External Advisory Board Meeting April 14, 2023
Welcome and State of the Center Giorgio Rizzoni Director Center for Automotive Research
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Agenda
9:00 – 9:45 a.m. Welcome and State of the Center 9:45 – 10:00 a.m. College of Engineering Update 10:00 – 10:15 a.m. Break 10:15 – 10:45 a.m. Battery Pilot Manufacturing Facility 10:45 – 11:15 a.m. CARMEN+ Research Program 11:15 – 11:30 a.m. College of Engineering Career Services 11:30 – 11:45 a.m. Presentation of the Blaser Award 11:45 – 1:15 p.m. Lunch 1:15 – 2:15 p.m.
Research Activity Updates o ARPA-E EVs4All Program o Return to Hydrogen: Back To The Fuel of the Future o OSU Connected Communities NSF Regional Innovations Engine Research and Development Break
2:15 – 2:30 p.m. 2:30 – 3:30 p.m. 3:30 – 3:35 p.m.
Closing Remarks
4:00 p.m.
Open House and Reception at Acculon Energy
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Under the FTA LONO program, Ohio State was awarded an additional $7M in capital funding bringing our total to $14M to develop and support the on-campus Bus Testing Center. FTA LoNo
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CARMEN+
The U.S. Department of Transportation has chosen a research consortium led by The Ohio State University to address cybersecurity risks in various modes of transportation. Ohio State will receive $10M in federal funding and $5M in cost-share over the next five years to establish a Tier 1 University Transportation Center (UTC).
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Accelerating tech insertion, manufacturing innovation, workforce development, and capital investment for electrification of the transport sector. NSF ENGINE Proposal
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The Department of Energy has awarded The Ohio State University a $3,876,363 grant from the Department of Energy Electric Vehicles for American Low- Carbon Living (EVs4ALL) program to address and remove key technology barriers to EV adoption by developing next-generation battery technologies. ARPA-E EVs4All Program
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Changes in Ohio State Leadership
Grace Wang named president of Worcester Polytechnic Institute.
New Hires
Allan Quattlebaum Financial Operations Manager
Cameron Rasey Project Manager
Patti Bockbrader Assistant to the Director of CAR
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News and Recognitions
U.S. Department of Energy officials spent a day on The Ohio State University campus to kick off their Connected Communities initiative. They were joined by leaders of Connected Communities project awardees, including an Ohio State team of researchers.
Vice President for Knowledge Enterprise Dorota Grejner- Brzezinskawas appointed to the National Science Board. Board members serve as independent advisors to president and congress.
Professor Zak Kassas has been elected to the Institute of Navigation (ION) 2023 Fellow Membership In recognition of his groundbreaking contributions to the theory and application of navigation with terrestrial and extraterrestrial signals of opportunity.
News and Recognitions
Assistant Professor Qadeer Ahmed received the Ralph R. Teeter Educational Award. This award, presented by SAE International, recognizes young engineering educators working to prepare students for careers in industry.
Chemical and Biomolecular Engineering Professor Josh Sangoro will be working with CAR in the area of batteries and energy storage.
Sponsored Research Awards
75%
$77,829,769 Total Amount Active Awards in Fiscal Year 2023
Federal
12%
80 Active Awards 55 Principal Investigators
State
13%
Industry
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Sponsored Research Awards
Federal Awards Broken Out by Sponsor
• Over 15% of awarded federal contracts are
DOE
23,504,854
greater than $2M and are comprised of teams that include multiple OSU investigators, and external partners. federal awarded amount is cost share committed by both OSU and external partners.
DOT
19,311,535
NASA
12,334,681
• Over 10% of the total
NSF
1,742,644
DOD
1,520,290
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Sponsored Research Awards
Partnerships
National Labs
Universities
Non-Profits
Industry
Industry and other key partnerships are vital to Ohio State’s success in pursuing and winning large federal opportunities 80% of CAR’s federal awarded projects are in partnership with Industry, other universities, national labs, and non-profits. Industry contributes 25% in required cost share on federal awards.
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Sponsored Research Awards
Coming in Fiscal Year 2024!
DOT University Transportation Center Highly Automated Transportation Safety CARMEN and CARMEN+ $18M
FTA Low-and-No Emissions Transit Testing $27.5M
ARPA-E EVS4ALL $4.3M
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Our People
Dr. Giorgio Rizzoni
Center Director
Dr. Chris Atkinson Dir of Smart Mobility
Dr. Marcello Canova Associate Director
Meg Dick
David Cooke
Assistant Director
Sr. Assoc Director
Outreach and Business Development
Technical Research Support Staff
Business Operations
Student Projects Coordination
Research Staff
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4
3
Our People
CAR welcomed 17 visiting scholars this year. 6 MS 8 PhD 3 Post Doc
LoNo Research Program and Building Project David Cooke Senior Associate Director CAR
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FTA Low and No Emissions Transit Program $27,500,000 Awar d fr om FTA to suppor t the futur e of tr ansit in Amer ica • New 20,000+ ft 2 research laboratory located at CAR to support the research, development, and testing of Low- and No-Emissions Vehicles and Components • Directed Research - In support of low or no emission vehicles as well as new and emerging technology components including batteries, hydrogen fuel cells, e-machines, and autonomy. • Component Assessment Program – Testing For Industry
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FTA Directed Technology Research • “research related to advanced vehicle technologies that provides advancements to the entire public transportation industry” - Infrastructure and Jobs Investment Act (Public Law 117-58) • Ohio State has $6,175,000 budgeted to support transit DTR through FY26 • FTA focus areas: Maintainability, Reliability, Performance, Structural Integrity, Efficiency, Noise, Safety 1 st Project Launched - Comprehensive Battery Report for Electrified Transit Activities and Services A comprehensive educational report detailing current battery technologies, failure modes within batteries, and current best practices to avoid battery failures.
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Commercial Vehicle Innovation Laboratory -CVIL
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Research and Validation Laboratories Full Vehicle Evaluation •HD Chassis Dynamometer •High bay workspace with HD lifts and equipment •Partnership with TRC proving ground and SMART Center Battery Evaluation •Module and pack facilities up to 500Kw •Walk-in thermal chambers for full pack evaluation •Battery safety lab for cell and small modules Specialized Research • Hydrogen production and refueling •EV Charging and interoperability lab •ADAS •Autonomy • Cybersecurity Fuel Cell Evaluation •500 kW test bench •Fuel cell training lab •Electrical load, H2 supply, conditioned water and air supplies •Full H2 lab safety systems E-Machine Evaluation • e-machine dynamometers with a full slate of power/speed capabilities •Battery emulation •Power electronics validation •Thermal evaluation
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Development of a Technical Advisory Committee • Technology officers and engineering leaders engaged in the transit industry, including vehicles, supply chain, infrastructure, and operations • The TAC will provide high-level industry prospective on developing technologies and directed research needs to support transit vehicle development, deployment, and advancement
• CVIL TAC will offer guidance on functional areas of interest and topics for Directed Technology Research
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College of Engineering Update Derrick L. Tillman-Kelly, PhD Chief of Staff College of Engineering
My Time with You • A Quick about Me • College’s Strategic Plan + OAA’s Academic Plan • Recent Wins • Developing Partnerships
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Education Professional experience Role with Dean Howard Derrick L. Tillman- Kelly
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College of Engineering Strategic Plan, 2022- 2027 Excellence at Scale to Problems of Consequence
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Build and nurture a community and culture of humanity that reflects our university values. 1. Develop an awareness and proficiency of inclusive excellence as individuals, communities and organizations. 2. Advance and implement equitable recruitment and retention of all our community members in a way that promotes social equity, addresses racial disparities, and increases access and success, while fortifying our growth. 3. Promote and encourage the health and well-being of our community members through a culture of care and compassion. 4. Create organizational practices and culture that respect the diversity and value of people’s contributions inclusive of all positions. Foundation 1 29
Cultivate and advance excellence in stewardship of resources across human capital, finance, infrastructure and technology. 1. Identify new funding sources and transparently allocate financial resources to have the greatest impact on achieving the college’s strategic goals. 2. Create and nurture collaborative learning, research, entrepreneurship and innovation through the development of shared, multi-disciplinary physical spaces. 3. Evaluate and implement information technology innovations and data needs to advance the college’s strategic goals and enhance stakeholders’ experiences. 4. Create a recruitment and talent ecosystem for all appointment types that emphasizes inclusiveness, competitive compensation, professional development, work-life balance and overall well-being with clear performance benchmarks.
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Foundation 2
Cultivate and advance excellence in stewardship of resources across human capital, finance, infrastructure and technology. 5. Integrate the operational excellence strategies by promoting data-driven decision making, agility, collaboration, coordination and communication of these resources to: A.Promote a culture of inclusiveness and community. B.Advance teaching and learning outcomes. C.Accelerate the growth of productive partnerships and relationships with industry partners, alumni, faculty and other key stakeholders. D.Expand collaborative entrepreneurship and research discovery.
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Foundation 2
Deliver the highest quality, evidence-based educational experiences in a diverse and inclusive community, accessible at all student levels, across all learning modalities. 1. Support students of all levels in their preparation for entering engineering, architecture and planning as professions. 2. Create greater learning opportunities across engineering for students of all backgrounds, geographies and paths. 3. Expand the application of evidence-based classroom practices while increasing the number, quality and diversity of engineering, architecture and planning graduates. 4. Maximize graduation and completion rates to increase the knowledge of engineering, architecture and planning in society and meet Ohio and global demands for increased STEM graduates
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Establish and grow productive partnerships and connections with alumni and external organizations for faculty, staff and students. 1. Grow and enhance constituent engagement, alumni loyalty and philanthropic revenues. 2. Build and nurture a culture of philanthropy amongst the college’s students and alumni, as well as faculty and staff. 3. Increase collaboration across the college by engaging and integrating internal stakeholders in advancement opportunities. 4. Lead the nation in industry engagement and partnerships. 5. Contribute to a growing, robust and technologically sophisticated economy in Ohio through student talent, faculty expertise and research capabilities. 33
Shape our research efforts to optimize collaborative discovery, especially at the edges and intersections of disciplines. 1. Enhance the college’s research support capacity, including pre- and post- award support, scaling this support to match research growth and accounting for diverse funding mechanisms. 2. Integrate areas of existing strength to foster innovations, translation, quality and growth in research, and to identify new frontiers. 3. Identify and implement mechanisms and strategies to scale existing creative research activities — in both depth and breadth — for team science. 4. Build on the research excellence and growth of activities across our entire geographic footprint. 5. Leverage the college’s unique relationships and competitive advantages found through partnership and integration to grow research and enhance the quality and impact of our research. 34
OAA Launches New Academic Plan
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OAA + New Academic Plan • Goal 1: Advance Faculty Eminence • Goal 2: Accelerate Student Success
• Goal 3: Enhance Impact through External Engagement • Goal 4: Strengthen Talent, Culture, and Inclusive Excellence
• Goal 5: Improve Technological Innovation • Goal 6: Achieve Operational Efficiency
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Recent COE Wins
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Recent COE Wins • Three (3) elected to National Academy of Engineering • Timashev Family Foundation Gift of $110M • Integrated Business & Engineering – Software Innovation • Center for Software Innovation • Record research expenditures in FY22 ($162M) • Student enrollment, diversity, and success • Leadership selections: MAE, EED
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Developing Partnerships
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Developing Partnerships • Intel • Amgen • Nanoracks/Voyager
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Questions?
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Questions?
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Break
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Battery Cell Research and Demonstration Center Jay Sayre
Chris Brooks Chief Scientist and Director of 99P Honda North America
Director of Innovation In stitute for Materials and Manufacturing Research
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Vision To be the nation’s exemplar, interdisciplinary academic battery cell research and demonstration center To achieve this state, we will: • create an environment where value is demonstrated at an advanced, industry-relevant (pilot) scale in a user facility for the battery industry • accelerate the development of battery cell materials and manufacturing technologies • produce an experiential learning setting to develop a workforce that can build and deploy advanced battery technologies • be the hub where academia and industry connect across chemical and physical sciences, engineering, business, policy, and more to influence and inform energy research agendas Mission Fill the current gap in EV batteries to translate fundamental research to cell manufacturing
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Electric Vehicle (EV) Battery Facilities
The Battery Cell Research and Demonstration Center:
• would be within 500 miles—or a one-day drive—of 75% of the plants in North America producing electric vehicles • would support and upskill Ohioans, the U.S.’s second-largest auto- related workforce • would help ensure the success of Ohio’s exports, 90% of which are related directly or indirectly to the automotive industry
46 The Honda - LG Energy Solution Battery Plant, 40 miles southwest of Columbus, will hire 2,200 associates to produce battery cells.
Battery Cell Research and Demonstration Center
Center’s Mission: Translate fundamental research to battery cell manufacturing
Coatema Click&Coat TM Pilot Line
Battery Center Site Concept
• 24,000 sq ft renovation on West Campus • ISO 7 Dry Room (Class 10,000) • Approx. 3,000 – 4,000 sq ft • Temperature 20ºC • Humidity • (-40°) Dew point at return (2,000 – 2,500 sqft) • (-60°) Dew point at return (1,000 – 1,500 sqft)
Center Concept
ISO 7* Clean + - 60 C dry room (ASSB)
ISO 7* Clean
ISO 7* Clean + -40 C dry room Assembly and Filling
Coating
Calendering and Slitting
*ISO 7 - the air contains less than 352,000 particles equal to or greater than 0.5 micron per cubic meter and 2,930 particles equal or greater than 5 micron per cubic meter
Research, Education, & Workforce Development With the State of Ohio’s goals to be a leader in the EV industry and support its thousands of manufacturing workers, the Battery Cell Research and Demonstration Center would have a unique impact on current and future Ohioans:
Oliver Student, Ohio State Goal: To be an engineer in a company that works in sustainable energy Needs: Experiential learning (MIO,
Carlo Engineer, Semiconductor Co. Goal: To expand product offerings in adjacent spaces on an industrial scale Needs: Access to an advanced battery fab line to perform manufacturing engineering studies on equipment
REU, GRA) in a clean-tech manufacturing environment
Anita Professor, Ohio State Goal: To be an entrepreneur and spin out her TRL technology Needs: Access to a facility that can demonstrate her technology at scale
Linsi Technician, Honda
Goal: To be a valuable member in Honda’s move to electrification Needs: Reskilling to learn battery manufacturing skills for a new role within the EV group
Initial Project Budget: $25 million • Current Commitments: $19.5 million • $4.5 million federal appropriation commitment • $10 million commitment from Honda as lead Foundational Partner • $5 million funding from Ohio State for infrastructure • Gap Funding: $5.5 million • Funds would cover additional pilot lines and research equipment
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Federal R&D Opportunities: Department Of Energy (DoE) Energy Storage Grand Challenge Roadmap Electrified mobility cell fab research areas • Materials • Robust (extreme use conditions) • Compact (fast charging/high power, high energy density) • Manufacturing • Supply chain (diversify critical materials sourcing & recycling) • Scale up (anode / cathode / electrolyte / chemistry) • Advanced processing (cell design, architecture, adjacencies)
https://www.energy.gov/sites/default/files/2020/12/f81/Energy%20Storage%20Grand%20Challenge%20Roadmap.pdf
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Li-ion Cell Manufacturing Specific S&T Needs • Cell designs that reduce processing time, enable faster assembly, and decrease formation costs • More resources for scale-up and commercialization of technologies and manufacturing techniques • Reduce cost of EV pack manufacturing by 50% - requires development and validation of materials, component, design, and advanced manufacturing and assembly techniques • Cobalt and nickel-free cathode materials and electrodes – need improved energy density, electrochemical stability, safety, and cost • Accelerate R&D to enable the demonstration and at-scale production of solid-state and Li-metal - production cost of less than $60/kWh, specific energy of 500 Wh/kg
From the Federal Consortium for Advanced Batteries National Blueprint for Lithum Batteries 2021-2030: https://www.energy.gov/eere/vehicles/articles/national-blueprint-lithium-batteries
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Battery Center Timeline and Next Steps
2022
2023
2024
Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4
Battery Cell R&D Center
Concept Phase Finalize funding commitments Design Phase Renovation Phase Opening
Next Steps
• Finalize design, operations, programming and research strategy • Develop large-scale battery manufacturing workforce training program for Honda employees • Secure additional foundational and state partners
CARMEN+ UTC Zak Kassas Director US Department of Transportation Center for Automated Vehicles Research with Multimodal AssurEd Navigation (CARMEN)
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Career Services Amy Thaci Director Engineering Career Services
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• Handshake Platform (for sourcing, hiring, and engaging students) • Co-op and Internship Program (87 % of BS graduates who have reported their jobs had engineering experience before graduation) • Career Fairs Services We Offer
• Career Week, Intern Week, Recruiter in Residence • Professional Development/Wellness Sessions • Recruiting Strategy Consultations • Resources/Guides/Policies/Statistics • ECS Insider, monthly employer newsletter • Employer Advisory Committee • Partner Program
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Engineering Career Services
How to reach us
Engineering Career Services 199 Hitchcock Hall, 2050 Neil Avenue Columbus, OH 43210 614-292-6651 Eng-ecs@osu.edu ecs.osu.edu Amy Thaci, Director, Thaci.1@osu.edu Jeremy Hale, Program Manager, Graduate Education
MS/PhD/Post-Doc Hale.516@osu.edu
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Engineering Career Services
Dwight Blaser Meritorious Service Award
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Dwight Blaser Meritorious Service Award The Dwight Blaser Meritorious Service Award is presented annually to individuals whose sustained and extraordinary personal services have had a significant and lasting effect on the advancement of Ohio State’s Center for Automotive Research (CAR). Dwight Blaser, PhD, was an alumnus of The Ohio State University. He was also a retiree of the General Motors Corporation where he served as the director of research and development. Additionally, Blaser had been a member of the CAR External Advisory Board since its establishment in the mid-1990s. To recognize Blaser’s generous gift of time, experience and wisdom, CAR created an award in his name.
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Ron Reese Ron is the Senior Technical Fellow, ICE Combustion and Thermodynamics at Stellantis. He has over 38 years of experience in engine system development, with 20+ years leading advanced and production programs. Ron serves as a champion for collaboration, industry partnerships and student recruitment between Stellantis and Ohio State. He has been the dedicated Stellantis representative on the CAR EAB for over two decades.
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Lunch
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Research Activity
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OSU Connected Community: Automated BUilding Control with Knowledge of Distributed EnergY Resources and Electrical Systems
for Grid Offerings (BUCKEYES GO!) Matilde D’Arpino Technical Team Lead Connected Communities
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22
37
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Our Community
North Campus
22 Buildings
• • •
40k+ ft2 photovoltaics;
Under construction + PV
37 EV charging stations with total 62 ports; 105 MW Combined heat and power plant & co-located central chiller plant; Wind power purchase agreement (50 MW); Two existing chiller plants; Ground-source heat pump plant.
steam and chilled water plant
105MW Combined Heat and Power (CHP) plant
•
•
PV
West Campus
East Campus
Chiller plant
• •
Ground source heat pump bunker
EAIC: Energy Advancement and Innovation Center
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COORDINATED BUILDING OPERATION
OTHER IMPORTANT DERS
Electrical and thermal energy
Automated energy management control
22 Buildings have been selected considering: • Variety of building functions; • No critical operation (i.e. no medical facilities); • Presence of renewables (solar, geothermal) ; • Presence of EV charging; • Availability of basic control systems. Total energy usage ≈ 12 MW Flexibility from DOE CC ≈ 2 MWp (17%)
• 40k+ ft2 photovoltaics (101 + 282 kW); • 37 EV charging stations with total 62 ports (300kW); • Combined heat and power plant & co-located central chiller plant (105 MW); • Wind power purchase agreement (50 MW); • Two existing chiller plants; • Ground-source heat pump plant.
Electrical energy Grid services
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Overview of selected demand side management strategies and their influence on the final energy demand of campus.
Energy efficiency
Load shifting
Optimized operation of plants Improved energy usage in buildings
Building pre- conditioning EV charging station deferral Use of storage
Load shedding
On-site energy production
Reduce energy consumption at peak time – building thermal zonal control – EV load curtailment
Energy generation with renewable and CHP (electrical and thermal)
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Fosas, Daniel, Elli Nikolaidou, Matthew Roberts, Stephen Allen, Ian Walker, and David Coley. "Towards active buildings: Rating grid-servicing buildings." Building Services Engineering Research and Technology 42, no. 2 (2021): 129-155.
Our Goals: • Energy Efficiency : 35% energy reduction from 2017 baseline • Demand Flexibility >2 MW flexibility at peak times • Asset Value: Increase in NPV of renewable assets (vs 2019) • Quantifiably Improved Occupant Experience • Improved Resilience to Extreme Events • Show how coordinated buildings operation can reliably and cost-effectively serve as grid assets • Increase building efficiency through energy conservation measures and selection of cost-effective power generation • Decreased time and disruption for set up • Increased insights on occupant impact , comfort, willingness to change timing of energy use • Create a Campus Energy Digital Platform for coordinated control operation. • New business models for demand flexibility and DER coordination, aggregation and optimization • Online solutions portal with case studies, best practices, analysis and associated analytical tools
Project Concept: Automate It!
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OSU DEMAND SIDE
OSU SUPPLY SIDE
ON SITE AND HEAT RECOVERY CHILLERS
E LECTRICITY P ROVIDER & D ELIVERY
G RID S ERVICES
WIND PPA
O CCUPANTS S ENSING AND E NGAGEMENT
AP I
POWER PLANTS AND CHILLER PLANTS
PV PLANTS
AP I
DERMS AND E NERGY M ANAGEMENT C ONTROLLER
C YBER S ECURITY F IREWALL
C YBER S ECURITY F IREWALL
AP I
AP I
AP I
EV CHARGERS
AP I
F ORECAST : W EATHER , R ENEWABLE P RODUCTION , E LECTRICITY AND G AS P RICE , G RID S ERVICES , O CCUPANCY , E LECTRIC AND T HERMAL L OAD
S MART I NSTITUTION D ATA
OSU RFP in process for dispatch services of the CHP Engie working on contracting CHP control company
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OSU DEMAND SIDE
OSU SUPPLY SIDE
ON SITE AND HEAT RECOVERY CHILLERS
E LECTRICITY P ROVIDER & D ELIVERY
G RID S ERVICES
WIND PPA
O CCUPANTS S ENSING AND E NGAGEMENT
AP I
POWER PLANTS AND
PV PLANTS
DERMS AND E NERGY M ANAGEMENT C ONTROLLER Coordinate operation of building and DERs under grid and occupants' constraints to C YBER S ECURITY F IREWALL C YBER S ECURITY F IREWALL maximize revenue and sustainable operation.
CHILLER PLANTS
AP I
AP I
AP I
AP I
AP I
EV CHARGERS
F ORECAST : W EATHER , R ENEWABLE P RODUCTION , E LECTRICITY AND G AS P RICE , G RID S ERVICES , O CCUPANCY , E LECTRIC AND T HERMAL L OAD
S MART I NSTITUTION D ATA
OSU RFP in process for dispatch services of the CHP Engie working on contracting CHP control company
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The Team DOE CC subrecipients
Supported by (no DOE funding)
Partnership under evaluation
Other Stakeholders (no DOE funding)
Smart Columbus
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Big Picture Timeline – 5 Year Project Horizon
March ’22 Jan ’24
Oct ’24 Nov ’25
June ’26
Nov ’27
Conduct initial assessments, develop appropriate plans, secure necessary approvals to future project work, install sensing equipment, characterize buildings and DERs, and establish baselines
Validate a model of the CC, and use it to identify control strategies, conduct distribution-level risk assessments, and pilot control strategies in a single building
Installation of all communication & actuation hardware for control of the CC, CC- wide control w/ manual approval, and pilot automatic control in a single building
Execute, assess and refine automatic control for the entire CC
Conduct final analyses and create recommendations for market transformation, regulatory policy, Smart Institutions business model, and CC operation. We will also hold an Expo to disseminate results
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Questions?
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Return to Hydrogen: Back To The Fuel of the Future Manfredi Villani Senior Research Associate Center for Automotive Research
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OSU-CAR is (Re)Launching Hydrogen Fuel Cell Research Activities
Venturi Buckeye Bullet 2 CAR designed, developed, and manufactured the world’s first hydrogen fuel cell-powered land speed electric vehicle, setting the international record of 303 mph
SARTA Hydrogen Bus Ohio State operated one of SARTA's hydrogen fuel cell buses on the Columbus campus for 12 months
2009
2016
2013 Hydrogen Fueling Station CAR operated a SHFA Model 300 hydrogen refueling electrolyzer; the model does hydrogen production,
2000s Early Research Projects developed at CAR cover research on modeling of fuel cells, FCVs and energy management
purification, compression, storage, and dispensing
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Fuel Cell Systems Research Program Scope of the program: Development of controls and diagnostics to improve efficiency , thermal management , and durability of PEM fuel cell systems in medium- heavy-duty vehicle applications
TM
DURABILITY
EFFICIENCY
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Fuel Cell Challenges in the Automotive Industry Going from Fuel Cell to Stack to Fuel Cell System
System
Cell
Stack
• System-level understanding. • Scaling up causes cell-to-cell non-uniformities in terms of reactants (air and fuel) delivery, water production and heat generation: • Instantaneous performance degradation and accelerated long-term degradation ( aging ). • Limited number of sensors . • Need multi-D control-oriented models and real-time control from limited sensing and data. 78
CAR Approach and Contribution • Design and build a Fuel Cell Testing Environment to measure and characterize non-uniformities in concentration of reactants/products and related issues: • In parallel, create a CFD model and a digital twin. • Control-oriented modeling via Model Order Reduction : • Hybrid methods (physics-based + data-driven). • Develop estimation and diagnosis algorithms to predict and prevent/limit performance degradation and aging. • Leveraging significant experience in aging and SOH in battery systems.
CFD study of non-uniform distributions of water, temperature and current within a fuel cell stack 1 .
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1. M. Pan et al., Impact of nonuniform reactant flow rate on the performance of proton exchange membrane fuel cell stacks, International journal of green energy, 2020, vol. 17, no. 11, 603–616
Outcomes Research on H 2 FCVs Can Open Many Opportunities:
Education & Training
Decarbonization
Attract Funding
• Recent DOE and NSF funding opportunities related to hydrogen and FCVs.
• Alternative to batteries in commercial and public transport decarbonization.
• Prepare OSU students to make an impact in the industry. • Develop training resources for automotive engineers.
Source: hydrogen-central.com
Prof. GuezennecFC Lab at CAR
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Our Plan
• Create a research community of students and visiting scholars (starting Summer 2023). • Engage with industry partners. • Re-establish the fuel cell systems lab facility. • Create foundational models to enable control, diagnostics and optimization: • Physics-based models – development and calibration (to predict non-measurable internal states and thermal behavior). • Data-driven models. • Test the developed controls and diagnostics: • Hardware-in-the-Loop setup. • Full vehicle scale on chassis dyno. Year 1 (starting Summer ‘23) 1. Setup fuel cell test rig at CAR Definition of fuel cell testing capabilities (e.g., rated power - 5kW) Market survey and cost estimation Test rig setup Testing
7 8 9 10 11 12
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This Is Just the Beginning! Medium–term plan • Proposals writing and attract funding opportunities. • Development of control-oriented models (1D, multi-D/reduced order). • Development of control strategies to trade-off FC stack performance, efficiency, cooling, and durability (optimization-based, MPC, etc…). • Implementation of Hardware-in-the-Loop platform for diagnostic and control algorithm verification. • Testing of medium- to heavy-duty fuel cell vehicles leveraging CAR facilities.
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Contact info Manfredi Villani Ph.D., Sr Research Associate OSU Center for Automotive Research 930 Kinnear Road, Columbus, OH 43212 villani.5@osu.edu
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ARPA-E EVs4All Program Extreme Fast Charging Batteries with Extended Cycle Life for EVs
Anne Co Professor Department of Chemistry and Biochemistry
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Extreme Fast Charging Batteries with Extended Cycle Life for Evs Tentative project start date: May 15, 2023
Partners
Team Members
Battery Innovation Lab Lithium Battery Engineering
OSU: Anne Co (lead), Jose Lorie Lopez, Qingmin Xu, Jung Hyun Kim, Marcello Canova, Jay Sayre
Applied Materials Empower Battery Technology Current Chemicals
Honda:
Christopher Brooks
Argonne National Lab: John Zhang Carnegie Mellon University: Jay Whitacre
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ARPA-E supports transformative research that has the potential to create fundamentally new learning curves
Submitted:
September 2022 December 2022
Selection Announced:
OSU Site Visit:
January 2023
Tentative Project Start Date:
May 2023 (36 months)
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EVs4All Program Goal
Category 1: Batteries with exceptionally high rates 200 - 400 Wh/kg @ 1.9 kW/kg Category 2: High energy batteries that can charge rapidly 400 - 600 Wh/kg @ 1.3 kW/kg 10 Wh cell deliverable in 36 months
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Extreme Fast Charging Batteries with Extended Cycle Life for EVs
Metrics
Category 1 Targets
Coin Cell Results (preliminary data) 175 Wh/kg @ 1.8 kW/kg (with 2x cathode excess) Projected 200-250 Wh/kg @ 1.8 kW/kg with no cathode excess*
Meets Target?
Gravimetric Full (OSU anode/LFP)
>200 Wh/kg @ > 1.9 kW/kg
promising
Volumetric Full (anode/LFP) Charge power
> 500 Wh/L
TBD
1.9 kW/kg
> 4.8 kW/kg
Y
% loss
90% (80% SOC swing) 80% (95% SOC swing)
Cycle life
> 1500
> 3000
Y
Cost ($/kWh)
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Less than Si/C, Si, SiO x systems
TBD
Co, Lorie Lopez, Bascaran, Smecellato, Lyons, PCT/US2019/044759 (filed 2018) Supported by Alfred P. Sloan Foundation, and Honda (since 2021)
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Extreme Fast Charging Batteries Low temperature goals (fast charge @ -20 o C)
BINDERS Jung Hyun Kim
ELECTROLYTES John Zhang
O
O
O
O
R 2
R 1
O
O CF 3 CF 3
O CF 3
O
CF 3
m.p. -83.6 o C
(-78 o C)
(-80 o C)
(-65 o C)
Fluorinated Carboxylate Ester
Low Li + - desolvation energy
contributes to the low temperature performance
Co, Lorie Lopez, Bascaran, Smecellato, Lyons, PCT/US2019/044759 (filed 2018) Supported by Alfred P. Sloan Foundation, and Honda (since 2021)
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Extreme Fast Charging Batteries Optimization goals
Cathode Electrode Optimization Jung Hyun Kim, Qingmin Xu
Anode Electrode Optimization Anne Co, Qingmin Xu
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Extreme Fast Charging Batteries Full cell testing, characterization and modelling Marcello Canova, Christopher Brooks
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Extreme Fast Charging Batteries Additional Partners
Technoeconomic Analysis Jay Whitacre
Battery Safety
Cell Assembly
Materials Manufacturing and Commercialization
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RFI Stage Transformational Energy Storage Solutions for the Electrification of Planes, Trains & Ships “EES-1K or Battery 1K”
“Rethinking batteries with NO BOX”
- Halle Cheeseman
How do we get > 1000 Wh/kg > 2000 Wh/L
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Thank you!
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Back up slides
ARPA-E funds: $5.12M Cost share: 24% 2760-1566
Notice: This Summary Slide Contains Confidential, Proprietary Information – Do Not Release
Extreme Fast Charging Batteries with Extended Cycle Life for EVs Anne Co, Ohio State University
Technology Summary •
Develop novel anode, which because of its structure and composition, has minimal expansion, stable for >2000 cycles, and no Li growth at high rates. • Develop novel electrolyte for low temperature (-20 o C) operation and compatible with anode and cathode interfacial chemistry. • Demonstrate manufacturability of components Technology Impact Affordable, extended life batteries to enable EVs Maintain US leadership in manufacturing
Proposed Targets Metric
State of the Art
Proposed
Gravimetric Energy Density 265 Wh/kg @ C/3
> 200 Wh/kg @ C/3
30 min
Recharge time
5 min @ 1.9 kW/kg
< 80% fade over 500 cycles
< 90% fade over 1500 cycles
Stability
Extreme fast charging lasting 1,000,000 miles
Notice: This Summary Slide Contains Confidential, Proprietary Information – Do Not Release
GR-NSF Engine Proposal R&D Giorgio Rizzoni Director Center for Automotive Research
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EMIE: Where We’ve Been Where We’re Going
Post-Submission Workshop March 14, 2023
Our History…
First regional stakeholder meeting (MI, OH, IN)
5-state partnership submits EMIE full proposal
Launch EMIE!
Dec. 2021
Jan. 2023
Jan. 2024
June 2022 5-state partnership submits Letter of Intent
May 2023 Site visit if advanced
The Context
Battery EV Growth Scenarios 2021–2040
EV adoption needs to explode to meet climate goals…
M units
Scenario aligned with a +1.5 o C warming with little or no overshoot. BEV share reaches 65% of annual sales by 2040. 2022 – 2040 Powertrain Outlook, KGP Powertrain Intelligence, Derby, UK (2022).
…but a number of critical barriers stand in the way
• Customer acceptance based on cost and range • Model availability • Fueling and energy • Resource/material availability • Workforce alignment 2022 – 2040 Powertrain Outlook, KGP Powertrain Intelligence, Derby, UK (2022).
The I-75 corridor is the heart of the US mobility sector
Planned battery plant capacity by 2030 (GWh/yr) overlaid by EV assembly locations (dots).
Over 500,000 automotive
manufacturing jobs in the five-state region More than 4,000 firms tied to legacy component and system production
https://publications.anl.gov/anlpubs/2022/11/178584.pdf
Since industry and technology don’t have state borders… …we knew we needed a regional approach
NSF Engines was the first chance to start building a regional resource • Up to $160M/10 yrs • The charge: use innovation to drive inclusive economic development
Our commitments to each other… • A lead university acts as convener for each state • We are inclusive and collaborative • Although the five universities submitted the proposal… • We will establish an independent entity when funded • We wear the “region” hat, not the “my organization” hat
Accelerate adoption of and access to electrified mobility
EMIE will focus on transformative technologies in the on-board component-to-system design and optimization for integration into vehicle- and grid-level systems...
…and the workers, companies, policy environment, and innovation infrastructure needed to get this tech into use
What EMIE is: • Independent, non-profit network linking business, academia, government • Intellectual property holding subsidiary • Allied venture studio model fund What EMIE will do: Accelerating the transition to Electrified Mobility through technology, manufacturing, and workforce EMIE. • Deploy public and private funds to pull forward use-inspired R&D • Fund education and training programs for workforce development • Streamline paths into the marketplace for knowledge, products and processes • Create new businesses
EMIE will stand as a nonprofit industry/government/academic partnership network.
The emerging EMIE partnership network
• Community and Technical College • Trade/Professional Societies • Innovation Sector
• FFRDC • Industry • University • State Initiative/Agency
Councils
Board
Inclusive, shared regional governance balanced with lean operations
EMIE activities: Grantmaking Area Type Purpose
$5M/yr for grantmaking budgeted in yrs 1&2
Duration, #/yr
R&D
Proof-of-Concept Grants Develop promising early-stage e-mobility concepts to TRL 2-3
1 yr, 5-7/yr
R&D
Prototyping or Validation Grants
Develop prototype or models needed to validate the technology for manufacture and/or adoption (if digital) Develop and test new training programming, implement new inter-organizational training collaboration, or support novel workforce pipeline development programming (including entrepreneurial pipeline) Support efforts that significantly expand the reach of demonstrated e-mobility workforce programming across the EMIE region One-year fellowship for diverse graduate students working on e-mobility platforms
TBD, 4-6/yr
Workforce Workforce Pilot and Demonstration grants
TBD
Workforce Workforce Scaleup Grants
TBD
Workforce Advanced Training Project Grants
1 yr, TBD
Project selection and initial technology translation network
EMIE activities: Generating products & startups • Allied venture fund with studio model • Affiliated LLC for IP management • IP agreements already in writing among core universities
Thank You!
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Thank You!
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