Related Presentations, Reports, and Projects

Energy Storage for Data Center and Transportation

Lithium 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. The company went public in 2022.

- For a silicon anode battery developer, designed and negotiated a pilot pouch cell manufacturing line for their development lab. Evaluated lab-scale pouch cell manufacturing lines from Korea, Italy, and China, and developed detailed cell performance model and manufacturing cost models. - 2020

- For a solid-state lithium battery developer, conducted a series of benefit analyses focused on EV applications. By benchmarking against state-of-the-art NMC811 lithium-ion battery packs, identified the proprietary solid-state batterys advantages in energy density, thermal management, and overall vehicle range. Also, a comprehensive competitor EV pack tear-down and cost analysis were conducted. - 2019

- 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.

- 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.

Advanced Lead Acid Battery

- For a California silicon wafer lead acid battery developer, developed a bottom-up manufacturing cost study. The silicon lead acid battery uses a bipolar battery structure where silicon wafers act as current collectors inside the cell stack. Gridtential says this reduces lead content and weight, improves power handling, and increases cycle life compared with standard lead batteries. - 2018

Flow Battery

- For a Canadian vanadium redox flow battery developer, helped optimize their flow-control system supply chain. The cost reduction was achieved by replacing existing components with lower-cost, high-quality alternatives. - 2023

- 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 diligence for a UK on-board flywheel developer. A detailed bottom-up manufacturing cost analysis was conducted to help the client understand current manufacturing costs, identify cost-reduction potential, and evaluate alternative fabrication methods.

- 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 .