Wind Sail Project Status Low-Maintenance Wind Power System IPP Project ID: LBNL-T2-0203-RU

1. Wind Sail Project StatusLow-Maintenance Wind Power System IPP Project ID: LBNL-T2-0203-RU Daryl Oshatz LBNL Engineering Division April 2003

2. Wind Sail Program U.S. Department of Energy (DOE) IPP Partnership • Makeyev Design Bureau State Rocket Center (SRC), Miass, Russia DOE Funded • Empire Magnetics, Inc., Rohnert Park, CA Matches DOE Funding • Lawrence Berkeley National Laboratory (LBNL), Berkeley, CA DOE Funded

3. Responsibilities • Design, prototype, and test wind power systems for commercialization in the Off-Grid and End-of-Grid markets. • SRC • Turbine rotor, tower, enclosure • Testing of scaled models and full size prototypes • Mechanical design and integration of all systems • Empire Magnetics • Alternator, power conversion and control electronics • Radial and thrust bearings for supporting the rotor • Day-to-day project management of SRC effort • LBNL • Overall project management – quarterly and annual reviews • Technical review of SRC engineering calculations and physical test results

4. Concept Overview • Vertical Axis Wind Turbine (VAWT) • Rated power of systems between 3 and 70 kW. • Direct drive alternator – no gear box. • Modern power electronics will convert variable frequency, variable voltage alternator output into clean AC power (in sync with the grid as required). • Design Goals - build it like a “Russian Tank” • Optimize for reliability and durability of the overall system, not just maximum efficiency. • Minimize maintenance requirements (2+ year cycle). • System must withstand climatic extremes (Siberian blizzard scenario) and continue to produce power without need for immediate repair.

5. SRC Overview • Lead developer of submarine-launched ballistic missiles during the Cold War. • Conversion efforts for space projects have met with limited success. • Has been pursuing diversification into other fields, including wind and diesel power stations since the early 1990’s.

6. SRC Capabilities • Engineering expertise • Fluid mechanics - experience performing numerical simulations for wind turbine design • Mechanical design and analysis • Experimental facilities and experience • Hydrodynamic test facility onsite • Access to aerodynamic test facilities and equipment • Fabrication and assembly infrastructure

7. Empire Magnetics • Expertise in design and production of electric motors that are durable in extreme climatic conditions. • Industry contacts and sales channels to bring the product to market in the U.S. and Europe. • Existing Partnership with Uralmet, a Russian company. • Uralmet will provide local oversight to the SRC effort. • Uralmet hopes to pursue commercialization of the wind power system in Russia after the R&D phase.

8. Bearing Assemblies Housing Assemblies Stator Assembly Rotor Assemblies Output Shaft Coolant Channels Axial Gap Alternator Technology • High efficiency: 95-98 percent. • Rugged, light weight design - well suited to small VAWT’s. • Versatile - stackable for low RPM, high torque applications. • Low cost - simple design • May be licensed from a patent holder (Lynx Motion Technology or other company)

9. Other Technologies • Rectifier, inverter, control electronics • Delivered by Empire Magnetics and partner companies (XZEL LLC, ElectriHydrolic Company) • Power conditioning for End-of-Grid applications. • Installation at the end of long transmission lines • 30 kW systems could control the voltage and power factor for 60 kW. • Control system enables autonomous and safe operation. • Bearing technologies • Long life radial and thrust bearings to support the rotor. • Hybrid magnetic thrust bearing is under consideration. • Permanent or electro magnets support the weight of the rotor. • Conventional radial bearings center load

10. Requested Funding • IPP funding over two years: $1,350 k • Year 1: $405 k • Year 2: $945 k • 70 percent of funds spent at SRC. • Empire Magnetics contribution: $1,350 k • $100 k cash - funds some technical work at LBNL. • Partner companies, in particular Uralmet, share in costs. • Once the project is funded there are plans to found the Wind-Sail company.

11. Challenges • Collaborative design and construction project • Early requirements and constraints definition critical to success. • Competing Agendas • SRC - existing designs for wind turbines and power stations. • U.S. companies want to bring a competitive product to market ASAP – not necessarily an existing design. • R&D schedule (IPP) vs. market opportunity • Project emerged out of entrepreneurial initiative in the spring and summer of 2001. • volatile U.S. energy market could affect enthusiasm. • Communication • Uralmet is intermediary. • Some details lost in translation so far.

12. DOE Progress • Funding began at LBNL in May 2002 to launch the project • CRADA agreement signed with Empire May 2002 • LBNL has performed technical feasibility and market research to guide the collaboration. • No DOE funding in Russia as of April 1, 2003 • An NGO, ISTC, has approval to distribute DOE funds to Russian staff • Agreement reached on a spending plan for the two-year effort (salaries, equipment, materials) • Equipment (PC’s, office equipment, etc.) purchases likely in April 2003

13. Empire Magnetics Progress • Empire staff visited SRC in November 2002 • Private company founded in Russia, SRC-Vertical, Ltd., in March 2003 • Will employ majority of the scientists and engineers working on the project outside of SRC during and after the DOE funded stage • Empire Magnetics, Uralmet, and SRC share ownership • Empire Magnetics and Uralmet are seeking investment to support their effort • Venture capitalists • Private non-OEM companies with retail wind turbine customers

14. Turbine Designs under Consideration • 3 kW Turbine • H-Darrieus • Design and prototype in first six months • Use prototype for marketing purposes in first six months • 30 kW Turbine • H-Darrieus • Prototype at end of year one • 70 kW Turbine • H-Darrieus or traditional Darrieus • Prototype at end of year two

15. 3 kW Turbine Concept • Functions • Residential net-metering or battery charging • Compliment to existing solar or diesel off-grid or backup power system • Features • Customer installed • Roof or tower mounted • Self starting • Use existing (for solar) or off-the-shelf power electronics • Low O&M -install and forget

16. 3 kW Turbine Concept for the Japanese Market • Designed for aesthetic appeal to residential consumers • Potential investor claims to have 1000+ customers willing to purchase turbines for $6k to $20k retail

17. 3 kW Turbine Sample Specification Specification: Type: H-Darrius Vertical Axis Wind Turbine. Two Sections, three blades each. Rated Power Output: 3KW at 15 m/s (31mph) Rotor Diameter: 1.8m (5.9 ft) Rotor Active Height: 2.2m (7.2 ft) Overall Height: 3m (9.8 ft) Start-up Wind Speed: <4m/s (9 mph) (Rotor starts turning) Cut-in Wind Speed: 4 m/s (9 mph) (min speed at which output voltage and frequency are in spec.). Wind Speed to produce 800 watts: 10 m/s (22 mph) Rated Wind Speed: 15 m/s (31 mph). (speed at which unit produces 3KW) Furling: None. Blade Pitch control: None Overspeed Protection: Rotor maximum rotational velocity limited by aerodynamics; active braking limits power output. Mechanical brake activated at 125KPH (77mph) Structural Design Wind Speed: 160KPH (100mph) Gear box: None. Direct Drive Temperature Range: -40 to +60 C (-40 to +140 Deg F) Generator: Axial Flux Permanent Magnet Alternator Output voltage: 300-400VDC; designed to operate with PV oriented inverters, such as the Sunny Boy 2500 Estimated installed price: Less than $6K USD.

18. 30 – 70 kW Turbine Concepts • No current conceptual designs have been released form SRC because of lack of funding thus far from DOE • Some generic ideas have been circulated