1. B ERKELEY L AB I NITIATIVES FOR P ROLIFERATION P REVENTION E NGINEERING D IVISION Wind Sail Project Status Low-Maintenance Wind Power System IPP Project ID: LBNL-T2-0203-RU Daryl Oshatz LBNL Engineering Division April 2003

2. B ERKELEY L AB I NITIATIVES FOR P ROLIFERATION P REVENTION E NGINEERING D IVISION Wind Sail Program U.S. Department of Energy (DOE) 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. B ERKELEY L AB I NITIATIVES FOR P ROLIFERATION P REVENTION E NGINEERING D IVISION Responsibilities Design, prototype, and test wind power systems for commercialization in the Off-Grid and End-of- Grid markets. 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. B ERKELEY L AB I NITIATIVES FOR P ROLIFERATION P REVENTION E NGINEERING D IVISION Concept Overview Vertical Axis Wind Turbine (VAWT) 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” 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. B ERKELEY L AB I NITIATIVES FOR P ROLIFERATION P REVENTION E NGINEERING D IVISION SRC Overview Lead developer of submarine-launched ballistic missiles during the Cold War. Lead developer of submarine-launched ballistic missiles during the Cold War. Conversion efforts for space projects have met with limited success. 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. Has been pursuing diversification into other fields, including wind and diesel power stations since the early 1990’s.

6. B ERKELEY L AB I NITIATIVES FOR P ROLIFERATION P REVENTION E NGINEERING D IVISION SRC Capabilities Engineering expertise Engineering expertise  Fluid mechanics - experience performing numerical simulations for wind turbine design  Mechanical design and analysis Experimental facilities and experience Experimental facilities and experience  Hydrodynamic test facility onsite  Access to aerodynamic test facilities and equipment Fabrication and assembly infrastructure Fabrication and assembly infrastructure

7. B ERKELEY L AB I NITIATIVES FOR P ROLIFERATION P REVENTION E NGINEERING D IVISION Empire Magnetics Expertise in design and production of electric motors that are durable in extreme climatic conditions. 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. Industry contacts and sales channels to bring the product to market in the U.S. and Europe. Existing Partnership with Uralmet, a Russian company. 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. B ERKELEY L AB I NITIATIVES FOR P ROLIFERATION P REVENTION E NGINEERING D IVISION 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) Coolant Channels Rotor Assemblies Stator Assembly Bearing Assemblies Output Shaft Housing Assemblies

9. B ERKELEY L AB I NITIATIVES FOR P ROLIFERATION P REVENTION E NGINEERING D IVISION Other Technologies Rectifier, inverter, control electronics Rectifier, inverter, control electronics  Delivered by Empire Magnetics and partner companies (X ZEL 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 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. B ERKELEY L AB I NITIATIVES FOR P ROLIFERATION P REVENTION E NGINEERING D IVISION Requested Funding IPP funding over two years: $1,350 k 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 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. B ERKELEY L AB I NITIATIVES FOR P ROLIFERATION P REVENTION E NGINEERING D IVISION Challenges Collaborative design and construction project 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 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 Communication  Uralmet is intermediary.  Some details lost in translation so far.

12. B ERKELEY L AB I NITIATIVES FOR P ROLIFERATION P REVENTION E NGINEERING D IVISION DOE Progress Funding began at LBNL in May 2002 to launch the project Funding began at LBNL in May 2002 to launch the project CRADA agreement signed with Empire May 2002 CRADA agreement signed with Empire May 2002 LBNL has performed technical feasibility and market research to guide the collaboration. LBNL has performed technical feasibility and market research to guide the collaboration. No DOE funding in Russia as of April 1, 2003 No DOE funding in Russia as of April 1, 2003 An NGO, ISTC, has approval to distribute DOE funds to Russian staff 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) 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 Equipment (PC’s, office equipment, etc.) purchases likely in April 2003

13. B ERKELEY L AB I NITIATIVES FOR P ROLIFERATION P REVENTION E NGINEERING D IVISION Empire Magnetics Progress Empire staff visited SRC in November 2002 Empire staff visited SRC in November 2002 Private company founded in Russia, SRC- Vertical, Ltd., in March 2003 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 Empire Magnetics and Uralmet are seeking investment to support their effort  Venture capitalists  Private non-OEM companies with retail wind turbine customers

14. B ERKELEY L AB I NITIATIVES FOR P ROLIFERATION P REVENTION E NGINEERING D IVISION Turbine Designs under Consideration 3 kW Turbine 3 kW Turbine  H-Darrieus  Design and prototype in first six months  Use prototype for marketing purposes in first six months 30 kW Turbine 30 kW Turbine  H-Darrieus  Prototype at end of year one 70 kW Turbine 70 kW Turbine  H-Darrieus or traditional Darrieus  Prototype at end of year two

15. B ERKELEY L AB I NITIATIVES FOR P ROLIFERATION P REVENTION E NGINEERING D IVISION 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. B ERKELEY L AB I NITIATIVES FOR P ROLIFERATION P REVENTION E NGINEERING D IVISION 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. B ERKELEY L AB I NITIATIVES FOR P ROLIFERATION P REVENTION E NGINEERING D IVISION 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. B ERKELEY L AB I NITIATIVES FOR P ROLIFERATION P REVENTION E NGINEERING D IVISION 30 – 70 kW Turbine Concepts No current conceptual designs have been released form SRC because of lack of funding thus far from DOE No current conceptual designs have been released form SRC because of lack of funding thus far from DOE Some generic ideas have been circulated Some generic ideas have been circulated