Featured Project

High-Efficiency Hybrid Power Generation

Real world results

Crazy Quiet Power (CQP) is a highly efficient 810kW power generation system designed by Czero for rigorous Department of Defense (DoD) applications. CQP combines two redundant variable speed Tier 3/4F diesel engines with high efficiency permanent magnet generators, energy storage system (ESS), optional renewables connectivity, and a proprietary advanced power management algorithm. CQP delivers demonstrated efficiency improvements of >40% at 200 kW, >60% at 100 kW, and a 5-10% improvement under typical max power conditions compared to conventional 1 MW systems. It is packaged in a 20-foot CSC certified ISO container and delivers clean 480 Volt 3-Phase AC exportable power, operating at up to 120°F ambient temperature and up to 5000-foot of elevation with no external infrastructure requirements. Due to CQP’s battery ESS and diesel driven generators, it is capable of rapid vehicle recharge and quiet mode to minimize noise and thermal signatures. The system has been built and tested with all power electronics and one of two redundant power generation units for around 200 hours of operation. The latest iteration is currently being integrated into Czero’s test facility with over a 200kWh capacity.

Single Engine Test Stand at Czero Facility

Hybrid Power

Generation for

Improved Fuel

Efficiency and

Performance

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Czero has formally demonstrated this technology twice now to its stakeholders. Please learn more about the demos below.


Demo #2 - August 2024


Czero demonstrated a functional Hybrid Genset/Mobile Tactical Battlefield Recharger (MTBR) to stakeholders at the GVSC Detroit Arsenal grounds.


Read the Official Press Release

MTBR Demo August 2024 MTBR Demo August 2024
MTBR leaving Czero and on its way to Detroit for the demo
MTBR Demo August 2024 MTBR Demo August 2024
Czero's Travis Johnson presents to MTBR stakeholders
MTBR Demo August 2024 MTBR Demo August 2024
Multiple EVs being charged by the MTBR
MTBR Demo August 2024 MTBR Demo August 2024
Czero's Bryce Whitehill presents to MTBR stakeholders
MTBR Demo August 2024 MTBR Demo August 2024
A look inside the MTBR

Demo #1 - December 2021

Czero demonstrated a functional CQP system to stakeholders at the Fort Collins facility in Colorado.


Technical approach

Standard generators are run at a constant 1800 RPM operating point regardless of the electrical load placed on the generator. When operated in a low load state, this is very inefficient for fuel costs. To address this, Czero built a hybrid-diesel generator system which can be run at any speed, allowing the generator to operate near peak efficiency for optimal energy conversion. To address transient load requirements, CQP incorporates an ESS in the form of battery packs. The system’s electrical topology contains a unified 750 VDC bus which is fed by both variable speed gensets, two independent sets of battery packs, and connections for external renewables such as photovoltaic arrays. This high voltage DC bus exports power via 480 Volt 3-Phase AC 50/60 Hz inverters capable of islanding or micro-grid operation. Two integrated 60kW DC chargers allow for rapid charging of electrified vehicles. When the electrical load demand changes rapidly, the batteries quickly supply or store the excess power to maintain high-quality power without the need to immediately adjust engine operation to compensate.

CAD Rendering of Deployed Configuration (doors removed for clarity)

Benefits

  • CQP is designed to fit into existing container transportation and logistics requirements, minimizing customization and cost to the military.
  • High-efficiency results in lower energy costs. More importantly, less fuel must be transported (and the risks associated with these convoys) to remote and austere locations where power generation is required.
  • Enables the military to effectively deliver energy solutions to critical mission environments.
  • Provides a more integrated and resilient response in supplying critical power to locations affected by conflict or natural disasters.

CQP Fuel Consumption Measurement Results

Reduction in operating & total costs of ownership

Reducing DoD expenditures is essential to future combat effectiveness. For a typical load profile, this equates to an annual fuel savings per system on the order of 25% or $250,000/year at $5 per gallon delivered cost without the addition of renewable energy sources. Over time and across geographies, these savings are significant. Additionally, the need for less fuel results in a decreased requirement for logistic support. While providing onsite energy, the system can also charge the electrified fleet of the future. Additionally, by running generators at peak efficiency, the need for maintenance and overhauls is reduced, enhancing the lifetime of power units, and reducing total ownership cost.

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Patents

Four patents have been issued for the CQP system.

    Reach out to us, schedule a meeting, and let's find your custom solution.

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    Aker Solutions

    "Czero is one of the best companies I have worked with for analysis and simulation; including dynamic modeling, CFD and FEA. Their deep expertise and comprehensive quality system ensure accurate results. Czero's project management is excellent, providing clean concise information on progress, schedule and budget. Czero is a go-to source for projects ranging from analysis and simulation to prototype product development and testing. They deliver strong solutions to the challenges faced by Offshore and Subsea markets."

    - Horst Moll, Former First Chief Engineer, Aker Solutions
    Nexceris

    "Nexceris has been working with Czero since 2018 to develop and demonstrate a 50-kW scale hybrid power system for a government customer (ARPA-E). Czero led system design and controls development, and currently is leading system construction and testing work on the project. Czero engineers are extremely talented, innovative, detail oriented and responsive. I have thoroughly enjoyed our collaboration and provide my highest recommendation."


    - Scott Swartz, Founder and CTO, Nexceris
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    "PDC Machines- a compression and refueling technology provider to the world’s emerging hydrogen economy has been working with Czero for over 6 years on a combination of greenfield new technology and incremental technology improvements to our product. They have been able to take our napkin sketch frameworks and work with our team to deliver minimum viable product to complete solutions which are efficient, marketable and in many cases patentable. Their clear and simple approach to partnership- working as part of one team PDC staff is why I believe in the growing foundation we started 6 years ago."

    - Kareem Afzal, Executive Chairman, PDC Machines
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    "We chose Czero since they have a stellar reputation for innovation and expertise in the automotive industry. They also have a proven track record and prior history with the original inventor [of Onboard Dynamics natural gas refueling technology]—who is on our team—that has already resulted in huge successes in meeting critical milestones and performing to expectations."

    - Rita Hansen, CEO Onboard Dynamics
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    "I have a >$1M US Department of Energy research effort for which I was understaffed and lacking specific subject area expertise. Czero was able to engage last minute to displace a well-known automotive engineering company at a fraction of the price. Over a year into the project, Czero has continued to be responsive and trustworthy; their engineering performance has contributed significantly to an increase in project funding from the sponsor. As the project principal investigator, selecting Czero as an engineering services company has been one of the best decisions I have made."

    - Chris Hagen, Assistant Professor, Energy Systems Engineering Oregon State University – Cascades
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    "Czero’s work with us to fully understand the requirements of the end product for the new reactor engine system has been instrumental in developing a completely new, innovative system. From these requirements, they were able to quickly come up with multiple concepts for vetting against the tough project objectives, which include not only technical feasibility but also aggressive cost targets. The in-depth simulation and analysis of the various concepts that Czero did ahead of time has built tremendous confidence we are going down the right path."

    - Devin Halliday, Principal Investigator, Gas Technology Institute
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    "Czero’s ability to work with our engineers in developing innovative, ground-breaking technology has been a great benefit to the SuperTurbo development. We have placed a lot of trust in Czero’s ability to deliver and have not been disappointed. They are a top-shelf organization."

    - Tom Waldron, Executive VP, SuperTurbo Technologies
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    “My initial request to Czero was to develop software and the associated controller needed for a very important competitive assessment of our product. Due to the nature of the project, I needed the work to be accomplished and in my customers hands within 2 months, which was a very aggressive necessary timeline for this level of work. Not only did Czero get the software and ECU requirements done to spec, but the system was delivered to my customer ahead of time to support the testing. The expertise, timeliness, and quality of the Czero solution was outstanding!”

    - Bradlee J. Stroia Ph.D., Stanadyne Operating Company LLC
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    "We’ve had an absolutely fantastic, positive experience with Czero and I wholeheartedly endorse them. They are more than a typical ‘throw it over the fence’ engineering consulting firm, as Czero not only develops a strong understanding on the background of the project, but they also think along the way and offer suggestions and ideas beyond the scope of the simple engineering contract deliverables. And, they deliver, too. They are really solid, outstanding people."

    - Steve Kloos, Former CEO AquaHydrex
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    "The engineers on the Czero team were proactive problem-solvers from our first introduction. They quickly applied the full breadth and depth of their engineering team’s impressive intellect to determine the most efficient and cost effective system to maximize the energy-harvesting capabilities of Brown’s concept.

    They were remarkably objective in their trade studies to find the best solution, favoring a simpler mechanical solution over their greatest strength: advanced hydraulics. They walked us through potential failure modes of each system, and educated the team about the pitfalls of component scalability. In addition to their technical solutions, Czero did an excellent job conveying their thought process and analysis to the Brown team with clear graphs, diagrams and presentations, which streamlined decision-making.

    Czero added tremendous value to the Brown project and was a pleasure to work with. We look forward to putting our heads together on future projects."

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    "Czero has been an invaluable and integral part of our program. From component and subsystem design to detailed system performance analysis, Czero’s integrated engineering approach has allowed us to develop elements quickly to meet the very ambitious schedule challenges imposed by our U.S Department of Defense contract."

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