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SA’s first wind turbine manufacturer gearing up for production

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Walking through Isivunguvungu Wind Energy Converter’s (I-WEC) workshop in the Cape Town harbour, one could feel the anticipation in the air. Soon this will be South Africa’s first large-scale wind turbine manufacturing plant. The reason for my visit was to witness the arrival of a 50 metre mould from China that will be used to manufacture the wind turbine blades. Due to technical issues, the unloading of the mould was postponed to the following day. I therefore decided to learn more about the project from Thomas Schaal, co-founder of I-WEC.

I-WEC's 50 metre wind turbine blade mould during transport to the company's workshop in Cape Town.

I-WEC's 50 metre wind turbine blade mould during transport to the company's workshop in Cape Town.

Through its R100 million (US$12.8 million) investment, I-WEC plans to supply turbines to independent wind energy producers in South Africa. While some of the components will be imported, a large percentage will be produced in South Africa. Everything will be assembled locally. “We estimate 65% local content right from the beginning of our operations,” said Schaal.

South Africa’s wind energy industry is expected to take off in the coming years as the government recently finalised regulation around the renewable energy sector. South Africa’s Integrated Resource Plan envisages renewables contributing 42%, or 17 800 megawatts (MW), of the country’s new generation capacity by 2030. In the first round of the procurement process, 1,850 MW are reserved for wind energy. Potential power producers will compete in a tender process.

Schaal revealed that I-WEC is in the process of negotiating with steel giant ArcelorMittal for the supply of six wind turbines to its Saldanha steel facility on South Africa’s west coast.

According to Schaal, I-WEC will be able to compete with Chinese manufacturers on price in the South African market. He noted that the transport costs of importing blades and other equipment from countries such as China, can be as high as 5% of the total amount. I-WEC’s products also carry the necessary certifications required in the South African market, which many of the Chinese products don’t have. He added that it is often difficult to secure financing and insurance for non-certified technology.

I-WEC’s long-term ambitions stretch beyond South Africa. “In the initial phase we will concentrate on South Africa, however, we have a licence which allows us to export. And we would certainly like to export our turbine to neighbouring countries . . . surely also the entire continent. We know that in Egypt there is also a wind turbine manufacturer. Most likely they will actually serve the northern part of Africa. But yes, we intend to export to Africa, perhaps also to South America,” explained Schaal.

I-WEC has set itself a goal of manufacturing 200 units per annum in five years’ time. “The market is good enough for that. And also we have the opportunity to export,” he said.

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  • louis beneke

    Hi, I am also busy with some research in the energy field. at this states I am looking for a turbine (small) where I can set the blades for my small project. If you may be know of a company in SA please let me know. Thanks

  • Barry Sahd

    Hi Marc

    I am interested in your product, especially if it proves to be more efficient than other designs.
    What kind of budget do you envisage?

  • marc dupreez

    To whom it may concern.
    Dear Sirs, Madam.
    30 September 2012

    Over the last year I have been developing a horizontal wind turbine generator unlike anything produced to date to.
    My intention was to design a low mounted low speed urban domestic wind generator that utilizes gusts that are generally prevalent in the urban environment with a Dc output exceeding a turbine of quadruple dimensions, an aesthetic garden appeal and a price tag to suit the masses, and so far I have succeeded.
    The turbine does not run on conventional propeller blades, has 60% more toque 60% less magnetic drag and reaches a speed of 180 Rpm in very light winds with a sweep of only 1.5m and only a 2m elevation.
    Though the rough prototype turbine itself has been on test for over 6 months with consistent results, the generator is still being bench tested and herein lies my main stumbling block.
    The design of my stator is unconventional to say the least with a potential output of 4 larger domestic turbines but the materials I’m using on this project have all been scrounged as I no longer have an income due to going almost blind after a stroke four years ago.
    I am in desperate need of an angel investor to bring this project to fruition. Someone in the know with vision who can help me create this thing of beauty and potential profit..
    I have never asked for anything in my life and now I’m on my knees.
    It would be a sad day to lay this project to rest after so much effort time and money have got it this far.
    One thing to consider is – those looking at this design will be able to reproduce the product and as I do not have any patient, I will only display my work to one genuine and honest investor.
    Please I need help now.
    Thank you.
    Marc.

    • Willie

      Marc, only today, 26 Aug 2014, am I reading your story re a potentially improved turbine. Are you still in the market? I also manufacture small turbines and is intersted in what you seem to be doing. I would like more info etc. If interested, let me know. Willie

  • Willie Joubert

    With regards to the “local content” what portion of the blades will be made up of fabric made in South Africa?