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Description
We design and manufacture water turbines used in inland waters, and we manufacture mechanical and electrical equipment for small hydroelectric power plants. The project idea came from our clients, owners of the hydroelectric plants, who voiced their needs unmet by what is now offered in the market. They pointed at restrictions in the height of river drops and insufficient technical parametres which lower the volumes of energy produced and prolong the time of return from investment.
This project addresses the above-mentioned limitations and fits into the growing demand for small hydroelectric power plants which results from convenient locations, numerous investment incentives and the guaranteed energy prices. We will introduce to the market new S- and Z-type Kaplan turbines for swells of 12 and 24 meters (higher than offered by any of the Polish producers), which will be used in small hydroelectric power plants. The competitive technological advantages of our new turbines will be the highest hydraulic efficiency and specific speed in the domestic market, accompanied by a lower cavitation index. This will reduce the costs of investment in small hydroelectric power plants by 5%, and prolong the turbine life by 2-3 years.
The more efficient production processes introduced as a result of the project will additionally lower the energy consumption of our production plant (by 8.2 MWh) and CO2 emission (by 6.35 tons). The project consists in R&D works, construction of a production hall and purchase of production machines.
Summary of project results
The aim of the project was to increase the competitiveness of WTW-Poland by developing and launching a new product in the form of Kaplan turbines of S and Z type for strokes of 12 to 24 m in height, which will find their application in small hydropower plants. To date, the turbines produced on the market have been used for staggered heights of up to 20 m, which excluded them from use in many potential inland water projects, particularly in the Scandinavian countries and Italy. Another major challenge of the project was to increase the hydraulic efficiency to 2%, achieve a better speed differential and reduce the cavitation coefficient. The improved turbine performance was expected to increase the amount of energy produced, reduce the cost of building a new turbine and extend the product life cycle. The new improved products were expected to broaden the company''s offering, increase the number of customers and consequently increase the company''s revenue.
Another challenge of the project was to improve environmental conditions by producing green energy through the conversion of the mechanical energy of water into electricity, which was expected to significantly reduce CO2 emissions. The project was also expected to have positive consequences for the local Bartoszyce community through the employment of an additional production worker. Every initiative taken to reduce unemployment has a positive impact on the socio-economic situation of local residents. Another factor is the increased awareness of the nature and importance of innovation in the area of inland waterways. During information meetings and conferences, we aimed to present the environmental objectives of our project and the fact that sustainable business development is not only achievable, but also necessary to achieve long-term economic growth in and around inland waterway areas. Another challenge of the project was to increase the transfer of knowledge between science and industry through cooperation with scientific institutions.
The implementation of the project has contributed to:
1.The development of an innovative product compared to the country.
Kaplan''s new water turbines are designed for damming from 12 to 24 m, a range not currently offered by other competing companies in Poland. In addition, the new products are characterised by technological innovation in the form of:
a. high hydraulic efficiency - defined at 91% which translates into the generation of more electricity
b. better speed differential - the use of turbines with an increased speed factor, for the same pitch, allows the same rotor power to be obtained with a smaller diameter, which translates into reduced investment costs in small hydroelectric power plants.
c. low cavitation coefficient - lowering the cavitation coefficient to 0.7 allowed the turbine to be installed at a higher level relative to free water, resulting in a significant reduction in production costs.
2. protecting the environment by generating clean electricity in the area of inland waters inland waters.
The project has contributed to the market introduction of new water turbines for use in small hydroelectric power plants, which aim to convert the mechanical energy of water in inland reservoirs and rivers into rotational movement of the rotor, thus generating clean electricity, contributing to the reduction of pollution in the immediate surroundings of inland waters. This has a direct impact on reducing CO2 emissions, which has a significant impact on the implementation of a green and competitive Europe strategy.
3. raising public awareness of the importance of innovation in the area of inland waters and sustainable development.
As a result of the project:
1. two new innovative products have been developed and launched on the market in the form of: a series of Kaplan S-type water turbines and a series of Kaplan Z-type water turbines used in inland water dams from 12 to 24 metres high. The new turbines are characterised by the highest hydraulic efficiency, better high-speed characteristics and low cavitation rates.
2 A new job was created - a female, aged 43, was recruited as a Production Worker as part of an open recruitment process.
3 The project has contributed to: an estimated reduction in annual CO2 emissions of 6.35 tonnes,reduction in annual electricity consumption by 0.008 GWh, an increase in annual revenue by 22.7% and an increase in annual net operating profits by 7.5%.
4 Cooperation was established with a research institute in Austria, which provided support in the development of the optimum design of, among other things, the rotor blades and the steering wheel, as well as confirmation of the validity of the assumptions in relation to the bearing system.
5 In order to achieve the project objectives, it was necessary to build a new production hall and purchase 4 machines: an overhead crane, a vertical machining centre, a turning centre and a paint shop with heat recovery. All machines are characterised by high energy efficiency, reducing electricity consumption and CO2 emissions into the atmosphere. The new products are designed for use in Small Hydroelectric Power Plants,
6 the purpose of which is to convert the mechanical energy of water into rotational movement of the rotor, which allows to generate clean electricity, helping to reduce pollution in the immediate surroundings of inland waters. the immediate surroundings of inland waters.
7 We held two information meetings and one conference for local residents and the company''s customers on the project and promotion of the Norwegian Funds. The aim of the meetings was also to raise public awareness of the importance of innovation in the area of inland waterways and sustainable development.
8 The new products are innovative on a national scale, which directly contributes to increasing WTW''s competitiveness, extending the company''s offer, expanding the number of customers and increasing revenues.