Membership Presentation

1
Green Innovations - Energies of the Future Rick
Schwerdtfeger, Michael Martin Edison Materials
Technology Center Green Building Expo
2006 Columbus, Ohio September 12, 2006
2
Outline

• Who is EMTEC?
• EMTEC project summary
• Where does our energy come from?
• Where does our energy go?
• How much energy do we use?
• How much does energy cost?
• What alternative energy options do we have?
• Is there a magic bullet?

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Who is EMTEC?

• EMTEC (Edison Materials Technology Center) is a
  501c(3)
• non-profit corporation dedicated to Ohio job
  creation
• through near-term commercialization of
  advanced
• materials and related technologies.
• EMTEC is one of 7 Ohio Edison Centers
• Over 140 Industry, University, and Government
  Members
• Manufacturing Small Business Development Center
• PTAC (Procurement Technical Assistance Center)
• Membership-based Core Technology (CT) program
• Alternative Energy Technology Group
• Fuel Cells, Hydrogen infrastructure,
  Photovoltaics, etc.
• PDQ Center
• www.emtec.org

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Hydrogen Program Objectives

• Edison Materials Technology Center (EMTEC) is
  using DOEs Hydrogen, Fuel Cells
  Infrastructure Technologies Program Multi-Year
  Research, Development and Demonstration Plan
  goals to find and fund projects to stimulate near
  term manufacturing based commercialization
  potential.
• Feasibility projects with job creation
  potential
• Cross cutting breakthrough materials technology
• Using three-phase EMTEC Core Technology (CT)
  model

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Approach

• EMTEC solicits and evaluates projects that
• Have Industry Relevance
• Are Appropriately Resourced
• Have EERE Hydrogen Goal Alignment
• Addresses DOE Barriers
• Have Commercialization Viability
• Phase I projects average 100,000 for one year
• Phase II projects average 200,000 for two years
• Phase III projects are custom designed with
  potential revenue sharing between EMTEC and
  participant

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Status and Budget

• Status
• 3 RFP Rounds
• 114 White Papers and Proposals Reviewed
• 42 Site visits performed
• 23 Projects funded
• Budget
• FY04 2.945 Million
• FY05 2.961 Million
• FY06 2.5 Million
• Contractor cost share gt 7 million
• State of Ohio cost share gt 2 Million

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Interactions - Collaborations

• State of Ohio Department of Development
  Technology Division
• State of Ohio Department of Development
  Third Frontier
• USAF AFRL Technology Transfer program
• Procurement Technical Assistance Center (PTAC)
• Manufacturing Small Business Development Center
  (MSBDC)
• Materials Technology Liaison at AFRL
• Technical Steering Committee (TSC)

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Novel Stackable Structural Reactor (SSR) for
Low-cost Hydrogen Production - Catacel Corp

• Novel Stackable Structural Reactor (SSR) for
  low-cost stationary hydrogen production
• Intended to be a drop-in replacement for the
  loose ceramic catalyst media in the stationary
  steam reforming process
• Accomplishment H2 Reformation Product Developed
• Future Work Installation and testing in steam
  reformer

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Nanocatalyst Development Employing Electrically
Mediated Processing for Hydrogen Generation
Faraday Technology

• A low-cost, mass production fabrication
  technology for catalyzation of membrane electrode
  assemblies (MEA) for PEM (Proton Exchange
  Membrane) electrolyzers and regenerative fuel
  cells
• Collaborators include Precision Energy
  Technologies (PET)
• Accomplishment Tunable catalytic loading process
  developed
• Future work Optimize catalytic loading

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Low Cost MEMS Hydrogen Sensorfor Transportation
Safety Makel Engineering

• Advanced hydrogen sensor system for hydrogen
  powered transportation applications
• Provides the means for low cost, compact, low
  power consumption, and miniaturized systems
  suitable for mass production
• Accomplishment Prototype H2 sensor developed
  and automotive testing initiated
• Future Work Final product testing and market
  development

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Development of Improved Materials for Integrated
Photovoltaic Electrolysis Hydrogen Generation
Systems - MWOE

• Developed manufacturing process for Integrated
  Photovoltaic Electrolysis (IPE) panel.
• This technology produces hydrogen from water
  using sunlight
• Average array H2 generation rate is 135 cc/min/m2
• Collaborators on project include the University
  of Toledo, Energy Photovoltaic, Inc, and National
  Renewable Energy Laboratory
• Accomplishment Pilot scale IPE H2 production
  operational
• Future Work Improve solar-to-hydrogen efficiency
  by using triple junction amorphous materials.

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High Strength, Low-Cost Microballoons for
Hydrogen Storage - Powdermet Inc.

• Numerical modeling of various microballoon
  materials and geometries validated the potential
  for these materials for high pressure storage
• Nanocomposite high-strength coatings on light
  weight, low strength microballoons by chemical
  vapor deposition for high volume, low-cost
  hydrogen storage developed
• Collaborators on project include Air Force
  Research Laboratory and Hy-Energy LLC.
• Accomplishment High strength microballoon H2
  storage concept verified
• Future Work Design, build and test H2 storage
  system with increased volumetric storage capacity

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Novel Ceramic Hydrogen Sensors for Fuel Cell
Applications NexTech Materials

• Novel ceramic sensor for hydrogen safety
  low-cost sensor technology with improved gas
  sensitivity, selectivity, and response time
• Safe practices in the production, storage,
  distribution and use of hydrogen are essential
  for a hydrogen economy
• Accomplishment H2 safety sensor performance
  verified
• Future Work Completion of prototype assembly and
  testing

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Reel-to-Reel Electrolyzer MEA Processing
Precision Energy Technology

• Develop continuous reel-to-reel manufacturing
  equipment and and control processes to bring
  lower cost commercialization for hydrogen
  producing membranes
• Thermal, pressure and speed control for catalyst
  application and MEA assembly
• Accomplishment Advanced reel-to-reel
  electrolyzer manufacturing process developed
• Future Work Equipment and process optimization
  and testing

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Future Work

• Catacel Installation and testing in steam
  reformer
• Faraday Optimize catalytic loading
• Makel Final product testing and market
  development
• Participant in RD 100 Applications where
  appropriate
• MWOE Improve solar-to-hydrogen efficiency
• Powdermet Design, build and test H2 storage
  systems
• NexTech Completion of prototype assembly and
  testing
• PET Equipment and process optimization and
  testing

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Hydrogen Program Summary
Hydrogen Program Performance
Reinvest. Position
Meeting Objective
Comm. Potential
On Schedule
Prtnr/Chmpn
On Cost
Match Ratio
Project Funding
Applicant
Project Title
EFC
Faraday
Nanocatalyst Development Employing Electrically
Mediated Processing for Hydrogen Generation (I)
H1-01
360,287
2.89
Catacel Corp
Novel Spiral Stackable Reactor (SSR) for Low-Cost
Hydrogen Production (II)
H1-09-2A
528,737
2.17
IAP Research Inc.
Commercialization of EM Solid State Welding for
High Pressure Hydrogen Storage (I)
H1-11
324,769
3.25
Makel Engineering
Low Cost MEMS Hydrogen Sensor for Transportation
Safety (I)
H1-15
1.99
260,727
MWOE
Development of Improved Materials for Integrated
Photovoltaic-Electrolysis Hydrogen Generation
Systems (I-II)
H1-16-2A
674,875
2.08
Regenerative Solid Oxide Fuel Cell (II)
390,000
UDRI
H2-20- 2A
1.95
H2-15
High Temperature Electrochemical Cells for
Hydrogen Production and Regenerative Fuel Cell
Systems (I)
2.15
215,000
NexTech
2.15
H2-21
215,073
Novel Ceramic Hydrogen Sensors for Fuel Cell
Applications (I)
NexTech
High Strength, Low Cost Microballoons for
Hydrogen Storage (I)
218,267
H2-12
2.23
Powdermet
H2-3
Hydrogen Storage Using Porous Silicon (I)
216,742
Dephi
2.46
17
Hydrogen Program Summary
Hydrogen Program Performance
Reinvest. Position
Meeting Objective
Comm. Potential
On Schedule
Prtnr/Chmpn
On Cost
Match Ratio
Project Funding
Applicant
Project Title
EFC
Ohio Univ.
H2-08
Electrochemical Coal Gasification with Novel
Electrodes (I)
70,070
2.00
Univ. of Toledo
H2-22
Fabrication of Metal-Carbon Nanostructure
Composites (I)
73,334
1.55
Hy-Energy
H2-18
Novel Materials for Reversible Hydrogen Storage
(I)
2.09
232,588
GFS Chemicals
Development of Complex Metal Hydrides for
Hydrogen Storage Applications (I)
H2-11
2.18
197,092
NFCRC
H2-16
Novel Intermediate-Temperature Reversible SOFC
for a Renewable Energy System that can Co-produce
Power and Hydrogen (I)
224,085
2.24
Reel to Reel Processing for Continuous Thermal
Pressing of the Catalyst Film onto a Membrane for
High Volume, Low Cost Commercialization of
Hydrogen Generating MEAs (I)
H2-23
PET
201,897
2.21
Electrochemical Conversion of Biomass to Hydrogen
(I)
H3-14
TMI
1.62
162,000
Improved Liquifaction Process (I)
Praxair
H2-2
2.01
200,804
18
Hydrogen Program Summary
Hydrogen Program Performance
Reinvest. Position
Meeting Objective
Comm. Potential
On Schedule
Prtnr/Chmpn
On Cost
Match Ratio
Project Funding
Applicant
Project Title
EFC
Protonex
H3-19
264,573
2.65
Methanol Reformed Hydrogen For Portable PEM Fuel
Cell Systems (I)
Proton Energy
H3-3
207,526
2.10
Development of High Pressure Electrolyzers for
Backup Power Systems (I)
Catacel Corp
H3-7
Scalable Steam Methane Reformer System for
Distributed Hydrogen Production (I)
209,998
2.10
Delphi
Low-Cost Manufacturing of Multi-Fuel Reactors for
an Innovative High-Efficiency Planar Reformer (I)
H3-13
219,084
2.19
Chemsultants
Innovative and Cost-Effective Micro-Process for
Roll-to-Roll Solution Casting of Multi-Layer PEMS
(I)
H3-5
203,657
2.11
19
Ohios Hydrogen Presence
Storage
PV Generation
Reformation
Sensing
FC Stacks
Manufacturing
20
Green Energy Technologies
Lets shift gears and discuss green energy
technologies and their relationship to green
buildings.
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U.S. Energy Usage

• Residential and Commercial buildings account
  for about 40 of our nations total energy
  consumption annually

http//www.eia.doe.gov/emeu/aer/pdf/pages/sec1_3.p
df
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Electricity Production

• 27 of all primary energy produced in the U.S.
  is lost in conversion to electricity
• Conversion efficiency improvements are critical

http//www.eia.doe.gov/emeu/aer/pdf/pages/sec8_3.p
df
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Residential Energy Usage
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Energy Demand
http//www.eia.doe.gov/emeu/aer/pdf/pages/sec8_3.p
df
http//www.eia.doe.gov/emeu/aer/pdf/pages/sec1_12.
pdf
EMTEC - Accelerating Technology to Market
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Oil Prices
http//www.eia.doe.gov/emeu/aer/pdf/pages/sec11_14
.pdf
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Energy Prices
http//www.eia.doe.gov/emeu/aer/pdf/pages/sec8_38.
pdf
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Atmospheric Impact

• Fossil fuel usage is not beneficial to long
  term environmental health
• Energy consumption is rising
• CO2 and Methane levels are rising

http//www.ases.org/chapter_newsletter/2006/JA06/C
limate_Change_JA06.pdf
http//www.eia.doe.gov
28
Renewable Energy Options

• Hydrogen fuel cells
• Solar
• Wind
• Hydropower
• Geothermal
• Biofuels
• Magic Bullet?

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Renewable Energy Sources
Renewable Energy Sources as Total of All Primary
Power 2005
http//www.eia.doe.gov/emeu/aer/pdf/pages/sec10_2.
pdf
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30
Energy Options - Fuel Cells

• Structure
• Function
• Systems
• Advantages
• Disadvantages
• Markets and Applications

31
Fuel Cell Structure
32
Basic Fuel Cell Operation
33
Fuel Cell Stack
34
Fuel Cell System

• Fuel Processing
• Fuel Cell Stack (Power Section)
• Power Conditioning
• Balance Of Plant

35
Fuel Cell System
www.ballard.com
36
Fuel Cell Advantages

• Zero to ultra-low pollutant emissions (NOx, SOx,
  HC, CO)
• High fuel-to-electricity conversion efficiency
• Low noise
• Modularity and applicability to diverse
  applications
• stationary, mobile, portable,
• POTENTIAL FOR
• High Reliability (No/Few Moving Parts)
• High Energy Density (e.g., compared to batteries)
• Power Quality
• Siting/Licensing Ease
• Distributed Generation Benefits

37
Fuel Cell Disadvantages

• Cost, Cost, Cost
• Track Record
• Low Power Density
• e.g., compared to gas turbine engine
• Reliability, Availability, Maintainability,
  Durability and User Friendliness (RAMDU)
• Siting/Licensing Complexity

38
Fuel Cell Markets

• Educational packages
• Critical Systems Backup Power
• Hospitals
• Financial / computer networks
• Communications towers
• Soldier power
• Personal electronics power
• laptops
• cell phones / PDAs / MP3
• Residential / commercial CHP (Combined Heat and
  
• Power)
• Transportation
• APUs
• Propulsion

39
Energy Options - PV
http//www.eia.doe.gov/emeu/aer/pdf/pages/sec10_12
.pdf

• Photovoltaic (PV) Solar Power
• One hour of sun could power Earth for one year!
• Still Expensive, 3 10 per peak Watt
  installed
• 0.10 - 0.40 per kWh depending on incentives
  and size

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40
Energy Options - PV
Ohio has 2/3 Solar Irradiance of Arizona!
6.5 7.0 kWh/m2/d
4.0 4.5 kWh/m2/d
41
Energy Options - PV

• Photovoltaic (PV) Solar Power
• Huge demand due to European feed-in tariffs
• Most PV companies are at capacity and expanding
• In 2005, the PV sector achieved 44 volume, 50
  revenue and 149 profit growth world wide

Installed Capacity (MW)
http//www.eia.doe.gov/emeu/aer/pdf/pages/sec10_12
.pdf
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42
Energy Options - PV

• Photovoltaic (PV) Solar Power Payback OH vs.
  AZ

New 2600 sq. ft. house with Electric Heat Pump
using 15,000 kWh/yr. 6kw PV system meeting 50
of load.
OHIO
Payback (years)
ARIZONA
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Energy Options Solar Thermal

• Residential water heating
• Fast payback in virtually any location
• Easy installation by certified contractors
• Several technologies to chose from

Efficiency
Water Temperature
http//www.solarserver.de/wissen/sonnenkollektoren
-e.html
www.solarradiant.com
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Energy Options Solar Thermal

• Stirling engine technology
• Estimating 2 per Watt once in full production
• A farm 11 square miles would produce the same
  power as Hoover Dam (Lake Mead is 247 square
  miles)
• A farm 100 miles x 100 miles would produce
  enough power for entire U.S.

http//www.sandia.gov/news/resources/releases/2004
/renew-energy-batt/Stirling.html
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Energy Options Solar Thermal

• Trough Systems
• 1 MW Arizona Public Service System at Saguaro
• 2630 kWh / m2 / year

http//www.powermag.com/archive_article.asp?a82-T
P_Saguaroy2006maugust
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Energy Options - Wind

• Wind
• Cost competitive, lt .05 / kWh
• Struggling with NIMBY
• Very site specific

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47
Energy Options - Wind

• Ohio has one utility-scale wind farm with four
  3-bladed turbines producing 7.2 Megawatts of
  maximum total power. Each blade is 30 meters
  long.
• 50 Megawatt wind farm proposed in Logan County
  Ohio, made up of 25-30 turbines on about 1500
  hectares of land.
• Ohio company (Ohio Alternative Power, LLC)
  currently importing and integrating wind energy
  technologies in Lorain Ohio.
• Ohio infrastructure in place for inexpensive,
  high quality component and balance-of-systems
  manufacture and integration for wind industry.

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48
Energy Options - Hydro

• Highest capacity alternative energy source
  world-wide
• Microhydro power rapidly growing residential
  market
• Hydro is very sight specific, like wind but
  unlike solar
• Different turbines to match flow level and head
  pressure
• Typical systems are hundreds of watts to a few
  kilowatts
• Trying to emerge from cottage industry status

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49
Energy Options - Geothermal

• Geothermal contractors readily available
• http//www.geoexchange.org/publications/ohio.htm
  
• Geothermal Heat Pump Consortium website
• Geothermal heat pumps use 33 less energy than
  air systems, but are 33 more expensive to install

Heating Cycle
Cooling Cycle
http//geoheat.oit.edu/pdf/tp88.pdfsearch22geot
hermal20heat20pump20Ohio22
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Energy Options - Biofuels

• Biomass-derived fuels
• All the corn in Ohio can only power 3 of
  Ohios cars
• We need new technology to more efficiently
  convert
• cellulosic biomass into ethanol

• Biodiesel produces 78 less CO2 than
  conventional diesel
• Biodiesel is more energy efficient to produce
  than ethanol

Millions of Gallons
http//www.biodiesel.org/resources/faqs/
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51
Energy Options - Ethanol

• Ohio has 3 facilities under construction which
  will produce 200 million gallons of ethanol per
  year
• It will take approximately 16 of Ohios entire
  corn production to fuel these three plants alone
• Surrounding states have similar issues
• Rising demand has increased the price of corn
• Price of ethanol will follow price of corn

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52
Energy Efficiency

• Small, simple actions by large numbers of
  people (110 million households) can produce real
  results
• The Department of Energy has estimated that LED
  lighting could cut national energy consumption
  for lighting by 29 percent by 2025
• If every household in the U.S. replaced ONE
  light bulb with an ENERGY STAR qualified compact
  fluorescent light bulb (CFL), it would power a
  city of 1.5 million people, or prevent enough
  pollution to equal removing 1.3 million cars from
  the road.
• If everyone in the U.S. exclusively used
  energy-efficient lighting, we could retire 90
  average size power plants.

http//www.eere.energy.gov/buildings/info/document
s/pdfs/26290.pdfsearch22Energy20saved20by20e
nergy20efficiency22
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Energy Efficiency

• An Atlanta community found that the annual
  energy bills for newly constructed, affordable
  homes averaged over 1,200. Increasing the energy
  efficiency of the homes saved over 400 a year
  and added less than 500 to construction costs.
• The savings on the mechanical systems alone can
  pay for the increased cost of insulation and air
  sealing.
• Exterior lighting can cost hundreds of dollars
  a year to operate if it is not energy efficient.
  Install only compact fluorescent or high-pressure
  sodium fixtures for security lighting, and
  consider motion sensors or photo cells that
  operate lights automatically.

http//www.eere.energy.gov/buildings/info/document
s/pdfs/26290.pdfsearch22Energy20saved20by20e
nergy20efficiency22
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Compact Fluoresent Bulbs
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Residential Efficiency Upgrades

• 2 x 6 stud construction (upgrade from 2 x
  4)
• 1 wall board insulation outside (upgrade from
  none)
• Seal all penetrations from air infiltration
• R-49 Attic Insulation (upgrade from R-30)
• Low e , high R windows (preferentially on
  south face)
• SEER 19 rated AC or Heat Pump (upgrade from
  SEER 13)
• All Energy Star Appliances (preferably Tier 3B
  compliant)
• 25 Watt CFB instead of 75 Watt incandescents in
  all fixtures
• Programmable Thermostat
• Right-sized HVAC and ducting based on lower
  energy demand

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Residential Upgrade Impact

• Added parts and labor for all upgrades
  (including profit)
• 8,000
• Impact on consumers mortgage
• 66
• Impact on consumers budget
• Reduces 250 monthly utility bill by 138
• Net impact on consumer 72 per month SAVINGS!
• Savings over 15 years 13,000!!
• Impact on home resale value marketing
  advantage

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Magic Bullet

• The best energy is saved energy
• Energy Efficiency is the Magic Bullet
• Number of new homes per year 1.6 Million
• If all new homes were built to these
  specifications
• Energy savings 2.5 Billion kWh
• Consumer savings 1.4 Billion / yr
• Contractors profits 3.9 Billion / yr
• Utility profits up
• Huge environmental benefits

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Government Climate

• 5 Billion per year to oil and gas industry
  subsidies
• 10-20 year tax subsidies for coal, oil, and
  natural gas
• 2 year tax subsidies for solar and wind
• Many states initiating their own programs due to
  lack of adequate federal support
• This is creating an us versus them climate
  among states we must work to avoid
• Ohio has the capability to produce excellent
  alternative energy solutions, but will be slow
  without competitive state programs similar to
  California, Colorado, New Jersey, Pennsylvania
  and others
• Ohio can immediately focus on supply chain
  involvement in fuel cells, solar, wind,
  geothermal, etc.

http//www.taxpayer.net/TCS/fuelsubfact.htm
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Business Opportunities and Links

• www.odod.gov
• Ohio Department of Development helps businesses
  in Ohio
• www.thirdfrontier.com
• State funded research and commercialization
  program
• http//www.energylens.com/
• Software to help businesses save money on energy
• http//www.energycodes.gov/
• Energy codes and software to assist with
  compliance
• http//www.eartheasy.com/live_energyeff_lighting.h
  tm
• Great efficient lighting resource web sight
• http//www.eia.doe.gov
• Energy information web site for all sorts of
  energy data
• http//www.dsireusa.org
• Database of state renewable incentives
• http//www.findsolar.com/
• Calculate solar system payback senarios
• http//home.altenergystore.com
• Example alternative energy on-line retail store

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60
Acknowledgements

• DOE Hydrogen Program solicitation number is
• DE-FC36-04GO14215
• State of Ohio Department of Development

EMTEC - Accelerating Technology to Market