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Energy Conversion and Management 90 (2015) 121–127

Contents lists available at ScienceDirect

Energy Conversion and Management


journal homepage: www.elsevier.com/locate/enconman

Performance analysis of a waste heat recovery thermoelectric


generation system for automotive application
X. Liu, Y.D. Deng, Z. Li, C.Q. Su ⇑
Hubei Key Laboratory of Advanced Technology for Automotive Components, Wuhan University of Technology, 205 Luoshi Road, Hongshan District, Wuhan 430070, China

a r t i c l e i n f o a b s t r a c t

Article history: Thermoelectric power generators are one of the promising green energy sources. In this case study, an
Received 19 August 2014 energy-harvesting system which extracts heat from an automotive exhaust pipe and turns the heat into
Accepted 9 November 2014 electricity by using thermoelectric power generators (TEGs) has been constructed. The test bench is
developed to analysis the performance of TEG system characteristics, which are undertaken to assess
the feasibility of automotive applications. Based on the test bench, a new system called ‘‘four-TEGs’’
Keywords: system is designed and assembled into prototype vehicle called ‘‘Warrior’’, through the road test and
Automotive exhaust
revolving drum test table, characteristics of the system such as hot-side temperature, cold-side temper-
Thermoelectric generator
Road test
ature, open circuit voltage and power output are studied, and a maximum power of 944 W was obtained,
Revolving drum test table which completely meets the automotive application. The present study shows the promising potential of
Temperature difference using this kind of thermoelectric generator for low-temperature waste heat recovery vehicle.
Ó 2014 Elsevier Ltd. All rights reserved.

1. Introduction In the case of TEG for waste heat recovery power generation,
there have been many conceptual designs of a power conversion
With the rapid development of semiconductor materials, the system which are potentially capable of obtaining application in
heat directly converted into electricity by the thermoelectric gen- this area. Lesage et al. [12] built a Bi2Te3-based thermoelectric
erators (TEGs) has begun to enter engineering applications. Due to liquid-to-liquid generator, a correlation between peak thermoelec-
the merits in energy conversion such as little noise and vibration, tric power and thermal input conditions is presented as well as an
high durability, environmental friendliness, and low quality ther- investigation into the validity of electrical load matching. Park
mal energy directly convert into high quality electrical energy, et al. [13] investigated a TEG energy harvesting system with a tem-
TEGs are of great interest in military applications and in deep perature-sensor-based maximum power point tracking (MPPT)
space exploration missions [1–3]. Over the last 30 years, there method, the proposed MPPT scheme can track the MPP of any
has been growing interest in applying this thermoelectric technol- TEG system without current measurement, power perturbation
ogy to improve the efficiency of waste heat recovery, using the or source disconnection, which enables optimal energy harvesting
various heat sources such as geothermal energy, power plants, with a much simpler and much less expensive circuitry. Niu et al.
automobiles and other industrial heat-generating process [4–9]. [14] constructed an experimental thermoelectric generator unit
For example, Li et al. [10] investigated a new type of solar with the parallel-plate heat exchanger, hot liquid and cold liquid,
thermoelectric co-generator (STECG) comprising parabolic trough the two operation parameters such as the hot fluid inlet tempera-
concentrators and thermoelectric modules (TMs). Nikolova et al. ture and flow rate are found to significantly affect the maximum
[11] proposed a specific system consisted of thermal power plants power output.
(TPPs), storage hydro power plants (HPPs), pumped-storage hydro Waste heat from automotive vehicles is considerable as well.
power plant (PSHPP) and wind power plant (WPP) to solve the Since the first automobile TEG emerged in 1963, the endeavor to
generation scheduling problem, wind power plants are integrated maximize its efficiency never stopped, and the methods were
into the system in order to minimize the total thermal unit mainly concentrated in changing the structure of heat exchanger
fuel costs. and introducing different heat transfer enhancement measures.
Likewise, a number of research groups have studied the potential
use of TEG systems as a thermal energy recovery method in
⇑ Corresponding author. Tel.: +86 18971577512; fax: +86 02787859667. automobiles, and this system was achieved by installing the ther-
E-mail address: suchuqi@whut.edu.cn (C.Q. Su). moelectric devices in automobile exhaust pipes. In 1998 Nissan

http://dx.doi.org/10.1016/j.enconman.2014.11.015
0196-8904/Ó 2014 Elsevier Ltd. All rights reserved.
122 X. Liu et al. / Energy Conversion and Management 90 (2015) 121–127

fabricated the first thermoelectric power generator based on Si–Ge 2. Experimental procedures
elements for automobiles [15]. The Bell Solid State Thermoelectrics
(BSST) team that includes BMW, Visteon, and Marlow Industries 2.1. TEG system architecture
began the development in 2004 of a highly efficient thermoelectric
system to recover waste energy for applications in passenger vehi- Fig. 1 shows the schematic diagram of the experimental auto-
cles [16]. With the same requirements for exhaust heat exchanger motive waste heat recovery system, including automobile engine,
in vehicle waste heat recovery by Rankine cycle, a shell and tube catalytic converter, muffler, TEG and so on. A completed TEG sys-
counter flow heat exchanger was used with exhaust gases in tubes tem to recover waste heat has been designed, simulated and fabri-
and working fluids in shell [17]. Yang [18] reports the possibility of cated to achieve the objective of recovered energy. The waste heat
generating an average of 350 W on Federal Test Procedure (FTP) recovery system shown in Fig. 2 was designed for use with the
cycles with a conventional full size truck. Aleksandr et al. [19] exhaust pipe of automobiles. The TMs are clamped with sufficient
developed a 1 kW TEG for the Heavy Duty Class Eight Diesel Trucks compressive force between a heat exchanger connected to the
to replace the shaft driven alternator. Most of them used BiTe- exhaust pipe and cooling water tanks in the exhaust-based TEG.
based bulk thermoelectric material because it is made commer- Four concave type steel is used as the clamping devices while the
cially available. Hi–Z Technology [20], tried to discover and to torque wrench used to provide an applied pressure at a pressure
improve the efficiency of TMs. HZ-14 modules are based on Bi2Te3, load of 2.50 kg/cm2 on the TMs. Exhaust gas flows into the heat
of theoretical and experimental efficiency to about 5% [21]; the exchanger through a bypass to provide a heat source. The cooling
goal of Hi–Z for a practical device is an efficiency about 20%. Kumar water is pumped into the water tanks to form the cold side. Then,
et al. [22] assessed the influence of four different topologies struc- electric power is generated due to the temperature difference
ture of the heat exchanger to the efficiency of TEGs, and the results between the two sides of the modules and stored in batteries.
revealed that a transverse TEG with a single module length is found TMs (Shanghai Institute of Ceramics of the Chinese Academy of
to be the most favorable design among all the designs studied, with Sciences) were arranged on both surfaces of the brass heat exchan-
the highest electrical power generation and lower pressure drops. ger where the exhaust gas passes. The geometric features and
Lu et al. [23] developed a test bench to test the thermal uniformity transport properties of the PN materials used in this work are
and pressure drop of muffler-like exhaust heat exchangers with listed in Table 1. Various measuring instruments were applied to
different structures, and the results revealed that the performance construct this experimental setup. A 2.0-L naturally aspirated
of exhaust heat exchanger such as the surface temperature and engine was used as study object. A dynamometer (maximum
pressure drop was dependent on exchanger’s type and geometry, power input 160 kW, maximum speed 6000 rpm) was also used.
operating condition, and the temperature field was coupled with Several transducers were used: K-type thermocouples and infrared
flow field. David et al. [24] proposed an optimization method for camera to record the temperature distribution of the exhaust heat
improving thermoelectric heat pump performance by operating exchanger, TMs and water tanks. A high power electrical load was
condition management of the TMs and design optimization of connected to the system and used to measure the voltage and
the heat exchangers. power output.
However, according the studies above, the majority of them The principal components of the experimental apparatus and
have focused mainly on the optimization of the heat exchanger manufactured TEG system, as illustrated in Fig. 2, are the main
geometry or the temperature difference of TM, and the maximum heat exchanger, TMs, the water tank (cooling system), the clamp-
power of all various TEGs is less than 200 W expect for the one ing device, and the charging system, with engine coolant as the
used in heavy diesel trucks, which cannot meet the requirement working fluid. The size is 620 mm in length and 310 mm in
for general automotive application. Also, external dimensions of width. There are 60 TMs in total, arranged in six rows, with five
those TEGs are another problem, the distance between chassis modules in each row on the upper and lower surfaces of the heat
and ground is short, and nearly all TEGs cannot be used to auto- exchanger. Table 2 lists the boundary conditions and dimensions
mobiles. In a previous study, we constructed various heat of each element used in this work. In subsequent analysis
exchangers, including maze-shaped, fishbone-shaped [25] and without special description, values are taken from Tables 1 and 2.
chaos-shaped [26] heat exchangers, to analyze their thermal per- The system efficiency can be calculated using Eq. (1) from the
formance. The height of those heat exchangers was also short, measured values maximum output power (Pmax) and engine
which was suitable for automotive application. The results power (Qengine).
showed that fishbone- and chaos-shaped heat exchangers resulted
P max
in a higher and more uniform interface temperature. At the cold g¼ ; ð1Þ
Q engine
side, a TEG water-cooling unit was inserted to the engine cooling
system (called an ‘‘ integrated cooling system’’ herein), which can
avoid problems such as lack of space when TEG systems are used
in vehicles [27]. In this study, the test bench are developed to
analysis the performance of TEG system characteristics, especially
the temperature difference, open circuit voltage and maximum
power output. A complete TEG system to recover waste heat has
been designed, simulated and fabricated to achieve the objective
of recovered energy, as explained in the following sections. Based
on the test bench, a new system called ‘‘four-TEGs’’ system is
designed and assembled into the prototype vehicle called
‘‘Warrior’’, transforming the energy of waste heat into electricity,
which is the specific issue of this research. Based on the road test
and revolving drum test table, the new system in ‘‘Warrior’’ to
recover waste heat has been designed, simulated, fabricated and Fig. 1. Schematic diagram of the experimental thermoelectric generator system 1:
Automobiles engine. 2: Catalytic converter. 3: Heat exchanger for passing exhaust
tested to achieve the objective of recovered energy, and large gas. 4: Muffler. 5: Water tank. 6: Clamping device. 7: Electronic load. 8:
output power of 944 W is obtained, as explained in the following Dynamometer. 9: Cooling system. 10: Controller. 11: Water pump. 12: Heat sinks.
sections. 13: Tachometer and K-type thermocouples. 14: K-type thermocouples.
X. Liu et al. / Energy Conversion and Management 90 (2015) 121–127 123

Fig. 2. TEG system.

Fig. 3. Inlet and outlet hot side temperature with engine revolutions of 2700–
Table 1 3200 rpm.
Parameters of PN materials.

Parameter P type N type


Seebeck coefficient (lV/K) 215 215
Electrical resistivity (X m) 1.04  105 1.04  105
Thermal conductivity (W/(mK)) 1.5 2.5
Height (m) 0.005 0.005
Sectional area (m2) 0.01 ⁄ 0.01 0.01 ⁄ 0.01

Table 2
Boundary parameters.

Parameter Value
Each module’s area A 0.050 ⁄ 0.050 (m2)
Total area 0.400 ⁄ 0.300 (m2)
Ambient temperature 25 °C
Ambient heat transfer coefficient 15 (W/(m2 K))
Material of heat exchanger Brass
Dimension of heat exchanger (mm3) 400 ⁄ 290 ⁄ 18 (h)
Thickness of heat exchanger 5 (mm)
Material of water tank Aluminum
Number of water tank 12 Fig. 4. Curves of output voltage-current for different engine revolution.
Dimension of water tank (mm3) 300 ⁄ 60 ⁄ 21 (h)
Thickness of water tank 3 (mm)
Flow rate of water 9.27 L/min exchanger absorbed a large amount of heat, whereas the hot-side
Cooling water temperature 90 °C (engine water) temperature of the TMs at the rear should be lower in this specific
Material of clamping device Steel case study; the average temperature between inlet and outlet can
be used as the hot-side temperature of the TEG. Fig. 4 shows the
measured curves of output voltage versus current for different
2.2. TEG system testing engine revolution, and the engine revolution is from 2700 rpm to
3200 rpm. Fig. 5 shows the curves of output power versus current
The experimental setup is presented in Fig. 2. Considering that for different engine revolution, the maximum electrical power out-
low-temperature TMs (limited temperature of hot side is 360 °C) put is 183.24 W. Under the experimental condition of 3200 rpm,
are used in the TEG, the maximum engine revolution is set to the average hot-side temperature of 325 °C can be used, An electri-
3200 r/min. At the cold side, the TEG water-cooling unit is inserted cal power of 183.24 W was generated with a current of 1.0 A when
to the engine cooling system, which can avoid problems such as DT was 235 °C, while an open-circuit voltage of 335.83 V was
lack of space when TEG systems are used in vehicles, so the generated with a current of 0 A, so there is a temperature differ-
temperature of cold side keeps around 90 °C. ence of up to 235 °C when the hot side reaches 325 °C, resulting
Sixty identical TMs were placed on the front and back surfaces in a performance of 183.24 W at open-circuit voltage of 335.83 V.
of the heat exchanger, aiming to test the power output of the mod- It is found that the temperature difference has the most important
ules using an electronic load. Experiments were carried out under impact.
the same external conditions, including the cooling conditions,
engine, modules, clamping device and ambient temperature, the 3. Bench test
only difference being the engine revolution rate. Fig. 3 shows the
inlet and outlet temperature of the TEG for engine rate of 2700– 3.1. Road test
3200 rpm. With the increasing of engine revolutions, the inlet tem-
perature shapely increased, leading to an increased temperature To enhance the power generation by the TEG, a new system
difference. The temperature difference between inlet and outlet with four TEGs was constructed, called the ‘‘four-TEGs’’ system,
was around 25–40 °C; however, for these experimental conditions, its dimensions were 1420 ⁄ 670 ⁄ 185 mm. The system shown in
it was very difficult to maintain all the TMs at a fixed hot-side Fig. 6 includes four identical TEGs which contain 240 TMs; the
temperature; That is, the TMs arranged at the front of the heat exhaust pipe of prototype vehicle connected to the heat exchanger
124 X. Liu et al. / Energy Conversion and Management 90 (2015) 121–127

Fig. 7. Each TEG inlet and outlet temperature under four working conditions with
hot-side.
Fig. 5. Curves of output power-current for different engine revolution.

was converted into a four-channel pipe to meets the requirements condition 1. From 35 to 40 min, the vehicle accelerated from 80
of ‘‘four-TEGs’’ system. Considering the stability of the ‘‘four-TEGs’’ to 95 km/h. From 40 to 45 min, the vehicle was running at a fixed
system, the four TEGs were connected in parallel. Fig. 6 shows the speed of 95 km/h, and engine rotation speed of 1900 r/min. From
parameters of our prototype vehicle called ‘‘Warrior’’, the space is 45 to 50 min, we started measuring the various data of working
large enough to contain four TEGs. In the road test, working condi- condition 2. Working conditions 3 and 4 were the same as the
tions with the same (fifth) gear but different vehicle speeds were above.
adopted to understand the characteristics comprehensively. Con- The steady temperature distribution results are shown in Figs. 7
sidering the need for a large amount of heat for the ‘‘four-TEGs’’ and 8, including the inlet and outlet temperatures for each heat
system, higher vehicle speed was used in the test as follows: work- exchanger and water tank. The maximum inlet hot-side tempera-
ing condition 1: vehicle speed, 80 km/h; engine rotation speed, ture difference between the four TEGs is 21 °C, while it is 13 °C
1600 r/min; engine power, 19 kW; working condition 2: vehicle for the outlets, so the four TEGs have almost the same average tem-
speed, 95 km/h; engine rotation speed, 1900 r/min; engine power, perature on the hot side. Fig. 8 shows the inlet and outlet temper-
28 kW; working condition 3: vehicle speed, 110 km/h; engine rota- atures of water tank (cold side); its trend curve is consistent with
tion speed, 2200 r/min; engine power, 37 kW; working condition Fig. 7. Theoretically, the temperature of the cold side remains
4: vehicle speed, 125 km/h; engine rotation speed, 2500 r/min; around 90 °C because the TEG water-cooling unit is inserted to
engine power, 47 kW. Some highways around the city ‘‘Wuhan’’ the engine cooling system. However, the cooling ability of proto-
were chosen for the road test, the ambient temperature was type vehicle is so good that the temperature of the cooling water
25 °C. In the road test, from 0 to 10 min, the engine was started cannot reach 90 °C. The exposure of the water pipes to the cold
and the vehicle was just stationary, the whole system was in the air is another reason decreasing the temperature of the water
warm-up phase with low engine rotation speed, and exhaust gas tanks. The lower temperature water tank also increases the tem-
temperature rapidly increased. From 10 to 25 min, the vehicle perature difference, which is beneficial to generate greater output
started running in the highway, and the exhaust gas temperature power. Under working condition 4, the average hot-side tempera-
rose again. From 25 to 30 min, the vehicle was running at a fixed tures of four TEGs are around 265 °C, while the cooling water is
speed of 80 km/h, and engine rotation speed of 1600 r/min. The 83 °C, so the temperature difference can reach nearly 182 °C.
vehicle and engine rotation speed were maintained for 300 s so Fig. 9 shows the output power and open-circuit voltage versus
that there was sufficient time for the whole system to reach steady temperature difference under four working conditions. The differ-
state. Thermocouples were arranged on both the inlet and outlet of ence between average hot-side and cold-side temperature was
the each heat exchanger and water tank to record the temperature used as the temperature difference, from Fig. 9, it was very clear
distribution. From 30 to 35 min, considering the stability of the that the temperature difference could enhance the power output.
whole system, we started measuring the various data of working It is found that the temperature difference has the most important

Fig. 6. Four thermoelectric generator system 1: Muffler. 2: Inlet pipe. 3: One TEG system. 4: Cooling system. 5: Supporting device.
X. Liu et al. / Energy Conversion and Management 90 (2015) 121–127 125

Fig. 8. Each TEG inlet and outlet temperature under four working conditions with
cold-side. Fig. 11. Curves of output power-current for four working conditions.

to 182 °C when the hot side reaches 265 °C, resulting in a perfor-
mance of 600 W at open-circuit voltage of 177.5 V.

3.2. Revolving drum test

Under these experimental conditions above, there was a good


performance of ‘‘four-TEGs’’ system, resulting in a performance of
600 W at open-circuit voltage of 177.5 V. To further improve the
power generation, there are three ways: raising the hot-side tem-
perature; lowering the cold-side temperature; increasing the
quantity of modules. However, the hot side temperature of module
is limited to 360 °C, and 240 pieces of TMs are also enough. An
independent cooling system was used to mandatorily lower the
temperature of water tank. Considering the difficulty of arrange-
ment of the independent cooling system, a revolving drum test
table was used to keep the prototype vehicle staying there without
Fig. 9. Output power and open-circuit voltage versus temperature difference under moving, which was just the opposite of that of the road test. The
four working conditions.
revolving drum test table is shown in Fig. 12, a fan system is
arranged at the front of the prototype vehicle, and it will automat-
ically regulate the fan speed to simulate the road condition
depending on the speed of vehicle. Compared with the road test,
the only difference is the independent cooling system, which can
further lower the temperature of the cold-side. Considering the
hot-side temperature under the working condition 4 of road test
was still below 300 °C, higher vehicle speed and engine power
was needed as follows: working condition 5: vehicle speed,
130 km/h; engine rotation speed, 2600 r/min; engine power,
51 kW. The ambient temperature was also 25 °C. At the beginning
of the revolving drum test, from 0 to 10 min, the engine was

Fig. 10. Curves of output voltage-current for four working conditions.

impact. Figs. 10 and 11 show the measured curves of output volt-


age and output power versus current under the four different
working conditions. Under working condition 4, the average hot-
side temperature of 265 °C can be used, an electrical power of
600 W was generated with a current of 6.5 A when DT was
182 °C, while an open-circuit voltage of 177.5 V was generated
with a current of 0 A, so there is a temperature difference of up Fig. 12. Revolving drum test table.
126 X. Liu et al. / Energy Conversion and Management 90 (2015) 121–127

Table 3
Performance characteristics of revolving drum test.

TEG Engine rotation speed Average hot side Average cold side Maximum output Open circuit Engine power
Number (r/min) temperature (°C) temperature (°C) power (W) voltage (V) (kW)
1 2600 312 69 944 201.7 51
2 308 71
3 311 68
4 319 70

Table 4 pipes to electric power is discussed, which might serve to decrease


Comparison of the performance between TEG system test, road test and revolving the consumption of petroleum. In this study, a completed TEG sys-
drum test. tem to recover waste heat has been designed, simulated and fabri-
TEG Road Revolving cated to achieve the objective of recovered energy. Based on the
system test test drum test TEG system test, road test and revolving drum test, a complete
Engine rate (rpm) 3200 2500 2600 automotive TEG system was constructed and large output power
Engine displacement (L) 2.0 3.9 3.9 of 944 W obtained. To further improve the power generation, the
Number of TMs 60 240 240 exhaust pipe needs to be improved to decrease the effect of
Open circuit voltage (V) 335.83 177.5 201.7
thermal contact and increase the hot-side temperature. Moreover,
I (A) 1.0 1.5 1.7
Temperature difference, DT (°C) 235 182 240 the connection method could also be optimized. To concern the
Maximum power (W) 183.24 600 944 optimization design, energy conversion efficiency and system
Engine power (kW) 20 47 51 power capacity that would be very important for prototype vehicle
Efficiency (%) 0.9 1.28 1.85
in next generation.

started, and the whole system was in the warm-up phase with low Acknowledgement
engine rotation speed. From 10 to 30 min, the prototype vehicle
accelerated to 130 km/h. From 30 to 40 min, the vehicle was run- This work was funded by grant no. 2013CB632505 from the
ning at a fixed speed of 130 km/h without moving, engine rotation National Basic Research Program of China (973 Program).
speed was kept at 2600 r/min, the vehicle and engine rotation
speed was maintained as 600 s so there was sufficient time for References
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