Design, Construction, And Testing of A 130w Wind-Powered Air Compressor System For Operation In Zaria, Nigeria.
Abstract
A wind rotor system to power a rotary air compressor of maximum discharge pressure of 3.53barg, a free air delivery (FAD) of 0.001179 m3/s at maximum pressure, and a nominal power requirement of 130W were designed, constructed, and tested.
The wind air compressor system included a wind rotor, a transmission mechanism, an air compressor, and a storage reservoir. The wind rotor was coupled to a selected air compressor and tested at Ahmadu BelloUniversity, Zaria, Kaduna State, Nigeria.
The compressor discharge pressure and flow rate increased with an increase in the wind velocity. A discharge pressure of 1.0barg was obtained during the testing period at the rated wind velocity of 5.10 m/s.
A maximum compressor capacity of 0.000833 m/s at a discharge pressure of 2.0 bar and a wind velocity of 7.90 m/s was obtained. At the rated wind velocity of 5.10 m/s, the power output was calculated as 98.56 W.
The overall efficiency increased as the wind velocity increased until it reached a maximum of27.6 % and then started to decrease gradually thereafter to a minimum of 7.6 %.
The actual efficiency of the system was found to be 24.2% at the rated wind velocity of 5.10m/s compared to the design efficiency of the system of 35 %. The installed capital costs for the 130W wind air compressor were N61,150.00.
Table of Contents
Title Page……………………………………………………………………………………….i
Declaration……………………………………………………………………………………………………………. ii
Certification………………………………………………………………………………………………………….iii
Acknowledgments……………………………………………………………………………………………….. iv
Table of Contents…………………………………………………………………………………………………… v
List of Tables……………………………………………………………………………………………………….. ix
List of Appendices………………………………………………………………………………………………… xi
Nomenclature……………………………………………………………………………………………………… xiv
CHAPTER ONE……………………………………………………………………………………………………. 1
INTRODUCTION …………………………………………………………………………………………………. 1
1.1 Background ………………………………………………………………………………………………….. 1
1.2 Statement of the Problem………………………………………………………………………………… 2
1.3 The Present Work………………………………………………………………………………………….. 3
1.4 Aim and Objectives……………………………………………………………………………………….. 4
1.5 Significance of Work……………………………………………………………………………………… 4
CHAPTER TWO …………………………………………………………………………………………………… 6
LITERATURE REVIEW………………………………………………………………………………………… 6
2.1 Wind and Wind Energy ……………………………………………………………………………………… 6
2.1.1 The History of Wind Energy…………………………………………………………………………. 7
2.2 Review of Related Past Work……………………………………………………………………………. 10
2.3 Theoretical background ……………………………………………………………………………………. 12
2.3.1 Available wind power………………………………………………………………………………… 12
2.3.2 Extractable wind power……………………………………………………………………………… 13
2.3.3 Compressor power…………………………………………………………………………………….. 14
2.4 Wind Air Compressor System Description ………………………………………………………….. 16
2.4.1 The wind rotor………………………………………………………………………………………….. 16
2.4.1.1 Rotor design ………………………………………………………………………………………. 17
2.4.1.2 Material Selection……………………………………………………………………………….. 26
2.4.2 Shaft Design…………………………………………………………………………………………….. 29
2.4.2.2 Belt and Pulley design………………………………………………………………………….. 30
2.4.2.3 Bearings…………………………………………………………………………………………….. 33
2.4.3 Compressors…………………………………………………………………………………………….. 37
2.4.3.1 Air compressor …………………………………………………………………………………… 37
2.4.3.2 Positive Displacement Compressors……………………………………………………….. 39
2.4.3.3 Non-positive Displacement Compressors………………………………………………… 43
2.4.3.4 Selection of Compressor Type ………………………………………………………………. 47
2.5 Pressure Vessels……………………………………………………………………………………………… 53
CHAPTER THREE………………………………………………………………………………………………. 54
MATERIALS AND METHODS…………………………………………………………………………….. 54
3.1 The Wind Compressor System ………………………………………………………………………….. 54
3.2 Materials……………………………………………………………………………………………………….. 55
3.2.1 Material Selection……………………………………………………………………………………… 55
3.2.2 Wind Speed Data………………………………………………………………………………………. 57
3.3 Design Theories ……………………………………………………………………………………………… 57
3.3.1.0 Rotor Design …………………………………………………………………………………………. 57
3.3.1.1 Rotor swept Area ………………………………………………………………………………… 57
3.3.1.2 Compressor Power………………………………………………………………………………. 58
3.4 Design Analysis ……………………………………………………………………………………………… 59
3.4.1 Compressor Selection Considerations…………………………………………………………… 59
3.4.2 Shaft design……………………………………………………………………………………………… 60
3.4.3 Bearing selection ………………………………………………………………………………………. 61
3.4.4 Tail vane design………………………………………………………………………………………… 61
3.4.5 Design Considerations……………………………………………………………………………….. 61
3.5 Design Calculations…………………………………………………………………………………………. 63
3.6 The Wind compressor system design………………………………………………………………….. 74
3.6.1 Design calculations……………………………………………………………………………………. 74
3.6.2 Design drawings……………………………………………………………………………………….. 74
3.7 System Component Construction……………………………………………………………………….. 75
3.7.1 Rotor Blades…………………………………………………………………………………………….. 75
3.7.2 Rotor Hub………………………………………………………………………………………………… 75
3.7.3 Rotor Shaft ………………………………………………………………………………………………. 75
3.7.4 Bearings ………………………………………………………………………………………………….. 75
3.7.5 Belt and Pulley …………………………………………………………………………………………. 76
3.7.6 Mounting Plate …………………………………………………………………………………………. 76
3.7.7 Tail vane………………………………………………………………………………………………….. 76
3.7.8 Tower……………………………………………………………………………………………………… 76
3.8 Cost Evaluation………………………………………………………………………………………………. 76
3.9 Installing and testing the system ………………………………………………………………………… 78
3.9.1 Testing Set up…………………………………………………………………………………………… 78
3.9.2 Testing Procedure……………………………………………………………………………………… 79
3.10 Calculations………………………………………………………………………………………………….. 79
3.10.1 Energy Pattern factor determination for Zaria ………………………………………………. 79
3.10.2 Power Output and Overall efficiency determination for wind air compressor…….. 81
CHAPTER FOUR………………………………………………………………………………………………… 84
RESULTS AND DISCUSSIONS……………………………………………………………………………. 84
4.1 Test results and discussions………………………………………………………………………………. 84
4.1.1 Results ……………………………………………………………………………………………………….. 84
4.1.2 Discussion of results……………………………………………………………………………………… 90
CHAPTER FIVE …………………………………………………………………………………………………. 92
SUMMARY, CONCLUSIONS, LIMITATIONS, AND RECOMMENDATIONS…………… 92
5.1 Summary……………………………………………………………………………………………………….. 92
5.2 Conclusions……………………………………………………………………………………………………. 92
5.3 Recommendations…………………………………………………………………………………………… 93
5.4 Contributions to knowledge………………………………………………………………………………. 93
REFERENCES ……………………………………………………………………………………………………. 94
INTRODUCTION
Background
Nigeria, a developing nation of 140 million (2006 census) with a growth rate of 3.20 %(Energy Commission of Nigeria, 2013), has an installed production capacity of about 6,000MW of power as of 2009 (Sambo, 2009).
In 2012, the installed production capacity stood at9,955.4 MW with an average availability of 5, 516.38MW (Energy Commission of Nigeria,2013).
The estimated daily power generation as of December 2009 was about 3,700MWwhile the peak load forecast for the same period was 5,103 MW, based on existing connections to the grid (Nigeria Vision 20-2020, 2010).
The Business day Newspaper of 21st July 2009 reported that manufacturers alone require about 2,000MW to power their factories, based on installed capacities as of 2009.
The power requirements of the nation have been projected at 28,360MW by 2015 at a modest economic growth of 7% (Sambo, 2009). There is, therefore, a need to bridge this energy gap.
“Fossil” fuel-driven machines are used all over the country to augment supply to meet these power requirements. The Energy Commission of Nigeria estimated that fuel-driven machines provide about 42% of the power needs of the country between the years 2000 and 2004(Sambo, 2008).
The Nigerian Tribune Newspaper of 21st August 2009 estimated a daily diesel consumption of 13 million liters. The Vanguard of October 2010 reported that the Central Bank of Nigeria (CBN) estimated that about $13bn (N1.989trillion) per annum is expended on diesel for power generation.
The use of fossil fuels adds to the carbon emissions in the world with their devastating effects such as global warming and acid rain to mention a few. It is an established fact that fossil fuels are an irreversible source of energy and their supply is depleting. In fact, the continued unrest in the Middle East creates an oil shortfall around the world.
From February to April 2011, crude oil prices have surpassed $120/bbl with oil prices reaching the $5 mark in the United States. Oil demand increase is expected to be about 40% over the next 20 years.
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StudentsandScholarship Team.
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