• ESCALATE - "Powering European Union Net Zero Future by Escalating Zero Emission HDVs and Logistic Intelligence"
• VERSAPRINT - "Versatile printed solutions for a safe and high-performance battery system"
• CoacHyfied - "Coaches with hydrogen fuel cell powertrains for regional and long-distance passenger transport with energy optimized powertrains and cost optimized design"
• Take-Off - "Sustainable aviation fuel from CO₂"

Completed projects:

• LONGRUN - "Development of efficient and environmentally friendly LONG distance poweRtrain for heavy dUty trucks aNd coaches"
• CEVOLVER - "Connected Electric Vehicle Optimised for Life, Value, Efficiency and Range"
• REDIFUEL - "Robust and Efficient processes and technologies for Drop In renewable FUELs for road transport"
• ALIGN-CCUS - "Research plant for producing soot-free diesel replacements"
• EAGLE - "Efficient Additivated Gasoline Lean Engine"
• PaREGEn - "Particle Reduced, Efficient Gasoline Engines"
• IMPERIUM - "IMplementation of Powertrain Control for Economic and Clean Real driving emIssion and fuel ConsUMption"
• POWERFUL - "POWERtrain for FUture Light-duty vehicles" (abgeschlossen 2014)
• BEAUTY – "Bio-Ethanol engine for Advanced Urban Transport by Light Commercial Vehicle & Heavy Duty" (abgeschlossen 2010)

Powering European Union Net Zero Future by Escalating Zero Emission HDVs and Logistic Intelligence

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The ESCALATE project aims to promote the integration of zero-emission vehicles into fleets, to reduce CO₂ emissions and meet the objectives of the Paris Climate Agreement and the Green Deal. The project plans to develop and demonstrate high-efficiency drivetrains for heavy-duty long-haul vehicles. These vehicles are intended to be capable of travelling 800 km without recharging or refueling and covering at least 500 km per day on average under real conditions.

ESCALATE focuses on three main areas of innovation: standardized, cost-effective modular and scalable multi-powertrain components; fast fueling and grid-friendly charging solutions; and digital twins (DT) & AI-based management tools. These innovations are expected to help consider the capacity, availability, speed, and nature of charging infrastructures as well as the structures of fleets.

Within the ESCALATE project, the TME is involved in the following tasks:

Battery Development:

• Definition of high-level performance requirements of the battery-electric storage system
• Implementation of a systematic battery concept method using virtual battery components enabling the efficient consideration of various layout concepts
• Early systematic evaluation of the generated base concepts according to several criteria such as packaging density, performance, cooling, expected LCA evaluation, etc.
• Development and dimensioning of a modular system design after concept selection according to the developed evaluation methods

Functional Safety:

• Development of a tool for design and evaluation of functional safety concepts for modular powertrains

Thermal System and Energymanagement:

• Development and application of intelligent system conditioning for charging (before, during, and after charging), including a scalable, modular predictive thermal control strategy for the powertrain and vehicle cabin
• Development of a system topology design to utilize waste heat, including efficiency requirements
• Application of energy-efficient cabin climatization that takes into account a hotel function, concerning the optimization of auxiliary load and comfort influence

Versatile printed solutions for a safe and high-performance battery system

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In order to boost the transition to a climate neutral transport sector, VERSAPRINT will bring innovations to the battery system to tackle safety issues, enhance performances as well as decrease cost and environmental impact. The VERSAPRINT technical solutions will be achieved mainly by 2D/3D printing directly on battery components and will operate from the heart of the battery system (i) providing an efficient cell thermal regulation in order to reduce risk of Thermal Runaway (TR) and increase density and lifetime; (ii) significantly improving the system thermal and safety management thanks to in operando sensoring; (iii) adding thermal and safety-oriented functionalities on busbars; (iv) allowing easy and safe dismantling and re-manufacturing; (v) lowering the casing’s weight, without losing its capability to contain TR and while ensuring good recycling rate; (vi) providing an advanced thermal/fire response; and (vii) controlling the exhaust gases released during a TR by cooling and evacuating them safely.

VERSAPRINT will also implement a Decision Tool in order to choose the most optimised configuration for a given end application and will provide a validation at TRL5 (i) at module level with two module prototypes (for automotive and aeronautics) as well as one virtual module prototype (for waterway transport); (ii) at system level through simulation for all these applications. Other applications such as bus, non-road mobile machinery and stationary storage will be explored as well, through simulation.

VERSAPRINT aims to reach the cost and performances targeted in Batteries Europe 2030 KPIs, while increasing module density by 5% and significantly improving the battery system fire resistance and safety (no fire outside module during TR). Sustainability will be assessed at all development stages. The multi-disciplinary consortium gathers 3 RTO/academic partners and 7 industrial partners (4 IND and 3 SMEs), and is completed by 12 industrial Advisory Board members.

Coaches with hydrogen fuel cell powertrains for regional and long-distance passenger transport with energy optimized powertrains and cost optimized design

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In the CoacHyfied research project, fuel cell systems for use in long-distance coaches are to be developed and tested together with 15 project partners. To this end, two solutions are being developed in CoacHyfied to overcome challenges such as the small installation space or the low recuperation potential. Furthermore, in this particular use case, numerous auxiliary consumers such as cabin air conditioning must also be taken into account. The coaches will be used and tested in two different regions for a period of 2-3 years.

The Chair of Thermodynamics of Mobile Energy Conversion Systems (TME) is developing a predictive maintenance scheduling concept based on generic state indicators for different components of the fuel cell system developed within the research project. With the help of the maintenance scheduler the lifeteime of the fuel cell system is to be increased.

Take-Off: Sustainable aviation fuel from CO₂

European Union´s Horizon 2020

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The Take-Off project, funded by the Horizon 2020 EU program, will explore the development of a unique technology based on the conversion of CO₂ and renewable hydrogen to Sustainable Aviation Fuel (SAF) via olefins as an intermediate. This technology route aims to deliver a highly innovative process that produces SAF at lower costs and higher energy efficiency compared to other power-to-liquid alternatives currently available. The Take-Off route consists of capturing CO₂ from industrial flue gas or direct air capture which reacts with hydrogen produced by renewable electricity to create light olefins. These light olefins are subsequently chemically upgraded into SAF. All innovative steps upgrading CO₂ will be demonstrated under industrially relevant conditions.

SAF produced through the Take-Off technology could significantly support the aviation industry in reducing its carbon footprint and replace the utilization of crude jet fuel products while proving:

• +70 % Carbon and hydrogen efficiency
• -100 % Sulphur emissions
• -20 % Total emissions compared to fossil aviation fuels
• -36 % SAF production costs

The project will also quantify the economic and environmental performance of SAF produced from CO₂ and renewable H₂ via the light olefins route and competing production routes including:

• Economic evaluation and identified opportunities for the reduction of fuel costs.
• Environmental assessment and identify opportunities for the reduction of environmental impacts of jet fuel.
• Optimization of the production of the SAF of the future by using cost and environmental performance data.

The overall aim of the conducted research at TME (RWTH Aachen) is to evaluate the emissions potential of the developed fuel candidates in comparison to commercial fossil based jet fuel and selected reference fuel components. One of the main objectives is to identify functional molecular structures responsible for NO_x and soot emissions as input for an optimized fuel composition. Therefore experimental and numerical investigations are carried out to additionally quantify the potential of NO_x and soot emission savings of SAF produced by the Take-Off project.

The achievement of the project objectives will contribute directly to the UN Sustainable Development Goals, European Green Deal, and the Renewable Energy Directive II, where sustainable aviation fuels are receiving increased attention.

01.01.2021 – 31.12.2024