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    Automotive Thermoelectric Generators and HVAC

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    Giry Makond
    Automotive thermoelectric generators and HVAC systems present an opportunity to improve vehicle fuel economy by converting waste heat from vehicle exhaust systems into electricity. John Fairbanks from the Vehicle Technologies Office discusses research into integrating thermoelectric generators (TEGs) into vehicles to power electrical components and reduce the load on the engine. Experimental testing has shown TEGs can improve fuel economy by over 3% without considering weight or backpressure. Significant government and private funding is supporting research at universities and automakers to develop higher efficiency TEG materials and integrate TEGs into vehicle systems to meet future fuel economy standards.

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    Automotive Thermoelectric Generators and HVAC

    Uploaded by

    Giry Makond
    43 views29 pages
    Automotive thermoelectric generators and HVAC systems present an opportunity to improve vehicle fuel economy by converting waste heat from vehicle exhaust systems into electricity. John Fairbanks from the Vehicle Technologies Office discusses research into integrating thermoelectric generators (TEGs) into vehicles to power electrical components and reduce the load on the engine. Experimental testing has shown TEGs can improve fuel economy by over 3% without considering weight or backpressure. Significant government and private funding is supporting research at universities and automakers to develop higher efficiency TEG materials and integrate TEGs into vehicle systems to meet future fuel economy standards.

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    Automotive thermoelectric generators and HVAC systems present an opportunity to improve vehicle fuel economy by converting waste heat from vehicle exhaust systems into electricity. John Fairbanks from the Vehicle Technologies Office discusses research into integrating thermoelectric generators (TEGs) into vehicles to power electrical components and reduce the load on the engine. Experimental testing has shown TEGs can improve fuel economy by over 3% without considering weight or backpressure. Significant government and private funding is supporting research at universities and automakers to develop higher efficiency TEG materials and integrate TEGs into vehicle systems to meet future fuel economy standards.

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    © All Rights Reserved
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    43 views29 pages

    Automotive Thermoelectric Generators and HVAC

    Uploaded by

    Giry Makond
    Automotive thermoelectric generators and HVAC systems present an opportunity to improve vehicle fuel economy by converting waste heat from vehicle exhaust systems into electricity. John Fairbanks from the Vehicle Technologies Office discusses research into integrating thermoelectric generators (TEGs) into vehicles to power electrical components and reduce the load on the engine. Experimental testing has shown TEGs can improve fuel economy by over 3% without considering weight or backpressure. Significant government and private funding is supporting research at universities and automakers to develop higher efficiency TEG materials and integrate TEGs into vehicle systems to meet future fuel economy standards.

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    of 29

    Automotive Thermoelectric

    Generators and HVAC


    John Fairbanks
    Solid State Energy Conversion
    Advanced Combustion Engine R&D Program
    Vehicle Technologies Office
    2013 Annual Merit Review and Peer Evaluation Meeting
    DOE Vehicle Technologies Office
    Washington, DC
    May 17, 2013

    ACE00E

    Vehicular Engine Waste Heat Energy


    Opportunity for improving fuel economy arises from high temperature of
    vehicle exhaust systems: converting heat to electricity reduces load on
    engine (electricity powers components; smaller alternator needed)

    Vehicular Engine Waste Heat Energy Recovery

    Goal: integrate vehicles with a technology that will


    improve fuel economy
    Approach: use thermoelectrics to convert energy in hot
    engine exhaust directly to electricity

    Target: > 5% improvement in fuel economy; achieved by


    using output of TEG to power key electrical components

    Fuel economy is improved when belt-driven accessories are


    replaced with electric motor drives powered by Thermoelectrics
    Starter
    Generator
    Motor

    Modular HVAC

    Auxiliary
    Power Unit
    Shore Power
    and Inverter

    Supplies DC Bus Voltage from


    120/240 Vac 50/60 Hz Input Supplies
    120 Vac outlets from battery or
    generator power

    Down
    Converter

    Supplies
    12 V Battery from DC Bus

    Compressed Air Module

    Electric
    Water
    Pump

    Toward the beltless engine


    4

    Electric Oil Pump

    Experimental Assessment of Potential of TEG to Improve


    Fuel Economy (GMZ Energy)
    Up 3.45% Fuel Economy Improvement
    potential with alternator removal in
    2.0L Engine
    1*Fuel

    economy improvements tested with no back


    pressure or weight considerations of a thermoelectric
    generator over US06 Cycle for Chevy HHR

    Constant Supplemental
    Power to Engine (W)

    Fuel Economy
    gain [%]
    + 2.94*

    480
    1+Fuel

    economy improvements tested with no alternator


    attached to engine. All power supplied to HHR by
    external power supply. Tested over US06 Cycle

    Supplemental Power to
    Engine (W)

    Fuel Economy
    gain [%]
    + 3.45+

    As needed

    1 Test Setup

    Off cycle credit granted of 2.9%*4 and HWFET


    Cycle Fuel Economy Gain of 4.07%+
    Credit granted by 132W power generation
    0.5% *2*3
    Credit granted by quick engine warm up0.9 *3*4
    Credit granted by quick transmission warm up
    using exhaust heat0.9% *3*4
    Credit granted by installation of device
    encouraging cabin heating to vehicle having
    idle start/stop function :0.6% *3*4
    *2 Power Generation based on average output power of TEG over 5 cycle
    *3 Credits based on fuel economy regulations of 2025
    *4 2.9% Fuel economy improvement based on a cold start from Cold FTP Cycle

    Supplemental Power
    to Engine (W)

    Fuel consumption
    [mpg]

    Delta

    to baseline
    [%]

    Baseline, 0 W

    39.67

    TEG, max. 330 W

    40.85

    + 2.97+

    TEG, max. 480 W

    41.28

    + 4.07+

    +Fuel

    economy improvements tested with no back pressure or


    weight considerations of a thermoelectric generator

    Car and Driver Most Promising Technology, January 2012

    The power of increasing fuel economy by 1% and 5%

    Segment

    Type of Savings

    Estimated Fuel Savings


    over 1 Year
    (Billion nominal US Dollars)

    Auto/Light-duty
    trucks
    Heavy-duty
    trucks
    Auto/Light-duty
    trucks
    Heavy-duty
    trucks

    Personal

    1% Fuel Savings

    $5.0 B

    Commercial

    1% Fuel Savings

    $1.4 B

    Personal

    5% Fuel Savings

    $25 B

    Commercial

    5% Fuel Savings

    $6.9B

    Reference: Davis (2012), Transportation Energy Data Book, Table 1.17. EIA (2013), Gasoline and Diesel Fuel
    Update (http://www.eia.gov/petroleum/gasdiesel/ accessed March 2013)

    TEG contribution to Future CAFE

    White House announced an agreement with 13


    major automakers to achieve 54.5 mpg by 2025

    Recovering engine exhaust waste heat using


    thermoelectric generators (TEGs) is consistent with
    this objective

    World Wide Funding of Thermoelectrics


    compiled by Gentherm (J. LaGrandeur)

    Global Investment in TE Technology- November 2012 Snapshot (~ 4 yr bucket)

    GM
    Ford
    BMW
    Honda
    Daimler Benz
    Volkswagon
    Fiat/Chrysler
    Renault
    Toyota

    Region

    Total Spent, USD

    Total Government funds, USD

    EU

    145,732,370 $

    97,336,809

    North America

    53,923,077 $

    37,250,000

    Russia

    40,000,000 $

    20,000,000

    Japan

    22,600,000 $

    21,700,000

    China

    15,100,000 $

    15,100,000

    Worldwide Total

    277,355,447 $

    191,386,809

    Thermoelectric Funding Partners


    California Energy Commission
    U.S. Army Tank, Automotive, Research,
    Tank
    Development and Engineering Center
    (TARDEC)
    National Science Foundation

    Program of R&D with Industrial and Academic Partners


    Lead Industrial Organizations:
    Ford, GM, GenTherm, GMZ Energy, BMW

    Lead Academic Organizations:


    Ohio State, Purdue, Stanford, SUNY-Stony Brook, TAMU, UCLA,
    UT-Austin, VT

    10

    R&D Project Presentations


    Lead Industrial Organizations (reviewed)

    Ford, GM, GenTherm, GMZ Energy, BWM


    Ford: Thermoelectric HVAC and Thermal Comfort Enablers for Light-Duty Vehicle Applications,
    Clay Maranville
    GM: Energy Efficient HVAC Systems for Distributed Cooling/Heating with
    Thermoelectric Devices, Jeffrey Bozeman
    GenTherm: Thermoelectric Waste Heat Recovery Program for Passenger Vehicles, Doug Crane
    GM: Cost-Competitive Advanced Thermoelectric Generators for Direct Conversion of Vehicle
    Waste Heat into Useful Electrical Power, Jim Salvadore
    GMZ: Nanostructured High-Temperature Bulk Thermoelectric Energy Conversion for Efficient
    Automotive Waste Heat Recovery, Jonathan DAngelo

    Lead Academic Organizations: (not reviewed)

    Ohio State, Purdue, Stanford, SUNY-Stony Brook, TAMU, UCLA, UT-Austin, VT


    Stanford: Automotive Thermoelectric Modules with Scalable Thermo and
    Electrical-Mechanical Interfaces, Kenneth Goodson
    Ohio State University: SEEBECK Saving Energy Effectively by Engaging in Collaborative Research
    and Sharing Knowledge, Joseph Heremans
    11

    Thermoelectric Power Generation

    Average demand for electric power


    .

    BMWs and VTOs Projections for BMW Sedans

    1000 W
    8%
    750 W
    6%

    190 W
    2% NEDC

    330 W
    3,5%
    customer
    116i

    Source: BMW Group


    12

    400W
    4%

    390 W
    4%
    NEDC

    Customer
    530dA

    NEDC

    customer
    750iA

    Vehicle Integration with Thermoelectics: FORD, GM and BMW


    Prototype integration pursued under DOE/industry sponsorship
    Ford Lincoln MKT

    Chevy Suburban

    13

    BMW X6

    GM TEG Design and Performance with Gen 2 Skutterudite Modules

    10% conversion efficiency with


    T=450K.

    14

    GenTherm/Ford/BMW/Faurecia Cylindrical TEG

    Cylindrical TEG design well suited for


    exhaust system

    15

    TEG Installation in BMW X6

    16

    NSF/DOE Partnership on Thermoelectric Devices


    for Vehicle Applications (2010-2013)

    Research in academia pursued under 2010 Solicitation


    NSF/DOE Partnership on Thermoelectric Devices for Vehicle Applications
    (see NSF 10-549 )

    Vehicle Technologies
    Office (EERE)

    17

    Thermal Transport
    Processes Program
    (Engineering Directorate)

    Much of effort directed toward material development (ZT)

    HVAC

    TH TC
    1 + ZT 1
    =
    TH 1 + ZT + TC
    TH

    18

    Power Generation

    ZT = (e + L) T
    2

    Wiedemann-Franz Law

    19

    NSF/DOE Partnership on Thermoelectric Devices


    for Vehicle Applications (2010-2013)

    Areas Targeted

    Funding: $9M over three years ($4.5M from DOE; $4.5M from NSF)
    20

    NSF/DOE Partnership on Thermoelectric Devices


    for Vehicle Applications (2010-2013)

    Funded projects (2010)


    Virginia Tech: An integrated approach towards efficient, scalable, and low
    cost thermoelectric waste heat recovery devices for vehicle. Scott T Huxtable
    Stanford: Automotive Thermoelectric Modules with Scalable Thermo- and
    Electro-Mechanical Interfaces. Kenneth E Goodson
    UT-Austin: High-Performance Thermoelectric Devices Based on Abundant
    Silicide Materials for Waste Heat Recovery. Li Shi
    Texas A&M U.: Inorganic-Organic Hybrid Thermoelectrics. Sreeram Vaddiraju
    UCLA: Integration of Advanced Materials, Interfaces, and Heat Transfer
    Augmentation Methods for Affordable and Durable Devices. Yongho Ju
    UC-Santa Cruz: High Performance Thermoelectric Waste Heat Recovery
    System Based on Zintl Phase Materials with Embedded Nanoparticles. Ali
    Shakouri
    Ohio State: Project SEEBECK-Shaving Energy Effectively by Engaging in
    Collaborative research and sharing Knowledge. Joseph Heremans
    Purdue: Thermoelectrics for Automotive Waste Heat Recovery. Xianfan Xu
    SUNY-Stony Brook: Integrated Design and Manufacturing of Cost Effective
    and Industrial-Scalable TEG for Vehicle Applications. Lei Zuo

    21

    NSF/DOE Partnership Thermoelectric: Stanford, U of South Florida)


    Title of project: Automotive Thermoelectric Modules with Scalable Thermo- and Electro-Mechanical Interfaces
    Academic PIs: K.E. Goodson (Stanford University), G. Nolas (University of South Florida)
    Industrial Collaborator: B. Kozinsky (Robert Bosch LLC)

    thermal interface materials


    carbon nanotube and metal
    nanowire arrays

    Nanostructured
    thermal interfaces

    Metal Nanowires

    2 m

    skutterudites and half-Heusler


    alloys

    Carbon Nanotubes

    Ceramic plate

    150
    m

    Concepts developed to be
    used by Robert Bosch LLC.

    22
    22

    Th = 300-700 K

    High-temperature
    skutterudite
    (Ba,Yb,Co,Sb Re
    structures)

    Connecting metal

    n-type
    Pellet

    p-type
    Pellet

    High-temperature
    Infrared microscopy
    500 m

    Heat Sink

    NSF/DOE Partnership Thermoelectrics: Virginia Tech


    Title of project: An integrated approach towards efficient, scalable, and low cost thermoelectric
    waste heat recovery devices for vehicles
    Academic PIs: Scott T. Huxtable, Srinath V. Ekkad, and Shashank Priya, Virginia Tech
    Industrial Collaborator: Andrew Miner, Romny Scientific, San Bruno, CA
    Developed n-type MgSi based alloy (ZT 1.1 @ 450C) with a new mechanical
    alloying process that is rapid, repeatable, and scalable to high volume
    production

    ZT

    Two Tier 1 automotive suppliers to use


    these materials for TEGs
    23

    23
    temperature

    23

    NSF/DOE Partnership Thermoelectrics : U of Texas, U of Wisconsin


    Title of project: High-Performance Thermoelectric Devices Based on Abundant Silicide
    Materials for Vehicle Waste Heat Recovery
    Academic PIs: Li Shi, John B. Goodenough, Matt J. Hall, Jianshi Zhou (U. of Texas at Austin);
    Song Jin (U. of WisconsinMadison)

    scalable method of synthesizing Mg2SiMg2Sn-Mg2Ge ternary solid solutions with


    ZT 1.08 at 800 K for Sb-doped
    Mg2Si0.4Sn0.4Ge0.2
    system level finite different model for a
    thermoelectric heat exchanger.

    24

    A TEG module made of


    Mg2Si based material as a
    n-type leg (left) and HMS
    based material as a p-type
    leg (right).

    NSF/DOE Partnership Thermoelectric: Purdue/UC Santa Cruz


    Title of project: High performance TE system based on Zintl phase materials with embedded
    nanoparticles
    Academic PIs: A. Shakouri (Purdue); Z. Bian (UC Santa Cruz); S. M. Kauzlarich (UC Davis)
    Industrial partners: NASA JPL
    scalable synthetic method to produce Mg2Si nanocomposites ZT ~ 0.7 at 500C - by reducing thermal conductivity.
    JPL/NASA collaborations/characterization
    Thermal conductivity

    Mg2Si/nanoparticles(NPs)
    NPs
    Mg2Si

    25

    Tani & Kido, Physica B 364: 218.


    Bux et al, J. Mater. Chem. 21: 12259.

    NSF/DOE Partnership on Thermoelectric Devices


    for Vehicle Applications (2010-2013)
    Title of project: Integration of Advanced Materials and Interfaces for Durable Thermoelectric
    Automobile Exhaust Waste Heat Harvesting Devices
    Academic PIs: Y. Sungtaek Ju and Bruce Dunn (UCLA)
    Industrial Collaborators: JPL
    metal matrix nano-composites with
    tailorable CTEs for electrodes and
    contact materials in TEG modules.

    Technology developed will be used by


    thermoelectric module manufacturers

    26

    NSF/DOE Partnership on Thermoelectric Devices


    for Vehicle Applications (2010-2013)

    Title of project: Purdue GM Partnership on Thermoelectrics for Automotive Waste Heat


    Recovery
    Academic PIs: Xianfan Xu, Timothy S. Fisher, Steven D. Heister, Yue Wu, Timothy D. Sands,
    Purdue University
    Industrial Collaborators: Gregory Meisner, James Salvador, General Motors R&D

    novel hot side (proprietary) heat exchanger


    with high heat transfer coefficient and low
    pressure loss
    GM to implement design

    Hot side heat exchanger


    (conceptual drawing; details
    removed)

    27

    The Way Forward


    Large volume/commercially viable production
    Improve thermoelectric materials and TEG efficiency
    Prototype evaluation in vehicles

    28

    Questions?

    THERMOELECTRICS:
    THE NEW GREEN
    AUTOMOTIVE TECHNOLOGY

    29

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