figures, a low Conservative figure
and a high Actual figure representing the total power generated by all columns combined:
A BSW with 30m x 40m frame has 15
columns lettered A, B, C, D, E. F, G, H, I, J, K, L, M, N and O. Each
column is 2m wide and 20m long
Starting from the far right-end of
the Spinning Frame and moving toward in a left direction to the
Central Post of the BSW,
column A is the farthest from the Central Post and J is the closest; the radius values of the columns from column A
to column O are as follow: 40m,
38m, 36m, 34m, 32m, 30m, 28m, 26m, 24m, 22m, 20m, 18m, 16m, 14m, and 12m.
Conservative
Power output:
In a Conservative power
output calculation, the radius of the
frame is 40m and its height 30m.
P = 0.5 x 1.23
x (2 x 40 x 30) x103 x 0.4 = 590KW
Actual Power
Output:
In an Actual power
output calculation, however, we shall calculate
the power output of each column, a total of 15 columns.
And because each column generates different amount
of power corresponding directly to the value of its radius, we shall calculate all 15 power output values, add them up and reach the Actual power
produced by a BSW with 30m wide x 40m
long frame, attached on 40m arm.
Power
produced by column A = 0.5 x 1.23 x (2 x 40 x 40) x 103 x 0.4 = 785KW
Power produced
by column B = 0.5 x 1.23 x (2 x 38 x 40) x
103 x 0.4 = 747KW
Power produced
by column C = 0.5 x 1.23 x (2 x 36 x 40) x 103 x 0.4 = 708KW
Power produced
by column D = 0.5 x 1.23 x (2 x 34 x 40) x 103 x 0.4 = 668KW
Power produced
by column E = 0.5 x 1.23 x (2 x 32 x 40) x
103 x 0.4 = 629KW
Power
produced by column F = 0.5 x 1.23 x (2 x 30 x 40) x
103 x 0.4 = 590KW
Power produced
by column G = 0.5 x 1.23 x (2 x 28 x 40) x 103 x 0.4 = 550KW
Power produced
by column H = 0.5 x 1.23 x (2 x 26 x 40) x 103 x 0.4 = 510KW
Power produced
by column I = 0.5 x 1.23 x (2 x 24 x 40) x
103 x 0.4 = 471KW
Power produced
by column J = 0.5 x 1.23 x (2 x 22 x 40) x
103 x 0.4 = 432KW
Power
produced by column K = 0.5 x 1.23 x (2 x 20 x 40) x
103 x 0.4 = 393KW
Power produced
by column L = 0.5 x 1.23 x (2 x 18 x 40) x
103 x 0.4 = 354KW
Power produced
by column M = 0.5 x 1.23 x (2 x 16 x 40) x 103 x 0.4 = 314KW
Power produced
by column N = 0.5 x 1.23 x (2 x 14 x 40) x 103 x 0.4 = 275KW
Power produced
by column O = 0.5 x 1.23 x (2 x 12 x 40) x 103 x 0.4 = 235KW
Total Power Output
= 7661KW or 7.6MW
Three phases of BSW
The
BSW project will go through three distinct phases.These phases will vary in duration due to various unpredictable circumstances including production problems,
evaluation method, potential governmental
bureaucracy as well as possible lack of
funding.
At
this stage it is fair to say that the three phases detailed below, may
last 12-18 months, at the most, if all critical
segments of the project are professionally managed
by highly qualified people. This time estimate will certainly be shortened depending on early successes achieved by the managing team.
Three critical phases of the BSW
project
The Prototype Phase
During
the prototype phase a strong and visionary partner is needed to finance the manufacturing of world-class
BSW prototypes. This phase will
require the manufacturing of 3 BSW
prototypes of different sizes.
The ultimate goal is to reach
the final desired BSW dimensions and power output capacity.
The
ideal investor-partner would have
the following essential qualifications.
1-
Sufficient funds to finance the
manufacturing of the 3 BSW prototypes. It is absoulutely critical to
secure a solid and binding comitmment from the partner that the agreed-upon
funds will be readily available to finish the prototype and certification
phases in order to complete these two crucial phase on time.
2-
Good grasp of the science and function of
the wind turbine to be able to appreciate what the team is trying to achieve.
3-
A spirit of support and cooperation to
back up the team and project to succeed.
Needless to say, if the partner is an
industrialist with access to sophisticated cutting machineries, advanced
welding tools, pneumatic presses and other vital machines, all under one roof
and operated by highly skilled technicians, the time to start and finish the
project will be considerably shorter.
Notes on the prototype phase
To follow tried and tested sceintific paths, a small BSW prototype with 10m x 10m wide Spinning
Frames will be the first prototype
to be manufactured. This would be the
smallest of the three prototypes to be manufactured.
Manufacturing the first prototype will shed ample light on several inter-related issues.
1- It will give the team a very good idea about production cost
and invalubale dollar and cents figures to budget for the second prototype.
2- It will highlight production pitfalls and how to avoid them
with the second prototype.
3- It will give the team managing the project an invaluable
experience that can be applied in manufacturing the second prototype.
4- Major parts of the first protoype will be used in manufacturing
the second prototype, thus saving money and reducing the overall production
cost and time of the second prototype. For example, the tower crane as well as the
200 Double Sided Units (DSUs) of the first prototype can be used in manufacturing
the second prototype. This represents a huge savings.
5- Perhaps the most important information that will be gleaned
from manufacturing the first prototype is the amount of power generated by this
BSW; the prototype will confirm the projected power output and inject the team
with a great dose of confidence that the project is resting on solid sceintic
foundation and that the second prototype with 20m x 20m wide Spinning Frames
will yield the projected power per the sceintific formula.
Construction cost of a BSW with 10m x 10m wide Spinning Frames
The following notes may shed some light on the cost of building a BSW with 10m x 10m wide four Spinning
Frames. A
potential partner-investor will be in a better position to complete the missing dollar figures, as
the patent holder, Jasim Al-Azzawi,
will currently not be able to provide exact figures
of some of the items that will be itemized below.
The overall cost of building a BSW with 10m x 10m wide Spinning
Frames will include 4 vital parts.
1-Spinning
Frames consisting of 200 DSUs
2-Construction tower crane to hang the Spinning
Frames on it
3-Generator
4-Foundation and stabalization of the BSW
Note:
As component prices, labor and transportation
cost and other relevant figures
related to manufacturing cost in specific country are currently
not available, the manufacturing cost breakdown below is based on
Sharjah, UAE, prices. Prices between the two countries are approximately similar.
The exchange rate of US dollar to UAE
dirhams is $1 = 3.65dhm. The figure of $72 includes prices of all DSU components (steel angle plates, Hollow Shafts,
ball-bearings, steel mesh, sail and bolts). The cost of materials,
however, was based on retail, not
wholesale, prices. Thus the overall material
price can potentially be reduced considerably, if a wholesale supplier can provide competetive prices.
Construction cost
of one Double-Sided Unit (DSU)
The DSU is the basic building block of the BSW. Different sizes BSWs
will have different number of DSUs. The bigger the BSW the larger number of
DSUs. The DSU is the heart of the BSW and as the size of the BSW increases the cost
of manufacturing the corresponding
number of DSUs will rise.
A BSW with 10m x 10m wide 4 Spinning
frames = 200 DSUs
A BSW with 20m x 20m wide 4 Spinning
Frames = 800 DSUs
A BSW with 30m x 40m wide 4 Spinning
Frames = 2,400 DSUs
What is extremely important to realize
is that power generation is
directly proportional to the increase in BSW size. The bigger the BSW the greater the power output.
A BSW with 10m x 10m frame will generate
= 388KW
A BSW with 20m x 20m frame will
generate = 2MW
A BSW with 30m x 40m frame will generate
= 7.6MW
A single DSU consists of the following
parts:
Angle Plates: 13
Shafts: 4m
shafts
Ball-bearings: 4
Swinging Window: 1
Flap: 1
Bolts: 8
Angle Plates: 4 dhm/meter (6m will cost 25dhm)
13 Angle plates x 4 = 52dhm
Hollow Shaft (4m needed): 1m shaft cost 5dhm
4 x 5 = 20dhm
Ball-bearings: 20dhm per ball-bearing
4 x 20 = 80dhm
Swinging Window: 40dhm
Flap: 30dhm
Bolts (8 are needed): 5dhm per bolt
8 x 5 = 40dhm
Total cost of components to build one
DSU = 262dhm
Total cost of components to build one
DSU = $72
Thus, the
total cost of the 200 DSUs of a BSW with 10m x 10m wide four Spinning Frames capable of producing 388KW is: $14,400 US dollars. The figure of $72 dollars does not take
into consideration labor cost, as no DSU
has so far been manufactured.
During the period prior to start manufacturing the
BSW a better understanding of labor cost will be investigated and factored in.
The BSW is modular and easily scalable, per customer needs
and cost considerations; however, the cost of manufacturing a DSU is fixed,
regardless of the BSW size. Thus, the dollar figures below provide good
indications of manufacturing cost as the size of the BSW increases.
A BSW with 10m x 10m wide 4 Spinning
Frames capable of producing 388KW:
Number of DSUs = 200 DSUs
Total cost of 200 DSUs = $14,400
A BSW with 20m x 20m wide Spinning
Frames capable of producing 2MW:
Number of DSUs = 800 DSUs
Total cost of 800 DSUs = $72 x 800 =
$57600
A BSW with 30m x 40m wide Spinning
Frames capable of producing 7.6MW:
Number of DSUs = 2400 DSUs
Total cost of 2400 DSUs = $72 x 2400 = $172,800
As precise cost of
tower cranes, foundation and labor cost are currently
unavailable these figures will be estimated and factored in prior to start manufacturing the prototypes.
Spinning Frames
Please bear in mind that the above figure of $72 dollars does not take into consideration
labor cost, as no DSU has so far been
manufactured. During the period prior
to start manufacturing the BSW a better understanding of labor cost will be investigated and added
to this figure.
The four Spinning Frames will hold 200 DSUs:
$72 x 200 = $ 14,400 cost of 200 DSUs
Tower crane with four intersected arms
Since neither the cost of building a tall tower
crane with two perpendicularly-intersected
arms to hang the four Spinning Frames nor the price of purchasing a second-hand tower crane from the local market and adapt/transform
it to fulfill the same function, are
currently not available to be included
in this cost breakdown, it is advisable to go ahead
now and survey the market to find out which
option is preferrable and more cost competitive..
As the current vision of the project is to
manufacture three BSW prototypes of
various dimensions (10m x 10m, 20m x
20m and 30m x 40m) we should explore and decide whether the lengths of the four arms of the tower crane
should match the legths of the Spinning
Frames for each BSW prototype or
should we use the same construction tower crane for all three different sizes prototypes?
For
the purpose of manufacturing the three BSW prototypes here are three options to consider and explore the cost of
each option.
1-
Use a tower crane with four perpendicularly-intersected
arms each 30m long for all three BSWs to hang the Spinning Frames on them. We
shall call this tower crane Type A.
2-
The lenghths of the four arms of each
tower crane used for each of the three BSWs should match the lenghths of the
Spinning Frames to maximize power outpu. We shall call this tower crane
Type B.
3-
A flexible tower crane whose four arms can
be extended and shortened to match the lenghths of the Spinning Frames of the
three BSWs; a purpose-built specially designed and manufactured tower crane
where 10m long segments can be extended or shortened from the four arms of such
felxible tower crane. We shall call this tower crane Type C.
So
what US dollar amount should we assign to the tower crane to be used with a BSW with 10m x 10m
wingspan Spinning Frames? The answer
depends on which of the three types enumerated
in the above paragraph we will use. While it is extremely difficult to speculate on the cost of designing and manufacturing Type C it should be a lot
easier to research the local market for a second-hand construction tower and adapt/transfor it to be used either as type A and B.
Having
highlighted the three types of tower cranes that can potentially be used with the BSW, for cost-saving purposes in
the prototype manufacturing phase of
the three different sizes of BSWs,
perhaps type A will be the logical choice for three main reasons.
1-
The same tower crane can be used with all
three BSWs
2-
Such tower cranes are widely available
worldwide.
3-
If the expected 7.6MW power generated by a
BSW with 30m x 40m wingspan Spinning Frames is achieved then we can deduce that
the expected power outpt of 388KW and 2MW of 20m x 20m and 10m x 10m
respectively will also be achieved.
Initial,
cursory prices of tower cranes provided by dealers of second-hand tower cranes ranged between
30-40K US dollars. But as of this moment no actual specifications, dimension, transportation cost or the actual locations of such tower cranes
have been confirmed. But perhapt it is
reasonable to assume that the cost is in the range quoted above.
Cost
of stabilization and foundation:
Unfortunately, at this stage it is rather difficult to
estimate the cost of securing
and stabilizing the BSW against hurricane
and powerful winds, since labor and transportation
cost as well as price of raw materials, such as
concrete and steel wires, are not available.
Among the four major cost items, i.e. Spinning
Frames, tower crane and generator,
foundation and stabilization cost,
the cost of the later item is the lowest and should not exceed $10,000 US dollars.
Generator:
A
generator is the only electro-mechanical purchased device needed for integration with the BSW; all other components will be manufactured or
purchased locally. The cost of the
generator constitutes a major percentage of the overall pricetag of an installed BSW.
It
is critical to keep the following important point in mind. As power output capacity of the BSW increases with size the cost of the inegrated generator
will also increase , while the cost of
other vital componenets (Spinning
Frames, tower crane, foundation and stabilization)
increases very modestly.
For
example:
1-
The cost of 500kW 250RPM 50Hz vertical PMG
generator used in 10m x 10m BSW is $52,600
2-
The cost of 2MW 500RPM 50Hz vertical PMG
generator used in 20m x 20m BSW is $99,900
3-
The cost of 5MW 600RPM 50Hz Vertical PMG generator
used in 30m x 40m BSW is $158,300
From the summary of power output capacities of the three BSWs
in ascending size (10m x 10m, 20m x 20m and 30m x 40m), the coressponding
expected power output of these BSWs is 388KW, 2MW and 7.6MW respectively.
BSW Manufacturing
Cost Breakdown
A- Final
manufacturing cost of BSW with 10m x 10m wide Spinning Frames using 500kW 250RPM
50Hz vertical PMG and producing 388KW
Estimatede cost of manufacturing 4 Spinning Frames =
USD 14,400
Estimated cost of procuring the right tower crane =
USD 30,000
Estimated cost of procuring the generator =
USD 52,600
Estimated cost of foundation and stabilization =
USD 10,000
Estimated cost of labor and transportation =
USD 20,000
Total cost of manufacturing 10m x10m BSW = 127,000
US dollars
B- Final
manufacturing cost of BSW with 20m x 20m wide Spinning Frames using 2MW 500RPM
50Hz vertical PMG and producing 2MW
Estimatede cost of manufacturing 4 Spinning Frames =
USD 57,600
Estimated cost of procuring the right tower crane =
USD 30,000
Estimated cost of procuring the generator =
USD 99,900
Estimated cost of foundation and stabilization =
USD 10,000
Estimated cost of labor and transportation =
USD 20,000
Total cost of manufacturing 20m x20m BSW =
$217,500 US dollars
C- Final
manufacturing cost of BSW with 30m x 40m wide Spinning Frames using 5MW 600RPM
50Hz vertical PMG and producing 5MW
Estimatede cost of manufacturing 4 Spinning Frames =
USD 172,800
Estimated cost of procuring the right tower crane =
USD 30,000
Estimated cost of procuring the generator =
USD 158,300
Estimated cost of foundation and stabilization =
USD 10,000
Estimated cost of labor and transportation =
USD 20,000
Total cost of manufacturing 30m x40m BSW =
$301,100 US dollars
BSW
Cost comparison with well-known International wind
turbine brand names
The costs for a utility scale wind turbine range from about $1.3 million to $2.2
million per MW of nameplate capacity
installed. Most of the commercial-scale turbines installed today are 2 MW in size and cost roughly $3-$4 million installed.
Maximum Power Output
|
Typical Turbine Type
|
Project Cost
|
800 kW
|
Enercon
E53/48/44
|
£1.4
million
|
900 kW
|
EWT DW61
|
£1.4
million
|
1.5 MW
|
GE
1.5sle
|
£2.7
million
|
2 – 3
MW1
|
Enercon
E82
|
£3.1
million
|
There are economies of scale, so larger turbines cost
less per KW-installed than smaller ones, and single turbine sites costing more
per KW than multiple turbine sites. Having said that, the table below shows budget
price for well-known international wind turbines.
Maximum Power Output
|
Typical Turbine Type
|
Project Cost
|
55 KW
|
Endurance
E-3120
|
£320k
|
800 KW
|
Enercon
E53/48/44
|
£1.4 million
|
900 KW
|
EWT DW61
|
£1.4
million
|
1.5 MW
|
GE
1.5sle
|
£2.7
million
|
2 – 3
MW1
|
Enercon
E82
|
£3.1
million
|
Final Important Note:
By carefully examining the price of the last two turbines
manufactured by GE and Enercon, £2.7 and £3.1 million British pounds to produce 1.5MW and 2-3MW respectively,
and comparing them with the cost of manufacturing a 20m x 20m and 30m x 40m
BSWs costing (approx) $300K and $400k US dollars we reach the following
inescapable conclusions:
1-
For
the price of one GE 1.5sle costing $3.5 million wind turbine we can manufacture
8 BSWs collectively capable of producing 40MWs.
2-
For the price of one Enercon E82 wind
turbine costing $4.2 million we can manufacture 10 BSWs collectively capable of
producing 50MWs.
Given the extreme low cost of manufacturing BSWs and the enormous amount of energy they can produce, an ideal partner is
needed to execute this project.
Executive Summary of Project Roadmap
Guidelines
Phase one:
1-
Identify a strong and committed partner/investor
2-
Project is formally presented to the partner
3-
Secure a binding financing commitment from the investor
4-
A project leader is presented to the investor
5-
Create a managing team to supervise project execution
6-
Identify strong windy location to deploy
prototypes
7-
Identify well-equipped workshop to manufacture prototypes
8-
Secure land rights to deploy prototypes
9-
Secure necessary permits to erect prototypes
Phase two:
1-
Place purchase orders for materials and parts
2-
Set specific time schedule to start and finish each phase
3-
Assign specific duties and responsibilities to section
managers
Phase three:
1-
Build first BSW (10x 10xm)
2-
Build second BSW (20m x 20m)
3-
Third BSW (30x 40m) should be built with 5MW generator to show
that this BSW can produce 5MW with fraction of the cost of very expensive
turbines built by GE and Enercon.
4-
While running and observing the second BSW, communication
should begin with companies authorized to issue certifications.
5-
The ultimate goal should be to secure three certified BSWs:
(A) A BSW capable of producing less that 1MW (B) ABSW capable of producing between
1-2 MW and (C) A BSW capable of producing 5MW. With these three BSWs the company will
be able to cover various commercial and consumer markets.
Phase four:
1-
Upon securing the appropriate BSW certificates a
professional feasibility study should be commissioned to cover all aspects of
the project, including production, financing, marketing, creation of
windfarms and identification of domestic and international suppliers of
materials and generators.
2-
A company will be incorporated to launch this
project.
3-
Simultaneously with exploring commercial aspects of the
project, a world class advanced production facility should be built in a
strategic location and staffed by highly skilled technicians.
4-
The Business Development Department should strive to secure
and sign Power Purchasing Agreements (PPA) with various utilities,
municipalities and governorates.
5-
Land rights necessary to establish windfarms must be secured
as well as agreements with the relevant entities to feed the power generated by
windfarms to the national grid.
Phase five:
1-
A year or two after launching the BSW project, the
R&D department will strive to move to a higher plane by securing
certification for BSW capable of producing 8MW and higher.
At this stage
of writing this prospectus an investor has not been identified and secured and consequently it is
difficult to know if funds will be extremely
tight or readily available. Some of the guidelines highlighted above assumes saving money is far more
important than completing the prototype
and certification phase as quickly as possible. If on the other hand availability of funds is not a
concern and the most important goal is to
finish the project and secure certification ASAP then some of the above recommendations can be ignored once we
know who the investor is and what sort
of funds will be allocated to the project.
The End
kirkuk BSW prototype plus links to all videos of BSW on
youtube