Application of In-House FRP Technology

Prepared for

GILGWANG
GREENTECH

2007. 9. 28 (Fri)

Jong-Won Lee betweenhint@paran.com 017-401-1040

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Contents In-House FRP Products

l l l l l Pipes & Ducts Fans & Pumps Tanks & Plating Tanks Lining, Flanges & Gratings Scrubber System

From From From From

Pipes & Ducts to Tower Structures Tanks & Plating Tanks to Closed Cells Fans & Pumps to Turbines Scrubber System to Clean Power Plant

l Wind Power Plant KIMM () l Tidal Power Plant KORDI ()

Captured Wind Energy Short-Term Targets New Technology to be applied Concluding Remarks
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In-House FRP Products In-House FRP Products

l l l l l Pipes & Ducts Fans & Pumps Tanks & Plating Tanks Lining, Flanges & Gratings Scrubber System

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In-House FRP Products In-House FRP Products

l Pipes & Ducts l Fans & Pumps
Motor : Offthe-Shelf (?)

l Tanks & Plating Tanks l Lining, Flanges & Gratings l Scrubber System

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In-House FRP Products In-House FRP Products

l l l l l Pipes & Ducts Fans & Pumps Tanks & Plating Tanks Lining, Flanges & Gratings Scrubber System

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In-House FRP Products In-House FRP Products

l l l l l Pipes & Ducts Fans & Pumps Tanks & Plating Tanks Lining, Flanges & Gratings Scrubber System

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From Pipes & Ducts to Tower Structures Pipes & Ducts + Axial Reinforcement = Tower Structures
l Development Test + Qualification Test + Certification Test

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From Pipes & Ducts to Tower Structures Pipes & Ducts + Axial Reinforcement = Tower Structures
l Development Test + Qualification Test + Certification Test
Wind Tower / Lighthouse Tower : Possible Candidate for KIMM Project

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From Fans & Pumps to Turbines Fans & Pumps + The Other Side of a Coin = Turbines
l Development Test + Qualification Test + Certification Test

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From Fans & Pumps to Turbines Fans & Pumps + The Other Side of a Coin = Turbines
l Development Test + Qualification Test + Certification Test
Vertical Wind Turbine Blades : Possible Candidate for KIMM Project Vertical Tidal Turbine Blades : Possible Candidate for KORDI Project

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From Fans & Pumps to Turbines Fans & Pumps + The Other Side of a Coin = Turbines
l Development Test + Qualification Test + Certification Test
Vertical Wind Turbine Blades : Possible Candidate for KIMM Project Vertical Tidal Turbine Blades : Possible Candidate for KORDI Project

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From Tanks & Plating Tanks to Closed Cells Tanks + Complex Shape = Closed Cell Structures & Containers
l Development Test + Qualification Test + Certification Test

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From Tanks & Plating Tanks to Closed Cells Tanks + Complex Shape = Closed Cell Structures & Containers
l Development Test + Qualification Test + Certification Test
Wind Turbine Nacelles : Possible Candidate for KIMM Project Aircraft Engine Nacelles : Possible Candidate for In-House Prepreg Project

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From Scrubber System to Clean Power Plant Scrubber System + The Other Side of a Coin = Clean Power Plant
l Development Test + Qualification Test + Certification Test

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From Scrubber System to Clean Power Plant Scrubber System + The Other Side of a Coin = Clean Power Plant
l Development Test + Qualification Test + Certification Test
Small Wind Power Plant : Possible Candidate for KIMM Project Small Tidal Power Plant : Possible Candidate for KORDI Project

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Captured Wind Energy Power extracted depends on the difference-squared of the incoming and outgoing wind velocities.
Po = 1 2 & 2 m(Vi - Vo ) 2

If mass-flow rate is the average of Vi and Vo,

0.6

Pmax = Cp Ar

V i3
Cp

0.5 0.4 0.3 0.2 0.1 0 0 0.2 0.4 0.6 0.8 1

Cp = [1 - (Vo / Vi )2 ] [1 + (Vo / Vi )]

Vo/Vi

Power Coefficient, CP = 16/27 (59%) at Vo / Vi = 1/3

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Captured Wind Energy Aerodynamic efficiency for various wind turbines

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Captured Wind Energy Aerodynamic efficiency for propeller type windmill

l 1 16/27
Betz 59% limit

l Loss due to swirl by torque

Slower rotors are worse.

l Wing tip loss

Tip vortex due to finite blade span.

l Loss due to drag

Lower lift/drag ratio causes more loss. Optimum tip speed ratio minimizes loss.

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Captured Wind Energy Aerodynamic efficiency for propeller type windmill

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Captured Wind Energy Final efficiency for propeller type windmill

l Wind Energy 100 Mechanical Energy 40 Electrical Energy 30 l This is the best we can do !

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Captured Wind Energy Wind Turbine Components & Their Functions

l http://www.eia.doe.gov/cneaf/solar.renewables/rea_issues/wind2.html
Turbine Component Nacelle Rotor blades Hub Low speed shaft Gear box Function Contains the key components of the wind turbine, including the gearbox, yaw system, and electrical generator. Captures the wind and transfers its power to the rotor hub. Attaches the rotor to the low-speed shaft of the wind turbine. Connects the rotor hub to the gearbox. Connects to the low-speed shaft and turns the high-speed shaft at a ratio several times (approximately 50 for a 600 kW turbine) faster than the lowspeed shaft.

High-speed shaft Drives the electrical generator by rotating at approximately 1,500 revolutions with mechanical per minute (RPM). The mechanical brake is used as backup to the brake aerodynamic brake, or when the turbine is being serviced. Electric generator Yaw mechanism Electronic controller Hydraulic system Cooling system Tower Usually an induction generator or asynchronous generator with a maximum electric power of 500 to 1,500 kilowatts (kW) on a modern wind turbine. Turns the nacelle with the rotor into the wind using electrical or other motors. Continuously monitors the condition of the wind turbine. Controls pitch and yaw mechanisms. In case of any malfunction (e.g., overheating of the gearbox or the generator), it automatically stops the wind turbine and may also be designed to signal the turbine operator's computer via a modem link. Resets the aerodynamic brakes of the wind turbine. May also perform other functions. Cools the electrical generator using an electric fan or liquid cooling system. In addition, the system may contain an oil cooling unit used to cool the oil in the gearbox. Carries the nacelle and the rotor. Generally, it is advantageous to have a high tower, as wind speeds increase farther away from the ground.

Anemometer and Measures the speed and the direction of the wind while sending signals to wind vane the controller to start or stop the turbine.

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Captured Wind Energy Cost Breakdown of Wind Power Plant

l Capital cost breakdown of a typical 5 MW onshore project
http://www.bwea.com/ref/econ.html

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Captured Wind Energy Cost Breakdown of Wind Turbine

l RE Power MM92 Turbine : Blade L =45.3m, Tower H = 100m
Why Turbine AND/OR Tower ?

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Captured Wind Energy Cost Breakdown of Blade

l http://www.sandia.gov/wind/other/031428.pdf

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Captured Wind Energy Material Characterization for Turbine Blade

l http://www.owenscorning.com/hiper-tex/pdfs/WindEnergyAnalysis.pdf

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Short-Term Targets Tower Structure

l Wind Tower Team up with KIMM l Lighthouse Tower Independent Trial

Turbine Blades
l Vertical Wind Turbine Helical Blades : Independent Trial l Vertical Tidal Turbine Helical Blades : Team up with KORDI

Closed Cell Structures & Containers

l Wind Turbine Nacelles : Team up with KIMM l Tidal Turbine Housings : Independent Trial

Small & Clean Power Plant

l Wind Power Plant : Team up with KIMM l Tidal Power Plant : Team up with KORDI

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Short-Term Targets Why WIND AND TIDAL together ?

l Water Density / Air Density 844
Same power with same fluid velocity : DAIR / DWATER 29 Small Tidal Power Plant = Big Wind Power Plant

Why small turbines ?

l Less Risk & Less R&D Cost
A giant turbine is too costly to learn know-how & know-why. Thousands of Smalls vs Several Giants After-Service Market

Why vertical arrangement ?

l Attack the niche market first, then the main stream.
However, the vertical turbine can provide most urgent technologies.

l Use ground vehicles instead of remote fixed sites for demonstration.

Why helical shapes ?

l To minimize the pulsating torque
In Darrieus-derived designs, pulsating torque has caused serious vibration. Korea (KORDI) has been testing a helical type as a tidal power plant.

However, the long-term target is GIANT HORIZONTALS ! l The above must be beneficial for themselves.
l The above shall serve as stepping stones toward giant horizontals.
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New Technology Build-Up

In-House Processing Trial
l Vacuum Assisted Resin Transfer Molding l Oven Curing with Vacuum Bagging l Metal-to-FRP Bonding & Fastening
Help from KIMM

l Test & Evaluation + Qualification & Certification

Help from KIMM

In-House System Integration Trial

l Support from KIMM : Small Wind Power Plant System l Support from KORDI : Small Hydro Power Plant System l Outsourcing from Universities :
Aero/Hydro Dynamics Material Characterization Static & Fatigue Structural Analysis Automatic Control, etc.

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Concluding Remarks
Examples of Positive Synergy Effect
l General Electric : , ,
/

l : + Crane + Bucket
2 Gyroplane

Examples of Negative Synergy Effect

l Vivendi : ,
Universal Studio , /

l : ,
1990 , 2

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Concluding Remarks
Long Term Target
l Pursue win and win games.
Positive synergy effect must be maximized. Slow and steady wins the race toward a global target.

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Concluding Remarks
Short Term Target
l Avoid all or nothing games.
Negative synergy effect must be minimized. Quick but quiet wins the race toward a local target.

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