Renewable Energy: Salih N. Akour, Mohammed Al-Heymari, Talha Ahmed, Kamel Ali Khalil
Renewable Energy: Salih N. Akour, Mohammed Al-Heymari, Talha Ahmed, Kamel Ali Khalil
Renewable Energy
journal homepage: www.elsevier.com/locate/renene
a r t i c l e i n f o a b s t r a c t
Article history: Micro wind turbine blades for low average wind speed regions like the Arabian Peninsula, Jordan Desert
Received 12 November 2016 and United Arab Emirates are designed and implemented. Wind profiles for two locations in UAE are
Received in revised form investigated and utilized in the design and the economic analysis. Airfoils BW3, A18 and SG6043 are
17 June 2017
selected and utilized as candidates for designing micro turbine blades. Blade element momentum theory
Accepted 25 September 2017
Available online 26 September 2017
is used to design the blade 3D geometry. A methodology to optimize the blade geometry for average
wind speed 5 m/s based on operational Reynolds number is developed and utilized. To account for the
aerodynamic behavior over the 3D blade geometry, the power coefficient for the blades of each airfoil is
Keywords:
Micro wind turbine
obtained using the simulation software QBlade. Blades developed using airfoil BW3 showed the highest
Arabian Peninsula wind profile performance. A prototype is built using 3D printer and tested in open air environment (natural envi-
Feasibility study ronment) to validate the simulation results. Comparison with existing commercial wind turbines ac-
cording to cost and output power is carried out based on the concept of replacing wind turbines swept
area with the equivalent array of micro wind turbines. The results show that the new design is more cost-
effective and more wind energy is harnessed using equivalent swept area.
© 2017 Elsevier Ltd. All rights reserved.
https://doi.org/10.1016/j.renene.2017.09.076
0960-1481/© 2017 Elsevier Ltd. All rights reserved.
216 S.N. Akour et al. / Renewable Energy 116 (2018) 215e223
The wind data of Abu Dhabi and Al Ain is obtained from Iowa
Environmental Mesonet (IEM) that collects environmental data
using the Automated Surface Observing System (ASOS) which is
located at airports. Table 1 shows summary of the data.
Weibull distribution is widely used by many researches for wind Fig. 2. Rayleigh and Weibull PDFs for Al Ain.
data analysis, but since the sites have low wind speeds, it has some
limitations for the low wind speed probabilities [15]. For this
reason, Rayleigh distribution is also used. Graphs for Weibull and 1. Each blade is divided into set of elements.
Rayleigh probability density function (PDF) for Abu Dhabi and Al 2. There is no aerodynamic interaction between elements (thus, no
Ain are shown in Figs. 1 and 2 respectively. radial flow).
It can be seen from Figs. 1 and 2 that wind speeds close to 5 m/s 3. The forces on the blades are determined by the lift and drag
have the highest probability. It is obvious that the average wind characteristics of the airfoil shape of the blades where these are
speeds of both sites are close to 5 m/s. Therefore, this speed is function of Reynolds number.
chosen to be the design rated wind speed for the micro wind tur- 4. The design is optimized for wind speed of 5 m/s. Two main
bine blades. variables are impeded in Reynolds number, the chord length
The wind rose for both cities Abu Dhabi and Al Ain are presented and the wind speed. The design wind speed is fixed at 5 m/s
in Fig. 3. These graphs illustrate that the wind dominant direction is whereas the chord length is varied to reach the optimum ge-
North-West. The wind turbine is equipped with guide vane to allow ometry for the blades that maximizes the power coefficient.
self-adjustment with the wind direction. 5. BEM theory for ideal rotor with wake is used in designing the
blade shape.
6. The performance analysis of the optimum geometry, which is
3. Theoretical modeling obtained from BEM, is performed using Qblade software Pack-
age. Qblade carries the performance analysis by considering the
Theoretical analysis is conducted for selected airfoils of high aerodynamic effects of the neighboring elements that is ignored
performance at low wind speeds (low Reynolds number), i.e. Air- by the BEM theory. This provides performance analysis that is
foils that have high lift coefficient. The blade geometry is optimized very close to the real life performance.
for wind speed of 5 m/s. It is well known that the lift and drag
coefficients are function of angle of attack and Reynolds Number
[11,12]. To reach highest performance, Reynolds number is
3.1. Airfoils
considered as an optimization parameters' along with the other
parameters' considered by the BEM theory. Fig. 3 illustrates the
The airfoils for the micro wind turbine blades are chosen from
developed methodology that considers Reynolds number in
‘Summary of Low-Speed Airfoil Data’ [11,12]. Three airfoils are
designing the blades. This method is developed to reach the opti-
considered for designing the micro wind turbine blades. Simulation
mum geometry of the blades.
is performed to choose the airfoils with highest Cp . Airfoils BW3,
The basic assumptions used in the design are mainly the as-
SG6043 and A18 have been chosen because they are designed to
sumptions of the BEM theory. The assumptions and conditions that
operate at low Reynolds number i.e. to operate at low wind speed.
are implemented in the design process are as the following:
These airfoils are presented in Fig. 4. Careful analysis is done on
these airfoils to investigate their performance at low values of
Table 1 Reynolds number that reflects the operational condition in UAE.
Descriptive statistics for Abu Dhabi and Al Ain.
Fig. 3. Illustration of Wind roses for both Abu Dhabi and Al Ain Cities in UAE.
chord length located at 30% chord length measured from the airfoil torque at low wind speeds that will lead to improve energy har-
leading edge and maximum camber of 3.84% of the chord length nessing [11].
located at 45% chord length measured from the airfoil leading edge
[12]. This model was introduced later as a small wind turbine airfoil 3.1.3. SG6043
because it has shown good results for constant speed and stall The SG6043 airfoil is one of the series that are designed for the
regulated wind turbines. In addition, it is suitable for variable speed small wind turbines by Giguere and Selig. This airfoil has a
wind turbines as it has shown good characterization of lift-to-drag maximum Cl of 1.22 at optimum angle of attack, a of 5 . This high
ratio as long as it is clean [12]. lift coefficient makes it a good candidate for the design [11].
3.1.2. BW3 3.2. Methodology for selecting the operational Reynolds number
Bergey Windpower has designed the BW3 for their wind turbine
system. Unlike other airfoil geometries, the BW3 is designed with a BEM theory is coded in MATLAB to obtain the optimum blade
relative thickness of 5% of the airfoil chord length. BW3 airfoil shape for the three airfoils. Reynolds number is function of chord
apparently does not experience the formation of large separation length and wind speed assuming the density and viscosity of air is
bubbles at Reynolds number of 100,000 contrary to other thicker constant. The methodology shown in Fig. 5 is developed and
airfoils. The high lift coefficient, Cl value of this airfoil makes it implemented to obtain the operational Reynolds number and blade
suitable for a small wind turbine blades from an operational point shape. Through the iterations the wind speed is fixed at 5 m/s and
of view because a high Cl provides the turbine with a high startup the chord length is varied along with the other blade geometry
parameters (the element location and twist angle).
Fig. 4. Illustration of A18, BW3 and SG6043 Airfoil Profiles in dimensionless format
with respect to the chord length. Fig. 5. Methodology to find the Reynolds number.
218 S.N. Akour et al. / Renewable Energy 116 (2018) 215e223
Table 2
Geometry of the blade made of BW3 airfoil.
Fig. 7. Variation of Cp with iterations. Fig. 8. Illustration of Cp at different TSR for ATT Blade.
S.N. Akour et al. / Renewable Energy 116 (2018) 215e223 219
system for its originally designed blades [17]. The tests have been 5.1. Open air environment tests
conducted by replacing the original turbine blades with the ATT
prototype blades on the AIR-X rotor as shown in Fig. 10. A total of 40,000 data points of both current and voltage have
been collected using the DAQ for a wide wind speed range
(2.7e5.9 m/s). Fig. 11 shows that as the wind speed increases the,
4.2.1. Measuring methods
electric current increases. The behavior of the rotor rotational
The electrical power, current and voltage of the wind turbine
speed with respect to the wind speeds is shown in Fig. 12. It is
have been recorded using an NI 6009 USB data acquisition system
obvious that the rotor angular speed is linearly varying with the
(DAQ) module at a 1 kHz sampling rate. The voltage is measured
wind speed.
directly by connecting the two terminal output of the wind turbine
The final power calculated from the wind turbine is not only
to the DAQ whereas the current is measured using a 5 ohm shunt
affected by the Cp of the airfoil but also by the generator, gear box
resistor. The DAQ has been connected to a PC via USB connection.
and all electric circuits used in the wind turbine. Fig. 13 presents the
Each test for ATT has been videotaped using a camera that has
calculated Cp at different TSR in the open air environment tests. The
capability of capturing 30 frames per second (FPS). The recorded
values of the calculated Cp versus TSR obtained from the open air
videos of the tests have been processed using slow-motion video
environment test shown in Fig. 13 closely follow the value of Cp
software VideoMach. The rotational speed of the rotor in terms of
versus TSR obtained from QBlade simulation shown in Fig. 8. Any
revolution per minute (RPM) has been measured through these
differences are due to the continuous variation of the air speed in
recorded videos.
the open air environment.
Fig. 10. AIR-X with ATT blades. Fig. 11. Current at different wind speeds.
220 S.N. Akour et al. / Renewable Energy 116 (2018) 215e223
Table 3
Characteristics of ATT.
ATT Characteristics
Radius 0.5 m
Area 0.79 m2
Rated Wind Speed 5 m/s
Rotational Speed 415 RPM
Rated Power 25 W
TSR of 3.5.
The variation trend of the current with the wind speed is linear
as it can be seen from Fig. 11 which agrees with the physics of
problem [16]. The flatness in the electric current graph in Fig. 11 can
be referred to the MPPT system that tries to operate the turbine at
Fig. 13. Calculated Cp at different TSR in the open air environment tests. the programed optimum TSR.
The stairway shape of Fig. 12 is due to the time needed for the
harnessing more power than the AIR-X. ATT is producing more turbine to respond to the changes in wind speed and due to the
power than AIR-X within the range of 2 m/s to 11.5 m/s wind speed recording of the average wind speed over half minute (every 30 s).
as shown in Fig. 15. AIR-X has a better performance in the range The linear trend of the variation of the rotor angular speed with
above 11.5 m/s which is beyond the operating wind speed of ATT. respect to the wind speed agrees with physics of problem [16].
5.5. Sub-conclusion
5.4. Discussion
The ATT has rated power of 25 W at the rated wind speed of 5 m/
Figs. 8 and 13 show the power coefficient obtained from the
s. Table 3 shows the final characteristics of ATT.
simulation analysis and experimental tests respectively. The
maximum power coefficient achieved from the simulation and the
experiments is 0.38 at TSR of 4.4 and 0.34 at TSR 3.5 respectively.
The differences in the maximum power coefficient can be referred
to two main reasons: first, the continuous variation of wind gust
speeds where the average wind speed over half minute (30 s) is
considered. Second the MPPT system of AIR-X is tuned for TSR of 3.5
whereas the ATT is design for TSR of 4.4. The second issue also
explains why in the simulation results the power coefficient peak
occurs at TSR of 4.4 whereas in the experimental results occur at
Fig. 14. Power curves of ATT and AIR-X for low wind speeds. Fig. 16. Energy (top) and CO2 footprint (bottom) analysis [21].
S.N. Akour et al. / Renewable Energy 116 (2018) 215e223 221
Phase Cost (USD) The payback period can be calculated using the following
Material 1.51
equation:
Manufacture 0.47
Transport 0 Total cost
Payback ¼ (1)
Use 0 Annual energy cost savings
Disposal 0
Total 1.98 According to Equation (1), the annual energy cost savings is
equal to the annual energy production of ATT in UAE multiplied by
the UAE green tariff rate of AED 0.23/kWh (USD 0.06/kWh). Abu
6. Economic feasibility study Dhabi is considered as sample location to calculate the annual ATT
energy production in UAE. Rayleigh PDF shown in Fig. 1 is used to
The economic feasibility study has been conducted for the ATT calculate the annual number of hours for different wind speeds as
blades as per the selected material and the selected mass produc- shown in Table 5. Annual energy production is calculated by sum-
tion technique. The software CES EduPack's eco audit tool is used to ming up the product of annual number of hours of different wind
generate the life cycle of ATT blades showing the cost, energy and speeds and power produced at those wind speeds. Power produced
CO2 footprint. by ATT at different wind speeds is determined by the data of the
The chosen material is thermoplastics because it is light in power curve shown in Fig. 15.
weight, durable, eco-friendly and can be recycled. The injection The annual energy cost saving is USD 27.36 calculated by
molding is chosen as manufacturing technique since it is cost- multiplying the total ATT annual energy production 456 kWh by
effective and suitable for thermoplastic material [21]. The relative the green tariff rate USD 0.06/kWh. The total price of single ATT
cost index for the injection molding is ranging from USD 16.44 to including all components is estimated to be USD 50. This gives
USD 111.63 per unit. This value is based on material cost of USD 8/ payback period for ATT of 1.83 years.
kg, blade mass of 1 kg and batch size of 1000 unit [21].
6.4. Comparison of ATT with other wind turbines
6.1. Energy and CO2 footprint analysis
To demonstrate the effectiveness of ATT, it is compared with
Fig. 16 shows comparison between the energy consumption and some wind turbines available in market. The comparison is in terms
CO2 footprint. It can be seen from Fig. 16 that the material pro- of swept area, power, cost and annual energy production. Table 6
duction ranks first in terms of the energy consumption whereas presents the comparison analysis between ATT and other wind
CO2 footprint and the manufacturing process rank second and third turbines available in market. All the values are obtained for wind
respectively. The material stage consumes 85% of the energy speed of 5 m/s. The price of a single ATT is estimated to be USD 50 as
whereas the manufacturing is 14% of the total energy. The material mentioned in previous section. All prices shown in the table are the
phase represents 81% of CO2 footprint whereas the manufacturing prices of the wind turbine themselves excluding the installation
represent 17.5% of CO2 footprint. Due to recycling process, there is cost which would vary depending on the location.
recovery of 36.5 MJ of energy and 2.11 kg of CO2 footprint. SY-1kw is so much cheaper compared to Britwind R9000 and
Bergey Excel 10 because it's Chinese product i.e. the labor cost is
6.2. Cost analysis cheap compared to USA and Europe. ATT has very low cost
compared to Britwind R9000 and Bergey Excel 10 and at the same
Cost analysis showed that the three ATT blades cost USD 1.98. As time it is producing more power. For SY-1kw turbine, the cost per
seen in Table 4, the material accounts for 76.3% of the cost and the Watt is similar to ATT but it has higher Cost compared to Equivalent
manufacturing makes up 23.6% of the cost. ATT in Terms of Swept Area.
Table 7 shows the annual energy production for the commercial
wind turbines SY-1kw, Bergey Excel 10 and Britwind R9000 based
Table 5
on the data of wind speeds and their corresponding annual hours
Annual energy production of ATT in UAE.
that are presented in Table 5. Power curves available at the website
Wind Speeds (m/s) No. of Hours Annual Energy of each commercial wind turbine are used to determine the power
Annually (h) Production (Wh)
produced at different wind speeds by these turbines. A concept of
1 467 0 replacing these commercial wind turbines with equivalent number
2 860 1222
of micro wind turbines (ATT in this case) in terms of swept area is
3 1125 5397
4 1238 14,084 presented.
5 1210 26,876 Table 7 demonstrates that more energy is produced from
6 1074 41,238 equivalent array of micro wind turbines in terms of swept area
7 878 53,521 compared to one wind turbine. This energy would also be produced
8 665 60,554
9 470 60,901
at a much lower cost as illustrated in Table 6. From the analysis, it
10 310 55,175 can be seen that the concept of replacing one wind turbine with
11 192 45,460 equivalent array of micro wind turbines in terms of swept area is
12 112 34,302 more cost-effective and harnesses more energy from equivalent
13 61 23,829
swept area. Other advantages would include producing power at
14 31 15,305
15 15 9117 very low wind speeds and the micro wind turbine system can also
16 7 5051 be installed in urban areas because unlike the large wind turbines,
17 3 2608 micro wind turbines can harness wind energy in turbulent air flow
18 1 1257 since the uniform air mass needed as small as the size of the ATT
Total Annual Energy Production (kWh) 456
rotor. For example, according to the last two rows in Table 7 the
222 S.N. Akour et al. / Renewable Energy 116 (2018) 215e223
Table 6
Comparison of ATT with wind turbines available in market at wind speed of 5 m/s.
Data at 5 m/s
Table 7
Comparison of annual energy production of ATT compared to wind turbines available in market.
Wind Speeds (m/s) No. of Hours Annually (h) SY-1kW Bergey Excel 10 kW Britwind R9000 ATT
1 467 0 0 933 0
2 860 0 0 859 1222
3 1125 0 114,720 15,745 5397
4 1238 1,238,080 493,994 259,996 14,084
5 1210 3,024,058 1,025,760 696,743 26,876
6 1074 3,759,333 1,621,883 1,185,801 41,238
7 878 4,389,259 2,109,478 1,565,210 53,521
8 665 4,990,297 2,396,673 1,691,378 60,554
9 470 5,874,892 2,383,326 1,574,001 60,901
10 310 4,966,607 2,128,191 1,265,553 55,175
11 192 4,035,194 1,703,044 889,280 45,460
12 112 2,791,944 1,215,612 548,449 34,302
13 61 1,525,534 733,416 309,134 23,829
14 31 784,477 388,943 161,319 15,305
15 15 379,959 189,903 78,150 9117
16 7 173,452 87,045 35,793 5051
17 3 74,669 37,343 15,582 2608
18 1 30,326 15,092 6322 1257
Total Annual Energy Production (kWh) 38,038 16,644 10,300 456
Total Annual Energy Production from Equivalent No. of ATT 38,752 22,339 13,677
in Terms of Swept Area (kWh)
annual energy produced by Bergey Excel, if it is installed in Abu parameters, the operational Reynolds number is considered since
Dhabi, is 16,644 kwh compared to 22,339 kwh produced by ATT the lift and drag coefficients of the airfoils are function of it. Rey-
array that covers the same area swept by Bergey Excel rotor. Also nolds number shows considerable effect on the turbine blades
the annual energy produced by Britwind is 10,300 kwh compared performance. Reynolds number sensitivity analysis shows that the
13,677 kwh produced by equivalent array of ATT. The energy pro- ATT turbine blade airfoil BW3 has the best performance compared
duced by equivalent arrays of 1.34 times of the energy produced by to A18 and SG6043 airfoils. Reynolds number is controlled by the
Bergey Excel and 1.32 times of the energy produced by Britwind. blade average chord length whereas the wind speed of 5 m/s is kept
For SY, the equivalent array can produce 1.02 times he energy constant as major objective for micro turbine blade design.
produced by SY. Wind profile for two sites in UAE: Abu Dhabi and Al Ain are
analyzed as sample sites. Based on the analysis of the wind data of
7. Conclusion Abu Dhabi and Al Ain cities, the rated wind speed of the micro wind
turbine blade is set to be 5 m/s. The accumulated hours of each
New efficient design of micro wind turbine for low wind speed wind speed range for Abu Dhabi site based on Rayleigh PDF are
regions such as Arabian Peninsula, Jordan Desert and UAE is ach- utilized to conduct performance and economic comparison with
ieved. The performance analysis for the theoretical design is vali- available commercial micro wind turbines. The economic feasibility
dated experimentally and both results show very good agreement study illustrates that the payback period for ATT is 1.83 years. The
with each other. The power coefficient for theoretical and experi- concept of replacing commercial wind turbines available in the
mental results are 0.38 and 0.34 respectively. In order to validate market with equivalent array of ATT micro wind turbines in terms
the simulation, a prototype is manufactured using 3D printer. The of swept area is presented. The economic feasibility study shows
ATT prototype blades are tested in open air environment to have that the concept is cost-effective and more energy is produced by
more realistic results. exploiting the same swept area. The results show that ATT micro
Methodology to design the ATT blades that considers Reynolds wind turbine is efficient and economically feasible of producing
Number as one of the design parameter is developed and utilized. energy in low wind speed regions such as Arabian Peninsula and
Along with the Blade element momentum (BEM) theory design Jordan Desert compared to available commercial wind turbines.
S.N. Akour et al. / Renewable Energy 116 (2018) 215e223 223
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