OVERVIEW
CONSULTING
PROJECTS
- Manufacturing Cost Modeling
- Product Development
- LabVIEW

CASE STUDIES

- Energy Storage
- Electric Vehicle
- Electrolyzer & Fuel Cell
- SOFC
- Hydrogen Storage
- Photovoltaic
- Appliance
- Stirling Engine
- Medical Device
 
 

Related Presentations, Reports, and Projects

Energy Storage for Transportation

Solid Lithium-Polymer Battery

- For a MIT battery startup,  led an solid polymer electrolyte lithium polymer battery cell manufacturing cost assessment project. The assignment required to assess the lithium polymer battery cells in three formats, 18650 cylindrical cell, prismatic cell, and pouch cell. Various manufacturing processes were evaluated. The results helped client better understand their lithium polymer battery cell manufacturing processes and costs.

Lithium-ion Battery

- Manufacturing Cost Analysis of Fuel Cell Plug-in Hybrid Electric Vehicle and Full Battery Electric Vehicle (PDF)  , Fuel Cell Seminar 2012, Connecticut, November 2012

- Cost Analysis of Direct Hydrogen PEM Fuel Cell / Lithium-ion Battery Hybrid Power Source for Transportation (PDF)  , Fuel Cell Seminar 2011, Orlando, November 2011

- For a leading lithium-ion battery manufacturer,  led an electrical vehicle (EV) Lithium Ion battery pack manufacturing cost assessment project. The assignment required to assess the manufacturing costs including battery cell, battery block, battery stack, and battery pack. Various manufacturing processes were evaluated, such as ultrasonic welding vs. laser welding and spot welding, etc. The results helped the better understand their electrical vehicle lithium-ion battery pack manufacturing processes and costs.

- PHEV Battery Cost Assessment, PHEV Battery Costing Phase II, 2009 (PDF), DOE Hydrogen Program Annual Merit Review, Arlington, VA 2009

- For the Department of Energy (DOE), led a plug hybrid electrical vehicle (PHEV) Lithium Ion battery technology & manufacturing cost assessment project (Phase II). The assignment required to assess the manufacturing cost on four different cathode materials (NCA, NCM, LiFeP4, and LiMnO4) for sixteen scenarios. The results helped DOE better understand the PHEV battery technical requirements and manufacturing costs.

- For a tier one automobile supplier,  led a hybrid electrical vehicle (HEV) Lithium Ion battery technology & manufacturing cost assessment project. The assignment required to assess the HEV battery pack manufacturing costs according to  various cathode active materials and manufacturing scenarios. The results helped the client better understand the HEV battery manufacturing cost drivers.

- For the Department of Energy (DOE), led a PHEV Lithium Ion battery technology & manufacturing cost assessment project (Phase I). The assignment required to assess the manufacturing cost on four different cathode materials (NCA, NCM, LiFeP4, and LiMnO4) for sixteen scenarios. The results helped DOE better understand the PHEV battery technical requirements and manufacturing costs.

Hydrogen Storage

- For US DOE, have worked on the US DOE’s on-board hydrogen storage project as part of its “Grand Challenge” program from 2004 to 2009.  This independent analysis project  helped guiding  the US DOE and Grand Challenge participants toward promising research and development (R&D) and commercialization pathways by evaluating the various hydrogen storage technologies on a consistent basis.  Six categories of on-board hydrogen storage have been evaluated - compressed hydrogen, metal hydride, carbon-based materials, chemical hydrogen storage, liquid hydrogen storage, and cryo-compressed hydrogen storage.  

Cost Analysis of Hydrogen Storage Systems, 2007 (PDF)

FY 2007 DOE Hydrogen Program Progress Report

Analysis of Hydrogen Storage Materials and On-Board Systems, 2007 (PDF)

2007 DOE Merit Review

Analysis of Hydrogen Storage Materials and On-Board Systems, 2007 (PDF)

2007 DOE Hydrogen Delivery Analysis Meeting

Cost Analysis of Hydrogen Storage Systems, 2006 (PDF)

FY 2006 DOE Hydrogen Program Progress Report

Analysis of Hydrogen Storage Materials and On-Board Systems, 2006 (PDF)

2006 DOE Merit Review

Analyses of Hydrogen Storage Materials and On-Board System, 2005 (PDF)

FY 2005 DOE Hydrogen Program Progress Report

Analyses of Hydrogen Storage Materials and On-Board Systems, 2005 (PDF)

2005 DOE Merit Review

Comparison of On-Board Hydrogen Storage Options, 2005 (PDF)

2005 Fuel Cell Seminar

Compressed Hydrogen and PEM Fuel Cell System, 2004 (PDF)

2004 Fuel Cell Tech Team Meeting, Detroit, MI

Energy Storage for Utility and Stationary Application

Lithium-ion Battery

- For the Electric Power Research Institute (EPRI), led a residential Lithium Ion battery backup power system technology & cost assessment project. The assignment required preliminary energy storage system architect design and detailed manufacturing cost analysis on four different cathode materials (NCA, NCM, LiFeP4, and LiMnO4). The results will help EPRI better understand the lithium ion battery stationary application as well as system costs.

- For a major computer manufacturer, led an assignment to develop a Lithium Ion battery pack manufacturing cost model for a major computer manufacturer. The assignment required to design high volume 18650 cell manufacturing process as well as cost analysis. Results from the analysis were used to help the client in a legal case.

Lead Acid Battery

- For a UK leading clean energy firm,  led a lead acid battery backup power system life cycle cost assessment project. The assignment required preliminary energy storage system architect design and detailed maintenance and operation analysis.  The results will help the client better understand the lead acid stationary battery ownership costs.

Flow Battery

- For a flow battery component developer (ARPA-E award winning team), performed a bottom-up manufacturing cost analysis.

- For a MIT flow battery start-up company (ARPA-E award winning team), performed a bottom-up manufacturing cost analysis.

- For a UK start-up company, performed a cost analysis for a Pt  free liquid cathode PEM fuel cell system based on redox flow battery technology. A bottom-up manufacturing cost model was developed which included the major stack components. The model showed the importance of Pt free liquid cathode in reducing the system costs. The major system cost drivers were identified. Additionally, the system cost comparisons were included by comparing to the conventional PEM fuel cells and SOFCs.

Solar-hydrogen Based Residential Energy Storage

- Due diligent for a potential commercial client , the assignment evaluated the system deisgns and manufacturing costs of the residential solar-hydrogen production systems. There were mainly two approaches for the residential solar-hydrogen production. Option one was the photoelectrochemical cell (PEC) which convert solar photon energy and simultaneously electrolyze water to hydrogen and oxygen. The generated hydrogen could be compressed and stored in the hydrogen storage tanks. Option two used the  conventional high efficient PV to produce DC electricity and to connect directly to an electrolyzer stack, which is the option two. We designed the system schematics and  will analyze the detailed manufacturing costs of the two systems according to the client request.

Flying-Wheel

- Due diligent for a potential commercial client at Austin TX,  the assignment evaluated the flying wheel system manufacturing processes.  The detailed manufacturing processes were studied via client plant visit. The results would help the potential client improve the manufacturing cycle time and  better understand the alternative fabrication methods .

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