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Experienced Clean Energy /Power
Technology Assessment and Manufacturing Cost Analysis Projects
Energy Storage
for Transportation
Lithium-ion Battery
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Cost Analysis of Direct Hydrogen
PEM Fuel Cell / Lithium-ion Battery Hybrid Power Source for Transportation (PDF)
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Fuel Cell Seminar
2011, Orlando, November 2011
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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.
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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
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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.
Redox Flow Battery
- 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 .
PEM Fuel Cell
2011
Cost Analysis of Direct Hydrogen
PEM Fuel Cell / Lithium-ion Battery Hybrid Power Source for Transportation (PDF)
Fuel Cell Seminar
2011, Orlando, November 2011
2010
Portable
Power Fuel Cell Manufacturing Cost Analyses (PDF)
Fuel Cell Seminar
2010, San Antonio, October 2010
Direct
Hydrogen PEMFC Manufacturing Cost Estimation for Automotive Applications, 2010
(PDF)
DOE Hydrogen
Program Annual Merit Review, Washington DC
2009
Direct
Hydrogen PEMFC Manufacturing Cost Estimation for Automotive Applications, 2009
(PDF)
DOE Hydrogen
Program Annual Merit Review, Arlington, VA
2008
Direct
Hydrogen PEMFC Manufacturing Cost Estimation for Automotive Applications, 2008
(PDF)
Fuel Cell
Tech Team Meeting, Detroit, MI
2007
Direct
Hydrogen PEMFC Manufacturing Cost Estimation for Automotive Applications, 2007
(PDF)
DOE Hydrogen
Program Annual Merit Review
Cost
Analysis of Fuel Cell Stack/Systems, 2007 (PDF)
FY 2007 DOE
Hydrogen Program Progress Report
2006
Direct
Hydrogen PEMFC Manufacturing Cost Estimation for Automotive Applications, 2006
(PDF)
DOE Hydrogen
Program Annual Merit Review, Arlington, VA
Cost
Analysis of Fuel Cell Stack/Systems, 2006 (PDF)
FY 2006 DOE
Hydrogen Program Progress Report
2005
Cost
Analysis of PEM Fuel Cell Systems for Transportation, 2005 (PDF)
NREL/SR-560-39104
Abstract: The
successful commercialization of PEM fuel cells in transportation markets
requires that the technology be competitive with internal combustion engine
powertrains with regard to performance and cost, while meeting efficiency and
emissions targets. TIAX has been working with the U.S. Department of Energy
(DOE) since the late 1990s to assess the cost of PEM fuel cell systems using
near-term technology as a basis, but cost modeled at high-production volumes.
Integral to this effort has been the development of a system configuration in
conjunction with Argonne National Laboratories (ANL), the specification of
performance parameters and catalyst requirements, the development of
representative component designs and manufacturing processes for these
components, and the development of a comprehensive bill of materials and list of
purchased components. The model, data, component designs, and results have been
refined on the basis of comments from the FreedomCAR Technical Team and fuel
cell system and component developers.
In 2005, the cost of an 80 kW direct hydrogen
fuel cell system was assessed relative to the DOE 2005 target of $125/kW. This
system includes the fuel cell stack and balance-of-plant (BOP) components for
water, thermal, and fuel management. Hydrogen storage is not included in this
target. In this report, we provide a comprehensive description of the
assumptions, approach, and final results of the 2005 PEMFC costing effort. The
results of sensitivity and Monte Carlo analyses on components and the overall
system are presented including the most important cost factors and the
uncertainty in the fuel cell system cost projection given the model
assumptions. The effects of selected scenarios on the fuel cell system cost
($/kW) were assessed, including the effect of platinum price and the effect of
individual component markups on overall system cost. The results of these
analyses are presented and their implications discussed.
PEM Fuel
Cell Cost Status, 2005 (PDF)
2005 Fuel
Cell Seminar
Cost
Analysis of Fuel Cell Stack/Systems, 2005 (PDF)
FY 2005 DOE
Hydrogen Program Progress Report
2004
Cost
Analyses of Fuel Cell Stacks/Systems, 2004 (PDF)
DE-FC02-99EE50587, 2004 Hydrogen and Fuel Cells Merit Review Meeting,
Philadelphia, PA
Cost
Analysis of Fuel Cell Systems for Transportation, 2004 (PDF)
DE-SC02-98EE50526, 2004 FreedomCar Fuel Cell Tech Team Meeting, Detroit, MI
Solid Oxide Fuel Cell (SOFC)
2011:
For Harvard University, developed a low temperature
SOFC stack manufacturing cost model. The cost analysis activity clearly showed
the major cost drivers and cost reduction potentials of the existing SOFC stack
design by value mapping the fabrication processes. The work was highly
appreciated by the researchers.
2004:
Cost Model of
SOFC Technology, 2004 (PDF)
Connecticut Global
Fuel Cell Center, First International Conference on Fuel Cell Development and
Deployment, 2004, Storrs, Connecticut
Solid Oxide Fuel
Cell Manufacturing Cost Model: Simulating Relationships between Performance,
Manufacturing, and Cost of Production, 2004 (PDF)
DOE Cooperative
Agreement Number DE-FC26-02NT41568
Abstract: The
successful commercialization of fuel cells will depend on the achievement of
competitive system costs and efficiencies. System cost directly impacts the
capital equipment component of cost of electricity (COE) and is a major
contributor to the O&M component. The replacement costs for equipment (also
heavily influenced by stack life) is generally a major contributor to O&M
costs.
In this project, we worked with the SECA
industrial teams to estimate the impact of general manufacturing issues of
interest using an activities-based cost model for anode-supported planar SOFC
stacks with metallic interconnects. An earlier model developed for NETL for
anode supported planar SOFCs was enhanced by linkage to a
performance/thermal/mechanical model, by addition of Quality Control steps to
the process flow with specific characterization methods, and by assessment of
economies of scale. The 3-dimensional adiabatic performance model was used to
calculate the average power density for the assumed geometry and operating
conditions (i.e., inlet and exhaust temperatures, utilization, and fuel
composition) based on publicly available polarization curves.
The SECA teams provided guidance on what
manufacturing and design issues should be assessed in this Phase I
demonstration of cost modeling capabilities. We considered the impact of the
following parameters on yield of cost: layer thickness (i.e., anode,
electrolyte, and cathode) on cost and stress levels, statistical nature of
ceramic material failure on yield, and Quality Control steps and strategies.
In this demonstration of the capabilities of the
linked model, only the active stack (i.e., anode, electrolyte, and cathode)
and interconnect materials were included in the analysis. Factory costs are
presented on an area and kilowatt basis to allow developers to extrapolate to
their level of performance, stack design, materials, seal and system
configurations, and internal corporate overheads and margin goals.
2003:
Manufacturing Model: Simulating Relationships Between
Performance, Manufacturing, and Cost of Production, 2003 (PDF)
SECA Core
Technology Program Workshop, Sacramento, California
Direct Methanol Fuel Cell (DMFC)
2010
Portable
Power Fuel Cell Manufacturing Cost Analyses (PDF)
Fuel Cell Seminar
2010, San Antonio, October 2010
Photovoltaic / Solar
Led an assignment to perform the photovoltaic (PV) manufacturing process
assessment and manufacturing commercialization analysis for a major CIS / CIGS
thin film PV manufacturer in California. The assignments required technology
assessment on client’s scale-up manufacturing line (20MW) step by step. The
major processes included sputtering / PVD, CVD, lasher scribing, sintering, etc.
The day-to-day manufacturing process data, such as SPC charts, material scrap,
cycle time, automation level, etc., were evaluated in detail. The process based
manufacturing cost model was also developed to analyze the potential cost
reduction goals.
Led an assignment
to evaluate a thin film A-Si roll-to-roll manufacturing process scale-up (40MW)
for a major PV manufacturer. The assignment required to evaluate the scalability
of the major processes / equipments to mass production, such as APCVD, PECVD,
laser scribing, etching, etc. The capital investment and time line were also
studied.
Due diligent on
varies photovoltaic technology and manufacturing process based on Arthur D.
Little /TIAX multi-years industrial experiences. The goal was to develop a new
photovoltaic technology platform to meet the rapid increased demand in
industrial. The in-deep studied technologies included a-Si, CdTe, CIS/CIGS,
crystalline, and wafer Si. The platform covered the cell technologies,
manufacturing processes, marketing, and policies.
Experienced
Product Development
Projects
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Residential Dishwasher
- Led
a multi million dollar residential appliance development project. The main
development role was focused on competitor product evaluations, washing system
development, motor/pump
specification, wash arms development, control algorithm development, cycle
development, and optimizing the prototype performance using Design of
Experiments.
- Led
a dishwasher fast drying system development assignment. The assignment
required the superior drying performance which means the china and silver
wares are completely dry after the cycle. The development role was focused
on blower and heat exchanger design.
- Assessed the feasibility of redesigning a US
dishwasher to meeting European standard with the minimum design changes for
a major appliance manufacturer. A serials of AHAM and European standard tests were performed.
- Conducted a pre-sale assignment to improve
the dishwasher performance without infringing the related patents for a
major appliance manufacturer. The preliminary prototype was built and a
serials of AHAM and DOE standard tests were performed.
Test and Automation Control Using
LabVIEW
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Developed a water heater test station for the Department of Energy. The test
station can test six different water heaters at the same time. The tests
continuously run 24 hours per day for 30 days. The test station used LabVIEW
and National Instrument hardware.
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Trouble shooting a
control software for a water heater butane test chamber using LabVIEW. The
hardware and interface included PCI DAQ card, SCXI chassis, GPIB, etc.
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Developed test control software for a 20 million dollar Stirling engine R&D
project using LabVIEW. In DAQ program, the hardware setting and logging data
were stored in Access database. The needed data was saved into Excel data file
using SQL query. In the control program, PID control algorithm was developed.
The hardware and interface included PXI chassis, E serials DAQ card, SCXI chassis, GPIB, RS232,
etc.
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Developed a test lab for a multimillion dollar dishwasher development project
using LabVIEW. The lab was AHAM and DOE qualified and conducted four
dishwasher tests at the same time. The hardware and interface included PCI DAQ
card, SCXI chassis, USB GPIB, RS232, etc.
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Developed a dishwasher fast drying system test station for a potential client.
The assignment requires the superior drying performance which means the china
and silver wares are completely dry after the cycle. The temperature, relative
humidity, power, energy, air flow rate were monitored and recorded during the
test. The test station used LabVIEW and National Instrument hardware.
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Developed a residential oven
prototype control and data acquisition program using LabVIEW. The complicated
test plans were stored in a Excel file which would control the oven for the
different tests automatically.
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Developed a RFID control system for a food packaging application. The RFID tag
contains the information of type of food, weight, and recommended cooking
processes. The new designed oven control system can scan the package tag, read
the cooking procedure, and cook the food according to the procedure. The
hardware and interface included PCI DAQ card, SCXI chassis, RS232, etc.
- Developed a product
management database using Visual Basic / MS Access for an electronics
manufacturer. The database can keep track senor and components in
manufacturing floor. The database will be combined with their current ERP
software to improve the quality and productivity.
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Led a
new water heater field test data analysis assignment for California Energy
Commission using Visual Basic. The assignment required to analyze 20 water
heaters in five years day to day data log file and evaluate the efficiency
performance. The data file size is about 2 G bytes.
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