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Research and Development: Advanced Transportation Topics

Ted Barnes, P.E.GTI – Director, R&Dtbarnes@gti.energy

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80-year History of Turning Raw Technology into Practical Energy Solutions

SUPPLY CONVERSION DELIVERY UTILIZATIONFOR A BETTER ECONOMY AND A BETTER ENVIRONMENT

World-class piloting facilities headquartered

in Chicago area

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Unconventional Oil & Gas> Well drilling & fracture

optimization> Reservoir modeling, diagnostics,

& data analytics> Water treatment & management

Decarbonization> GHG emissions reduction> Renewable energy integration> Carbon capture> Carbon utilization

Alternative Transportation > Medium/heavy-duty on-road/off-road

vehicles & hybridization> Alternative fuel infrastructure> Smart dispensing> Biogas upgrading to CNG/LNG/H2

Clean Fuels and Chemicals > XTL fuels & chemicals> Bio-methane/renewable gas systems> Desulfurization> Direct methane conversion> Advanced ammonia production

Power Generation & Energy Storage> Supercritical CO2 power cycles> Hydrogen to power> Combined heat & power (CHP),

micro CHP, distributed generation

Pipeline Integrity> Distribution/transmission integrity> Advanced risk models/risk

mitigation planning> Forensics, testing, & materials

analysis

Chemical & Biological Analyses> Natural gas and bio-methane

composition & quality assurance

> Gas, liquid, solids analyses> Microbial genotyping

Hydrogen Energy Systems> Advanced hydrogen generation> Carbon-free hydrogen> Pipeline transport> Hydrogen vehicle & fuel station

development & demonstration

Our Expertise

Infrastructure Asset Management > Data analytics & artificial

intelligence> Pipeline GIS location, inspection, &

maintenance> Methane monitoring & mitigation

Energy Efficiency> Energy efficiency program design &

implementation> Residential/Commercial/Industrial

equipment & emerging technologies> Building envelopes

Water Treatment and Reuse> Produced water treatment> Electrodialysis> Membranes> Nanofiltration> System design and analysis

Reactive Systems > Advanced combustion processes> Gasification> Catalysis> Pyrolysis> Fluidized bed processes

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• R&D topics presented to Federal (US DOE) and State (CEC) Organizations

• Specific Topics Include:

NGVAmerica R&D Working Group

oImproved Engine EfficiencyoDevelop More/Larger Low-NOx

EnginesoSimplify Engine CertificationoAdvanced Natural Gas Storage

oAdsorption TechnologiesoConformable

oGrow RNG as a Fuel

oSupport Virtual PipelinesoStation Improvements

(compression, dispensing, etc.)oAdvanced Emission ControlsoSupport Natural Gas Use in

Marine and Rail ApplicationsoHydrogen and Fuel Cell/ICE

Trucks

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• Advanced Prototypes and Large-scale Demonstration Programs

GTI R&D – Demonstrations

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• Turning concepts into technology

GTI R&D – Technology Development

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• R&D Focus Areas– Innovation, Design, Fabrication, Deployments, Operations,

Data Collection/Analysis, Codes & Standards, Safety/Hazard Reviews

– Advanced vehicles, fueling stations, and fuel production• RNG, Hydrogen, Electric, Hybrids

• Testing Capabilities– Large-Scale Environmental Chambers

• Wide Temperature Range (-40 to 160° F)• Fully Instrumented - mass flow meters, gas detection, data

acquisition– High-Pressure Hydrogen and Natural Gas Cascade– Up to 10,000 psi natural gas and hydrogen testing

GTI Advanced Energy Systems – Capabilities

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Technology Focus – CNG Full Fills with a Complete Smart Fueling System

• Problem: Heat of compression– Solution: Novel CNG expander will provide additional cooling

during fueling• Problem: Temperature compensation/Filling algorithm uncertainty

– Solution: Vehicle/Dispenser wireless communication system– Solution: Advanced dispenser logic (better filling algorithm)

Storage

High PressureStorage

Expander

CNG

$/GGE

Electricity Generation

CNG

Wireless Communication

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• Development for CNG full fills using:– Smart vehicles and dispensers– Advanced full fill algorithm– Cost effective pre-cooling

• Build and test lab-based dispenser and vehicle– Done

• Build CNG reciprocating free-piston expander– Assembly of test unit has begun

• Demonstrate full fills in Smart Station lab setup– Test system in construction

Smart Station and Expander Development

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• Main Objective: Develop NGV driver information system that predicts miles-to-empty within 5% or 25 miles

– Reduced range anxiety by NGV drivers– Increased range per fill and/or fewer fills– Enable optimization of fleet resources by linking ‘miles-to-empty’

prediction back to fleet dispatch center to aid in route selection• Addresses final stage of the fueling solution – the driver• Partners

– Argonne National Lab: application development– Ozinga Concrete: deployment partner

Next-Generation NGV Driver Information System

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NGV R&D Sponsors - Thank you!!!

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US DOE H2@Scale ProgramH2@Scale in Texas and Beyond

$11 Million US DOE Program with two major tracks:1. DEMONSTRATION at University of Texas – Austin

– Renewable hydrogen production• Reformation of renewable natural gas (RNG)• Electrolysis using wind and solar

– Multiple end uses• Hydrogen vehicles and drones• Stationary fuel cell to power data center

2. FRAMEWORK STUDY– Actionable H2@Scale pilot plans in Texas,

Port of Houston and Gulf Coast region, including energy storage

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Timeline• Air Liquide• Chart Industries• ConocoPhillips• Frontier Energy • Gas Technology Institute• Mitsubishi Heavy Industries • LCRI• OneH2• ONE Gas• ONEOK• Shell• SoCal Gas• Toyota• University of Texas at Austin• Waste Management

Partners

New partners• CenterPoint• McDermott

Support partner• IdeaSmiths

US DOE H2@Scale ProgramH2@Scale in Texas and Beyond

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Heavy Duty EV Truck with Near-Zero CNG Range Extender Production Kenworth T680 DayCab• Cummins Westport Inc. Near-

Zero L9N Natural Gas Engine• BAE Generator, Propulsion

Control Systems, Power Interface Module, 650V to 24V inverter

• Custom Dual-Remy ACTM• XALT 100kWh battery packs• Custom 650V A/C

compressor, Air compressor, power steering

• Multiple cooling loops

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Fuel-Cell Terminal Tractor

• $12M project partially funded by CARB

• 2 x Capacity of Texas TJ9000 tractors• 200kW BAE electric powertrain• 85kW Ballard Fuel Cell• 9.1kg H2 storage and 85kWh battery• Onsite H2 dispenser with 182kg

storage• Start of operation at TraPac 2022

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CARB Fast Track Fuel Cell Truck

• “Fast Track” development and demonstration of five fuel cell trucks – two different designs

• Operation at the Port of Los Angeles/Long Beach in full commercial duty cycle

• 3 trucks are currently in operation with one in testing– ~60 – 100 KW of Fuel Cells– ~220 KWH NMH battery storage– ~30 KG of hydrogen storage at 5,000 psi– ~200 mile range

R

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Michigan to Montana I-94 Corridor Project (M2M)

Existing Fueling Station Map – M2M Corridor (Blue – DCFC, Red – Propane, Green – CNG)

• M2M corridor will cover I-94 from Billings, MT to Port Huron, MI

• Deployment: 40 trucks, 15 alternative fueling stations committed

• Planning: Sustainable alternative fuel corridor model (outreach, training, community-based partnerships)

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Rail Demonstrations – Hydrogen and Natural Gas

Long-haul CNG locomotive demonstration• Department of Energy

• OptiFuel

Hydrogen fuel-cell switcher locomotive demonstration• California Energy Commission

• Sierra Northern Railway

• Ballard

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GTI CNG and Hydrogen Fueling Station Research Projects

• Linear Motor Compressor and Expander • DOE Leak Recovery and CO2 applications• DOE Smart Fuel Gauge • Smart CNG Station

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Free-Piston Expander for Hydrogen Cooling

Eliminate hydrogen pre-cooling by using an expansion device!

The proposed expander will remove energy from the gas by subjecting it to a near-isentropic expansion. With current technology, the hydrogen pressure reduction during fueling is isenthalpic, with no energy extraction. Utilization of an efficient expansion device for the pressure reduction allows extraction of significant amounts of energy from the gas stream, causing the gas to cool down to as low as -100°C at the beginning of a fill. The proposed expander is targeted to achieve an average delivery temperature equivalent to the SAE J2601 T40 pre-cooling requirement over the course of a hydrogen fueling event. This will completely remove the pre-cooling requirement, resulting in significant capital and operating cost savings.

Technology Summary

Technology Impact• Replace pre-cooling unit with expansion device with

60% lower cost

• Remove pre-cooling electricity demand

• Reduce cost of gas conditioning to < $0.20/kg (currently $0.50-$5.00/kg, dependent on station utilization)

• Support DOE target of achieving <$2/kg for compression, storage and delivery

Program SummaryPeriod of performance: 36 months

Federal funds: $2,500,000Cost-share: $625,000Total budget: $3,125,000

Project PartnersArgonne National LaboratoryUniversity of Texas at Austin – Center for ElectromechanicsQuantum Fuel Systems