Solar, Battery, Fuel Cell, Hydrogen and the Future with Re:Build Optimation

Battery Technology

As we started the interview with Bill, he shared an easy and brief description of battery technology. “If you have solar, what do you do with the power? Of course, if you generate solar on the grid, then you get your solar during the day when the sun is shining. But when the sun goes down, it all goes away unless you have a way to store it, which is why batteries come into play.”

During our conversation, an excellent analogy was drawn between battery technology and the operation of Niagara Falls. Imagine the Falls at night—quietly, they fill up their reservoir, storing water while demand is low. Then, during peak daytime hours when electricity demand spikes, water is released, powering turbines to generate electricity. This process at Niagara Falls mirrors how battery storage works with renewable energy sources like solar and wind, which don’t produce energy consistently throughout the day. Batteries store energy when production is high but demand is low, then release it when the situation reverses, ensuring a reliable energy supply despite the natural intermittency of these sources. This technique is essential for maintaining a stable and continuous power supply as we increase our reliance on renewable energy.

On that note, recent advancements in battery technologies have also presented a significant development in the exploration of iron-air batteries as alternatives to traditional lithium-ion technologies. Iron-air batteries offer a distinct advantage in terms of cost, as iron is significantly cheaper than lithium. However, they also present challenges, as they are “half as efficient or less than half as efficient as lithium batteries,” according to Bill Polock. This efficiency variance renders them less suitable for dynamic applications such as powering vehicles but potentially ideal for stationary storage solutions on the power grid. This approach to battery technology reflects a broader trend in seeking sustainable and economically feasible energy storage solutions.

Bill elaborates on their innovative approaches to battery technology manufacturing, particularly in adapting to different market needs. “We help people to make manufacturing lines to build lithium batteries which can be designed for various markets including automotive and hand tools,” he explains, pointing towards the agility and broad applicability of their technology. This adaptability is crucial as the global battery market is projected to grow significantly, from $108.4 billion in 2019 to $308.3 billion by 2027, at a compound annual growth rate (CAGR) of 14.1% during the forecast period, driven largely by the increasing demand for electric vehicles and advancements in battery technology (IEA).

Re:Build Optimation also ventures into the realm of battery recycling—a critical aspect of sustainable manufacturing. Bill discusses the complex chemical processes involved: “We’ve been engaged with people who recycle batteries… it’s just a big chemical process and we’re really good at big chemical processes.” This focus on recycling is essential given that, according to the Environmental Protection Agency (EPA), only about 5% of lithium-ion batteries are recycled in a way that recovers valuable materials.

Furthermore, Bill details the specialized manufacturing processes they employ, particularly web-based manufacturing techniques for making anodes and cathodes, crucial components of lithium batteries. “They need anodes and cathodes… all made on a big wide web where they coat and put conductive and isolated parts, print those on the webs,” he states. This efficient production method is vital as advancements in manufacturing technologies are expected to reduce production costs by up to 20% and improve manufacturing line efficiencies.

On scaling production, Bill underscores the gradual transition from small-scale prototypes to industrial-scale operations, a necessary step to refine processes before full implementation. “You can’t scale from a really small machine to a huge one right away… You build what we call a pilot line.” A pilot line is an intermediary step between lab-scale experiments and full-scale production. It allows companies to test and refine processes on a smaller scale, ensuring efficiency and viability before large-scale implementation. This step is crucial for optimizing production details and minimizing risks in scaling up.

Electric Vehicles

As government funding continues to shape technological advancements in renewable energy, the electric vehicle (EV) market has seen a significant boost. Subsidies have helped double the sales of electric cars to a new record of 6.6 million globally in 2021, marking a substantial increase from previous years and underpinning the rapid adoption of EVs, particularly in leading markets such as China and Europe (IEA).

Bill identified: “There are places where it’s adaptable, but in terms of battery technology, it’s the hybrid cars that are catching on and popular, because with electricity, you can have the best of both possible worlds.” He underscores the efficiency and convenience hybrids offer, allowing drivers to switch between electric and gasoline power. This flexibility is critical in areas like warehouses and golf courses, where electric vehicles (EVs) excel due to their operational efficiency. The U.S. Department of Energy highlights that hybrids can decrease fuel consumption by about 30% to 60% compared to their gasoline counterparts.

The adoption of electric and hybrid vehicles is also propelled by improving infrastructure, such as the increasing availability of charging stations. According to an analysis by McKinsey & Company, the expansion of charging infrastructure is key to supporting the growing EV market, with projections indicating that the number of public charging points could grow tenfold by the end of the decade.

Fuel Cell Technology

Another innovative potential that’s undergoing extensive and rigorous improvements include the fuel cell technology, which is specifically advantageous for heavy-duty vehicles like buses and tractor trailers. Fuel cells provide significant benefits compared to conventional battery systems, such as the ability to refill quickly and a lighter weight, both of which are essential for optimizing the performance of large vehicles.

During the interview, Bill emphasized the strategic placement of hydrogen refueling stations and highlighted their pivotal role in advancing the integration of hydrogen fuel cell technology in transportation, particularly for large commercial vehicles. He notes, “The strategic placement of hydrogen refueling stations along major highways could revolutionize how we think about fueling large commercial vehicles,” pinpointing the necessity for well-thought-out infrastructure to support new energy technologies effectively.

While regulations and measures on technology adoption are designed to reduce environmental impacts—such as those promoting LED lighting and electric stoves—they can also bring practical challenges. For example, the initial rollout of low-flow toilets led to widespread plumbing issues, illustrating that the transition to new technologies can have unintended consequences. Such experiences underscore the necessity for ongoing adjustments in standards and practices to ensure that environmental policies achieve their intended benefits without disruptive side effects.

Research from the National Renewable Energy Laboratory (NREL) suggests that the strategic placement of refueling infrastructure is important for reducing operational costs and enhancing the adoption of hydrogen-powered vehicles. Investments in hydrogen infrastructure, such as refueling stations, are expected to surpass $10 billion globally by 2025.

Carbon Capture Technology

Bill highlighted the environmental and practical dimensions of carbon capture technologies and emphasized the significant role of government incentives, “There’s huge amounts of government money and mandates around the fact that we can’t keep creating carbon dioxide and putting it into the air because that’s causing global warming which is causing us to all die.” This urgency reflects the growing regulatory focus on reducing carbon emissions, a sentiment echoed by a 2021 report from the International Energy Agency, which states that carbon capture, utilization, and storage (CCUS) projects have surged, driven by new government climate ambitions (IEA, 2021).

Pollock discusses a notable application of carbon capture in the construction industry, where CO2 is used to strengthen concrete. “They found out that if they took the carbon dioxide and impregnated it into concrete for making concrete blocks, it would capture the carbon that was in the air and now it’s embedded into a concrete block so it can’t escape any longer. And they found that the concrete blocks were stronger.” You capture the carbon emitted from furnaces and convert it into methane or other fuels for reuse, effectively recycling energy and reducing emissions. This innovative approach not only sequesters CO2 but also enhances the building material’s performance, aligning with research indicating that carbon-infused concrete can have a compressive strength up to 10% higher than traditional concrete (Journal of Cleaner Production, 2020).

Grants and Government Funding

After an introduction to battery technology, Bill offered a deep dive into the challenges and innovations within the renewable energy sector, particularly emphasizing the evolution of offshore wind energy infrastructure. One standout project involves the use of advanced 3D printing technology to create concrete towers for wind turbines. Pollock highlights the precarious reliance of such innovative projects on government funding: “A lot of government money came into the development of these towers. And then when the government money ran out, the excitement and interest in continuing to invest in the technology waned and that project stopped.”

The conversation also touches on the broader implications of government incentives and their role in shaping industry practices. Reflecting on the influence of government funding on the sustainability of business models and technological innovations, Bill notes, “If the carbon tax on flaring the gas is high enough, then you can take the combination of those tax savings and the cost of the technology and it justifies doing a conversion.” This perspective is critical in understanding the financial dynamics that drive green technology adoption.

In terms of validating new projects, the importance of feasibility studies should be the main focus, ensuring investments are made into technologies that have a real chance of making a positive impact and becoming commercially viable. This approach is fundamental in navigating the complex pathways through which renewable energy solutions and green technologies advance towards mainstream adoption. In terms of validating new projects, engineering studies should always be the first step. If somebody has an idea, you’ve got to prove that the idea is viable.”

Using green polymers as an example, Bill Pollock discusses the economics and problems of bringing breakthrough technology to market. Pollock says, “Other ones will function, but the economics are such that it won’t operate well enough to make it feasible. “Nice technology, but too expensive to be viable.” The balance between innovation and economic feasibility in commercial applications is crucial.

Pollock describes their work with a client who created carbon dioxide and air-based plastic. Some years ago, they discovered how to create green plastic. Instead of using all oil-based hydrocarbons to create plastic, they used a substantial percentage of carbon dioxide and air.” This idea attracted large industry players “We helped them scale from a leader-sized lab to hundreds of gallon vessels. Later, they sold company technology to Aramco.”

Partnership in Technological Development

Re:Build Optimation’s approach to business focuses on building long-term relationships. They understand the value of that in comparison to pursuing immediate financial gains: “And the idea that optimization takes a partnership approach where you would much rather spend low dollars to get great answers instead of spending high dollars to just take the big paycheck and walk away whether they’re happy or not.” This method not only fosters trust but also supports sustainable project development.

The fact is that retention is a big issue in the industry. Re:Build Optimation is in a narrow niche but also a competitive industry where quality is above quantity. The belief is this. Nurture and perfect what we have in hand instead of focusing on building a big pipeline that serves under deserving quality. On top of that, there are also vulnerabilities among many energy startups: while they are innovative and capable of rapid initial growth, their reliance on government grants can lead to financial instability when the funding dries up. Bill explained that these ventures often experience rapid growth, secure funding, and establish their factory in a certain location, only to encounter severe financial difficulties later due to a lack of sustainable business models or insufficient commercial planning. This pattern underscores the need for more robust financial strategies and feasibility assessments in the early stages of technology development, ensuring that these innovative solutions can transition from temporary projects to permanent fixtures in the energy sector. Re:Build Optimation has been around for a long while to understand the importance of ensuring feasibility and safety first and can remove the gap between ideation and implementation for companies.

Conclusion

In conclusion, the journey through Re:Build Optimation’s involvement in the alternative energy sector not only highlights the practical implementations of emerging technologies but also sheds light on the broader impacts of governmental policies and the necessity for robust commercial strategies. From advancing battery technology and supporting the rise of electric vehicles to pioneering carbon capture applications, the company exemplifies a commitment to innovation paired with sustainability. As the industry continues to evolve, the focus on creating viable and efficient solutions underscores the importance of partnerships and rigorous feasibility assessments. Re:Build Optimation stands at the forefront of this transition, proving that the future of energy is not just about generating power but about fostering resilience and sustainability for global communities.