COST EFFECTIVE WELLSITE MANAGEMENT SUPPORT OF ENERGY ENVIRONMENTAL & REGULATORY ISSUES. James Durand Director: CAR-TESS

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1 COST EFFECTIVE WELLSITE MANAGEMENT SUPPORT OF ENERGY ENVIRONMENTAL & REGULATORY ISSUES Environmentally Friendly Drilling Program Workshop: Natural Gas Power for Shale Development September James Durand Director: CAR-TESS

2 car.osu.edu

3 OVERVIEW Founded in 1991 as an interdisciplinary research center in the College of Engineering, located in a 50,000 square foot complex on the West Campus of The Ohio State University Advanced propulsion systems research facilities PHEV and HEV test beds CNG and H2 refueling stations Battery aging laboratory Battery thermal and electrochemical characterization lab Energy storage systems lab Engine combustion and flow research facilities Autonomous vehicle fleet V2V and vehicle autonomy laboratories Dynamometer test cells Engine dynamometers (4) Light-duty chassis dynamometer 4WD heavy duty chassis dynamometer Noise and Acoustics laboratories: 2 hemi-anechoic chambers (one with chassis dynamometer)

4 HUMAN RESOURCES 80 Graduate Students 46 Student Assistants 23 Visiting Scholars 9 Primary Faculty 22 Secondary Faculty 17 Research Staff 3 Post Doctoral Fellows 6 Facility Support Staff 7 Administrative Staff Total: 213 people The center also provided facilities and support, in collaboration with the college and Mechanical and Aerospace Engineering department, for six student project teams consisting of over 200 active undergraduate students and 45 FIRST (robotics project) high school students.

5 TESTING, ENGINEERING AND SOFTWARE SERVICES TESS TESS GROUP OVERVIEW car.osu.edu/facilities/tess

6 TESS OVERVIEW Goal: Apply CAR expertise using experienced professionals and world class facilities to solve transportation related problems. Basic Services Engineering Analysis Testing Software Development Policy Analysis IP Development

7 TESS OVERVIEW Current Status $1M in annual revenues Growing rapidly 15 people engaged Over 20 projects covering a large range of issues Goal: grow to $4M in 5 years

8 TESTING, ENGINEERING AND SOFTWARE SERVICES TESS PROJECTS AND SERVICES car.osu.edu/facilities/tess

9 CNG VEHICLE CHARACTERIZATION AND MODEL DEVELOPMENT Objective: to develop dedicated experimental, modeling, and simulation capabilities especially suited for NG Engines at CAR Project Plan Year 1 (Ongoing) Literature and Technology Survey Instrumentation of a dedicated CNG vehicle and setup in the test cell Design of experiments and execution of the experimental plan Year 2 Development of a 1-D model of the NG engine Model based sensitivity study of engine parameters Identification of pathways for engine optimization Year 3 Investigation of selected pathways for NG engine efficiency optimization (boosting, direct injection, etc)

10 SIMPLE-FILL: HOME REFUELING FOR CNG VEHICLES Objective to develop a transformative and potentially disruptive compression technology based on the liquid piston concept Status Early stage of technical development Completed a preliminary design and thermodynamic analysis Established spinoff company for development and commercialization Attracted initial funding for development Actively searching for commercial/strategic partners 5. Separator 4. HP Compression 3.Transfer Valve 2. LP Compression Plan Alpha prototype design, build and full integration in the next 14 months Beta prototype in the next 18 months with following beta trials 6. Reservoir 1. Pump

11 FLEETCALC: A TOOL TO HELP RESHAPE OUR NATION S VEHICLE FLEETS Objective to develop a user-friendly web-based tool to assist fleet managers/owners in technology sorting for new vehicles acquisitions Unique Features FleetCalc will be the first online tool to provide accurate information on alternatives for fleet vehicles through simulated vehicle performance based on specific missions Status Completed comparison assessment of other fleet calculators Surveyed and interviewed various stakeholders for needs and wants for program Developed initial economic analysis Built initial web-based interface prototype Developed preliminary framework for education component Current Funding Sources Ohio State University Engagement Impact Grant

12 CNG SYSTEM FOR HD APPLICATION: MODELING AND ANALYSIS Objective to develop a simulation tool that can assist in the design and optimization of a CNG fueling system for HD truck applications Needs Addressed CAR TESS is providing research and engineering support to a Ohio based start-up company specialized in CNG fueling systems for class 8 trucks CAR TESS is developing a simulation platform to help in the design and optimization of the current system Initial discussion also included CAR TESS providing testing services for validation/verification of fueling systems prototypes

13 ANALYSIS OF THE PHYSICAL CONSTRUCTION AND PERFORMANCE OF CNG AND LNG FUELING SYSTEMS Objective to develop a comprehensive understanding of the CNG/LNG fueling systems currently available, their performance characteristics, and to assess potential for future technical development and system integration Outline of the Study Identification of Market Suppliers Survey of Existing Systems in the Market Detailed Analysis of the Identified Systems Opportunities in the market

14 POTENTIALS AND BARRIERS OF CNG VEHICLES IN US Objective To improve the understanding of the role that NG can play as an alternative fuel for the transportation sector in US Topics Covered General energy landscape State of technology of NG engines and vehicle systems NG Infrastructure and implications of increased use of NG for transportation Experience of other countries in using NG for transportation Distribution of World Proven Reserves of NG Using NG in an Engine Several Possibilities Main Achievements Identified and analyzed potentials and barriers to CNG vehicles adoption touching on technology readiness, infrastructure, market/consumer and policy Provided comparison with the relevant experiences of other countries Pre-mixed Spark Ignition Otto Cycle Direct Injection Compression Ignition Diesel Cycle Direct/ Indirect Injection Current Funding Sources CAR Industrial Consortium Mixer Multi-port Injection Mono Fuel Glow plug ignition Dual Fuel Diesel Oil Pilot

15 EUROPEAN UNION MARKET ANALYSIS OF NG POWERED VEHICLES Objective To improve the understanding of the European Union market of CNG Vehicles Topics Covered CNG Production Vehicles in EU, comparative assessment Deep dive into CNG fueling system characteristics and performance Policy Framework, Incentives Customer Perception and technology acceptance CNG Vehicles Sold in Italy FIAT OPEL VOLKSWAGEN Main Achievements Identified and analyzed EU market of CNG vehicles with detailed performance and cost analysis of models available Identified and compared policy and incentive scenario Fiat Panda Bi-Fuel VW Touran (7-Seater) Current Funding Sources CAR GasWorks Consortium

16 COMPREHENSIVE POLICY STUDY OF NG USE IN US TRANSPORTATION Objective provide key information to inform industry and government of supply chain & jobs at stake, policy needed to get what is desired, and how to avoid what is harmful Project Phases Phase 1 CNG Landscape (Ongoing) Current supply chain and employment conditions, estimated business and job increases for different penetration levels of NGVs Phase 2 Road Blocks to NGVs adoption Policy initiatives that could overcome hurdles to achieve a particular level of NGV penetration; Phase 3 Policy Consequences Positive and negative repercussions of following a particular policy path including estimates of increases in employment Current Funding Sources Phase 1 of the study funded at 50% Seeking additional funding sources for further phases

17 SYSTEM LEVEL TECHNOLOGY DEVELOPMENT FOR VEHICLE ANCILLARY LOAD REDUCTION AND THERMAL MANAGEMENT Objective Demonstrate a 25% FE improvement in EPA City/Highway cycle for a demonstration vehicle (Chrysler minivan) Critical Path for OSU Powertrain thermal management and exhaust gas waste heat recovery for engine and transmission oil rapid warm-up and advanced fluids temperature conditioning Ancillary load management for advanced fuel shutoff strategy and crankshaft energy harvesting; Overarching vehicle energy optimizer for displacing loads Vehicle Controls Deliverables Broad Literature and Technology Survey Development, calibration and validation of vehicle system models inclusive of methods and assumptions Experimental and simulation-based system analysis Integrated supervisory energy manager development for vehicle advanced thermal management and ancillary load control ENGINE T ω ACCESSORIES/ ELECTR. SYSTEM T ω TC/TRANSM VES Driver T ω V VEHICLE DYNAMICS

18 TESTING, ENGINEERING AND SOFTWARE SERVICES TESS WELLSITE APPLICATIONS car.osu.edu/facilities/tess

19 APPLICATIONS TO WELLSITE MANAGEMENT Evaluation of Market Size Regulatory Analysis Analyze & Improve Existing Engine Technology Wellsite Environmental Assessment Develop Wellsite Analysis Tools Comprehensive Support Package

20 EVALUATION OF MARKET SIZE In 2011 the U.S. consumed a total of 97,770 trillion BTU 03% 02% 02% 01% 01% 00% Perspective of Total Consumption % 1.7% 1.3% 0.9% 0.5% 0.1% Agriculture Mining Costruction Rail Marine Power Gen

21 3.3% 0.2% 4.2% 1.7% 0.5% 8.5% 12.5% 69.1% EVALUATION OF MARKET SIZE The Mining sector consumed a total of 2,054 trillion Btu in 2011 Mining Sector Energy Consumption 2011 Residual Fuel Oil Distillate Fuel Oil Motor Gasoline Natural Gas Lease and Plant Fuel Steam Coal Renewables Purchased Electricity Lease and Plant Fuel: Natural gas used in well, field, and lease operations and as a fuel in natural gas processing plants. Source: EIA Annual Energy Outlook 2013

22 Conversion to Dual Fuel Recertification required REGULATORY ANALYSIS EPA Field Fix Memo OEM can certify a conversion technology Customer can apply tested technology in the field

23 IMPROVE EXISTING ENGINE TECHNOLOGY Analyze existing technologies Determine effectiveness of conversion packages Work to improve performance Conversion technologies Assist OEMs in developing better engines

24 WELLSITE ENVIRONMENTAL ASSESSMENT Onsite testing of engine emissions Regional testing Dispersion modeling & prediction

25 DEVELOP WELLSITE ANALYSIS TOOLS WellsiteCalc Simulation based using actual engine performance maps Mission based with how the engine is really used Accurately predict economic & environmental performance Compare technologies and fuel types Optimize Energy Utilization Utilize waste energy Look for synergistic opportunities Improve operating characteristics

26 COMPREHENSIVE SUPPORT PACKAGE Offer One Stop Shopping Technical review Regulatory evaluation Economic & environmental evaluation Field testing File for regulatory certification

27 TESTING, ENGINEERING AND SOFTWARE SERVICES TESS THANKS! QUESTIONS? car.osu.edu/facilities/tess