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Innovative wind turbine design triples output

Posted by: Adam Aston on October 12

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From the first flight at Kitty Hawk, it took about 50 years to engineer the switch from spinning propellers to more efficient jet engines. Now wind technology could be about to make a similar design leap, barely a decade after the commercial industry’s birth in the U.S.

Using features drawn from jet engine design, FloDesign Wind Turbine (shown above in an artist’s rendering) has developed a prototype that is three times more efficient at turning the wind into electricity than today’s towering, three-bladed models, according to CEO Stanley Kowalski III. Carefully shaped cowlings channel air into patterns that create spinning vortexes – like miniature tornadoes – as the currents exit the device. This trick accelerates the air as it pass through.

The technology could transform the commercial wind business with units that are easier to install, longer lasting, and more adaptable to a variety of environments. Today’s wind turbines can top out at 300 feet or taller, requiring a train of tractor trailers to haul tower sections and blades that are as a long as a football field. FloDesign’s new approach fits on a single rig.

Because its blades are lighter and smaller, the design starts spinning and making energy at lower wind speeds and is more tolerant of volatile wind patterns, making it a natural for windy niches where big turbines can’t fit, such as in cities, on ridgelines and beaches.

Scaled down blades also spin faster, reducing the need for the costly gear boxes that today’s windmills must use to connect slow-moving rotors to a high-speed generator kits. With fewer gears and other moving parts, the company claims it can reduce the parts count in a turbine by up to 75%, thereby boosting reliability, too.

The Wilbraham (Mass.)-based company, which has also received funding from the Energy Dept., is hunting for another $25 million to deploy full scale test rigs. Last year, it landed two start-up awards from the Massachusetts Institute of Technology, including cash grants of $300,000. Kleiner, Perkins, Caufield & Byers committed $6 million in venture capital in an initial funding round in 2008.

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Reader Comments

Eugene

October 13, 2009 08:46 PM

coolest looking wind turbine i have ever seen !!! just watched their youtube video...looks very impressive..can't wait to purchase one when it comes out for my home.

Jonathan Teller-Elsberg

October 15, 2009 01:43 PM

Is the CEO really "Stanley Kowalski"? That's either a tip-off that the design is fiction or a marvelous curiosity.

But regardless of the CEO's name, I'd be extremely wary of this latest entry into the field of ducted turbines. To quote from Paul Gipe's _Wind Energy Basics_, "Do augmented turbines work? Yes, of course. Cup anemometers work, too, but we don't use them to produce electricity. Why? Because cup anemometers can't compete with modern high-speed turbines. The same is true with ducted turbines. They have been tried--time and again--and found wanting.... One outspoken critic of diffuser augmentation is Professor Heiner Dorner at the University of Stuttgart's Institute of Aircraft Design. Sure, Dorner says, wind tunnel tests show you that a duct can double the wind speed across the rotor. But for this to happen, the wind must flow directly into the concentrator, a condition found in a wind tunnel--but only rarely in the real world. Yes, he says, the complete ducted assembly can turn to face changes in wind directly, but rarely accurately enough. Thus, the concentrating effect will be difficult, if not impossible, to achieve in operation.... Over the years augmented and ducted turbines have never produced the amount of energy promised at the cost promised. They have never fulfilled their often highly touted claims."

I should acknowledge that I work at Gipe's publisher. Anyway, before someone goes and invests a lot of money in this new venture, I'd recommend they ask to see some verifiable results from a prototype in the field. True, the soundtrack won't be as exciting as in that promo video above, but the bottom line will look a lot better when the adrenaline isn't doing the thinking for you.

George I

October 15, 2009 08:13 PM

Seriously awesome!!! Jonathan, before pouring cold water over these people, why don't you let them actually test the thing, and hopefully prove the naysayers wrong!

PeteT

October 19, 2009 09:01 AM

I agree with George I.
It is a relatively easy life being a professional cynic, pouring cold water and sniping at others attempts to move technology forward. Try making something new and improved, its a lot more rewarding and better for society.

Jonathan Teller-Elsberg

October 19, 2009 07:43 PM

Har--I'll take that push-back in the friendly way that it sounds like it was given. Two points in my defense: first, if you knew me better you'd know I'm far from a professional cynic. For example, I believe the folks who say that properly managed and pastured animals can be carbon negative through the creation of new topsoils (see carbonfarmersofamerica.com for example) and I believe that biochar can also be used responsibly to draw additional carbon out of the atmosphere.

Second, my cynicism in this case stems from the fact that the proposed "revolutionary advance" in wind turbine design shares many identical features with numerous designs from previous years, none of which was able to test out as legit. It's not impossible that this thing will deliver as promised, or even vaguely like promised, but the onus is on the salesman to actually conduct the tests and have viable evidence to show, not on the customer to hand over money based on a snazzy artists rendering of an concept. The real issue for me isn't that Kowalski and company have produced their marketing materials--more power to them!--it's that the BW Green Business blog has too credibly (in my opinion) allowed itself to be a PR outlet for FloDesign. I expect BW to be more journalistic than that.

GP São Paulo

October 20, 2009 06:10 PM

I personally assisted some years ago here in Brazil to some similar experiments. They were non-conclusive. Prof. Dorner and Jonathan got it right.

This might work for some short moments on a very windy day on some street corner in N.Y. City.

If some oxygen-burning combustion were added (principle of the jet engine or "Staustrahlrohr"), something may come out of all this one day. But the hurdle there will be to have cheap enough burning material to end up with a "profitable operation".

As it now stands, I would not put any money into it. Nevertheless, somebody should continue trying, of course!

Ed

October 27, 2009 08:33 AM

I think this is partially a question of what metrics you use. The claim of 3x efficiency depends on:

1. what free stream area you are using for the calculations
2. what baseline 'unducted' design you are comparing to

Betz says you can convert 59% of the free stream area captured in the Cp value for the turbine:

Pshaft = 0.5*rho*Cp*Area*Velocity^3
Pshaft/Pwind = Cp

Most unducted turbines top out around Cp=45% and average something less. To say 3x on the same area obviously is impossible, but clearly their design draws from a larger free stream area (just like a venturi tube).

Since the MIT testing report does not seem to be available to the public, the questions are:

a. Is the baseline comparison an unducted turbine of the same blade diameter or is some other size comparison used?

b. Is the baseline comparison an optimized unducted turbine, or did they just model their turbine with the shroud off?

c. How does the 3x factor change with wind conditions?

If they can really get 3x on a constant blade diameter comparison, then they might be able to justify the added material cost of the FloDesign turbine but I just don't see enough science to justify that claim yet.

john

October 28, 2009 10:58 PM

Guys,
I work for a turbine maker, these flowdesign guys are absolutely real. We have verifiied their performance and frankly, our management is freaking out. We're banking on the fact that they'll run out of cash. We invest $100M in order to launch a new turbine. This economy will kill them. I would love to work for them, they just don't have the cash to survive in my opinion. it's a big gamle. I don't think they'll make it. We know the us gov just awarded them $8M, they'll never get far on certification on that budget. If they keep going, we'll just buy them, i'm certain of that. I just hope it's not squashed, I am convinced on the idea, my management wants us to wait for them run out of cash and scoop them up. I hate capitlism. Sometimes good ideas are simply, too good.

bob

October 28, 2009 11:11 PM

I watched the video and get it. If this doesn't get launched its becaus the big guys wanted it stoppd My brother lives in texas by a wind farm, the fikin things are always broken. This is simple and will work a long time. Why are you so convinced it won;t wrk? My dad wants to invest in them. He's an engineer and suggested I invest too. Why do you think we fly in jets today and not airplane? Duh??

Aaron

October 28, 2009 11:17 PM

I want one, it just looks really cool. I will put it on my car. I don't care if it doesn' work, i will put it in my living room/ It look like it might be noisy, i'm not a scientist, but, why wouldn't the cover make it louder?

Ed

October 29, 2009 10:41 AM

How can anyone say they are 'real' without numerical data to compare for the 3x claim? Maybe they are, and maybe they aren't. But until that is published, just stating MIT's name because they did some unpublished scale model testing of a FloDesign design doesn't cut it in terms of science. If someone has a published ref I'd be interested to see it.

If 3x

Cp = 45% is current SOA for unducted
Cp = 59% is theoretical limit

then

3x = (59%*Area_FloDesign)/(45%*Area_Unducted)

Area_FloDesign/Area_Unducted > 2.29X

therefore

R_FloDesign/R_Unducted > 1.5X = sqrt(2.29)

If, more rationally, the FloDesign Cp is no better than unducted then the radial comparison is really:

R_FloDeisgn/R_Unducted > 1.73X = sqrt(3)

So:

1. Are they drawing from at least 73% larger radius free-stream area?

2. How much of a hit in terms of energy lost from the ducting are they taking which may reduce their Cp below that of an optimized unducted turbine?

3. Is the added cost of the ducted hardware less than 3x that of an optimized unducted 3-blade design of the same blade diameter?

Not that Wikipedia itself is scientifically peer-reviewed, it does reference peer-reviewed publications. See below for an explanation of the use of captured area, Cp, and efficiency when referencing Betz:

http://en.wikipedia.org/wiki/Betz'_law

Ed

October 29, 2009 11:23 AM

Also, I should note that I don't think the rear cowl area can be considered part of the control volume with regards to Betz limit calculations because the energy conversion (i.e. transfer of energy from wind to shaft) occurs in the front section before the additional flow volume enters.

The rear cowl does definitely add gross, if not net, value to the product as is qualitatively demonstrated by the video by enhancing the flow velocities, but that doesn't change the area and volume going through the front section (only the velocity of it) where the energy conversion occurs.

Don't get me wrong, I think this is an interesting engineering concept to consider. I just feel the marketing hype is leading and distorting the science at the moment with the 3x claim.

Jonathan Zhang

November 6, 2009 10:42 PM

Looking for Wind Turbine Blade Designing Companies

As a professional consultant in China, I have bee well involved in green energy development in China, especially wind power manufacturing. We have helped with the setting up of a Canadian invested company in Suzhou, China : www.redmaplewind.com Red Maple is a major producer of wind blade mould, hydraulic mould turn over system and electrical heating system. So far, Red Maple has built over 100 moulds for wind blade manufacturers and supply moulds wind farms in Daqing, Lianyungang, Nantong, Dezhou, Deyang, Inner Mongolia, etc. These companies all use the designs from Aerodyn Energiesysteme GmbH, a German designing company who has been very successful in China.
Due to my direct participation of all business negotiation with these blade manufacturers, I become very familiar with all their production. Chinese government is giving all favorable support to wind engery development, so the development is very fast. These blade manufacturers are looking for more designers, who can quickly deliver their designs. The size of the bade are mostly large size, such as : 1.5MW, 2.0MW, 2.5MW, 3MW, 5MW for all wind classese.
We are urgently and seriously looking for some designing companies who can work together with us to servce our existing customers.

www.5cgroup.net 5cgroup@5cgroup.net

Arun

November 21, 2009 03:05 AM

Guys, why dont we just wait and see how this whole thing goes about. Isn't it pretty obv. that one would test drive a lamborgini before actually investing in one? Check if its efficient and worth the money.

Ed, Johnathan absolutely agree with your statements. However, don't you think its way better to see if they can actually deliver what they promised.

As John said, these guys need trucks of cash! If such articles can help them get it, why oppose?

If they fail, US looses money... if they succeed, The World gains a life!

brian wilson

November 21, 2009 09:41 PM

Wind Turbines

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In Green Business, BusinessWeek Energy & Environment Editor Adam Aston and Associate Editor Heather Green cover the green scene from New York, with Senior Correspondent John Carey in Washington D.C. and correspondent Mark Scott filing from London. Keeping on top of the business aspects of energy, the environment and climate change, their focus is the technologies, policies, markets and people that are shaping how the earth's resources will be used in the century ahead.