A Finite Volume Analysis of Thermoelectric Generators

ABSTRACT

The electric power produced by a thermoelectric generator (TEG) is strongly influenced by the applied heat sink. While a TEG is aimed at harvesting waste heat, the optimization of the efficiency of the heat sink is a key task for the design of waste heat recovery systems implementing TEG. A TEG model is proposed and implemented in an open source toolbox for field operation and manipulation (OpenFOAM) for the purpose of performing optimizations of the heat sink, using a commercially available TEG as basis. This model includes the multi-physics thermoelectric coupled effects. Conservation principles of energy and current are considered simultaneously. This includes the thermal and electric conduction, Seebeck effect, Peltier effect, Thomson effect, and Joule heating. Particular attention is given to a proper modeling of the boundary conditions. The thermoelectric model is implemented in such a way that it can readily be combined with other physical models in OpenFOAM. The model is validated by comparing the predictions to analytical results, measurements as well as the simulation data of other authors.     

Parametric study of asymmetric thermoelectric devices for power generation

Thermoelectric devices are considered a promising technique for recycling waste heat. In the present work, a three-dimensional numerical model is developed to study the output performance of thermoelectric devices. A comprehensive analysis is performed based on a conventional π-type thermoelectric couple. The results indicate that the maximum power of thermoelectric devices generally increases with a decrease in height and an increase in cross-sectional area; the maximum efficiency exhibits the opposite trends. The best way to reduce heat losses is by using ceramic plates with higher thermal conductivity. Moreover, the parasitic internal resistance exists in the thermoelements, and its influencing factors are studied. To minimize electric losses, an asymmetric structure is proposed for thermoelectric devices. The results exhibit that the optimal cross-sectional area ratio of the p-type and n-type legs (S_p/S_n) is mainly contingent upon the thermoelectric material parameters; the greater the differences in the parameters of p-type and n-type thermoelectric materials, the greater the gains provided by the asymmetric structure. Furthermore, the experimental data present great consistency with the numerical results. The research results may help guide the design of thermoelectric devices with relatively lower power losses.     

A conceptual spacecraft radioisotope thermoelectric and heating unit (RTHU)

Spacecraft venturing to the outer planets and beyond—or onto the planetary surface where available solar energy is reduced—benefit from the longevity and consistency of electrical and thermal energy derived from radioisotope energy sources. A review of likely mission requirements and concept studies of small electrical generating units (<10 W_e) reveals a potential opportunity for a unit with an electrical output of around 1 W_e that can also supply some heat to the spacecraft to aid thermal control: a radioisotope thermoelectric and heating unit. This power requirement cannot be achieved with current US space‐qualified modular radioisotope fuel assemblies. Additionally, new European programmes consider ²⁴¹Am fuel to be much more cost effective than ²³⁸Pu. Taken together, these factors provide the rationale for taking a relatively ‘clean‐sheet’ approach to design of a radioisotope thermoelectric and heating unit fuelled with ²⁴¹Am. In this paper, initial requirements and performance targets for such a unit are developed, a simple concept design and thermal model is presented and the performance and mass are estimated. The results suggest that units generating 1–2 W_e may achieve a specific power of around 0.7–0.9 W_e kg^?1 without the thermal inputs to spacecraft becoming impractically large. Such units can use a bismuth telluride thermoelectric material, which is commercially applied in terrestrial applications and is therefore likely to incur lower cost and development risk than more specialised compounds. This study may form the basis of a more detailed design effort. Copyright © 2011 John Wiley & Sons, Ltd.     

Experimental investigation on controlled cooling by coupling of thermoelectric and an air impinging jet for CPU

In this study, experimental tests have been carried out on the coupling thermoelectric cooling module with minichannel heatsink subjected to impinging airflow for cooling desktop central processing unit (CPU). A controlled thermoelectric-forced test system was designed for this purpose. This was designed using electronic Arduino card. The proposed hybrid cooling system was compared with the conventional forced air-cooling technique. Three power of heat source (CPU) were adopted, investigated, and compared, namely 60, 87, and 95 W. Performance of controlled thermoelectric cooling with three preset temperature were experimentally examined. The effects of air velocity and thermoelectric input current on the case temperature (T_case), thermal resistance, and heat transfer coefficient were analyzed. Results showed that the T_case increases with the increase of its input power. In addition, increasing air jet velocity and thermoelectric input current improve CPU cooling significantly. For a CPU power of 95 W, the recorded T_case temperature was 57°C with the conventional system. While it was maintained below 50°C in the hybrid system. The thermoelectric cooler has had a major effect on CPU cooling, having 15% improvement over conventional forced air-cooling. However, this was accompanied by an increase in energy consumption in the range of 45 W.     

Experimental investigations on start-up performance of static nuclear reactor thermal prototype

Nuclear power is most suited to satisfy the energy demands of future deep space exploration. In this paper, we propose a static nuclear reactor (the nuclear static thermoelectric reactor [NUSTER]), which offers the advantages of superior modularization, simplification, a fully static state, and passive operation. Based on the conceptual design of a static nuclear reactor, an electrical heating principle prototype was designed and fabricated to validate the feasibility of the fully static passive energy conversion concept. Skutterudite thermoelectric generators (TEGs) were used for static energy conversion, and potassium heat pipes were employed for passive heat transfer. The system start-up performance, restart performance, and thermoelectric performance were investigated using the thermal principle prototype. We proposed a new approach to analyze the heat pipe start-up process based on the heat transfer performance. The experimental results indicated that the restart process can be used to reduce the start-up time, because the low heat flux stage is avoided. During the start-up process, the TEGs hot side heat flux and temperature difference were gradually established, and the TEGs open circuit voltage and power density gradually increased. A maximum open circuit voltage and power density of 38.2 V and 0.92 W/cm², respectively, were achieved when the TEGs temperature difference reached 575°C. The high performance of the thermal principle prototype demonstrated the feasibility of the NUSTER conceptual design, and the experimental data can serve as a valuable reference for optimization of static reactor designs.     

Investigation on generated power of thermoelectric roof solar collector

The aim of this paper was to conduct lab-scale investigation of a new roof design concept termed “the thermoelectric roof solar collector (TE-RSC)” for power generation using solar energy. The TE-RSC was composed of a transparent acrylic sheet, air gap, a copper plate, thermoelectric modules and a rectangular fin heat sink. The incident solar radiation heats up the copper plate so that a temperature difference is created between the TE module that generates a direct current. This current generated was used to run a fan for cooling the TE modules. The TE-RSC surface area was 0.0525 m² and 10 thermoelectric cooling modules (Tianjin Lantian model TEC1-12708) were used. Investigations were done by varying solar radiation, simulated by using a halogen lamp, between 400 and 1000 W/m².It was found that this new roof design can generate about 1.2 W under solar radiation intensity of about 800 W/m² at ambient temperature varying between 30 and 35 °C. The corresponding air velocity generated by the ventilation fan was about 1.7 m/s. Therefore, the proposed TE-RSC concept seems to be an interesting new alternative for various purposes such as power generation in remote areas, roof heat gain reduction and indoor ventilation of spaces.     

Effects of fuel cell vehicle waste heat temperatures and cruising speeds on the outputs of a thermoelectric generator energy recovery module

A thermoelectric generator (TEG) module is designed to harvest low grade waste heat from a 2 kW fuel cell vehicle and improve its energy utilization. The module integrates a TEG cell with a heat pipe and a finned heat sink. A numerical model is developed based on an experiment setup where the fuel cell temperature is 45–60 °C while the cruise speed is 25 kmh^?1. The numerical model is validated with less than 5% deviation. Extended cases are simulated for series and parallel power train configuration under changes to the waste heat temperature and vehicle speeds to evaluate the power and heat recovery ratio. A single TEG cell output between 2 and 3 W is achievable even at low grade heat. The parallel drive generates 50% more power than the series drive at 100 kmh^?1 speed. A 2% heat recovery is theoretically achievable for a 16 cell module assembly.     

Fiber-based flexible thermoelectric power generator

Flexible thermoelectric power generators fabricated by evaporating thin films on flexible fiber substrates are demonstrated to be feasible candidates for waste heat recovery. An open circuit voltage of 19.6 μV K per thermocouple junction is measured for Ni–Ag thin films, and a maximum power of 2 nW for 7 couples at ΔT = 6.6 K is measured. Heat transfer analysis is used to project performance for several other material systems, with a predicted power output of 1 μW per couple for Bi₂Te₃/Sb₂Te₃-based fiber coatings with a hot junction temperature of 100 °C. Considering the performance of woven thermoelectric cloths or fiber composites, relevant properties and dimensions of individual thermoelectric fibers are optimized.     

Experimental validation of CFD modelling for heat transfer coefficient predictions in axial flux permanent magnet generators

This paper describes the experimental validation of CFD modelling for heat transfer coefficients in an axial flux permanent magnet (AFPM) generator. A large scale low speed test rig was designed and constructed. The geometric parameters and the rotational speed of the test rig were determined by dimensional analysis, to ensure the flow characteristic remains unchanged as compared with commercial AFPM generators. The heat transfer coefficients in the test rig were measured at rotational Reynolds number, Re_ω from 0 to 2 × 10⁶, non-dimensional flow rate, C_w up to 11,000 and gap ratio, G = 0.016, by using the combination of heat flux sensors and thermocouples. Due to the large size of the scaled-up rig, natural convection played a significant part in the heat transfer and this had to be compensated for in the forced convection heat transfer coefficient calculations. Extra experiments were designed and conducted to identify the effect of natural convection on the machine’s cooling. The experimentally determined results were compared to heat transfer coefficients predicted by CFD models and good agreement was obtained.     

System level heat integration and efficiency analysis of hydrogen production process based on solid oxide electrolysis cells

The solid oxide electrolysis cells (SOEC) technology is a promising solution for hydrogen production with the highest electrolysis efficiency. Compared with its counterparts, operating at high temperature means that SOEC requires both power and heat. To investigate the possibility of coupling external waste heat with the SOEC system, and the temperature & quantity requirement for the external waste heat, a universal SOEC system operating at atmospheric pressure is proposed, modeled and analyzed, without specific waste heat source assumption such as solar, geothermal or industrial waste heat. The SOEC system flow sheet is designed to create opportunity for external waste heat coupling. The results show that external waste heat is required for feed stock heating, while the recommended coupling location is the water evaporator. The temperature of the external waste heat should be above 130 °C. For an SOEC system with 1 MW electrolysis power input, the required external waste heat is about 200 kW. When the stack operates at thermoneutral state and 800 °C, the specific energy consumption is 3.77 kWh/Nm³-H₂, of which electric power accounts for 84% (3.16 kWh/Nm³-H₂) and external waste heat accounts for 16% (0.61 kWh/Nm³-H₂). The total specific energy consumption remains almost unchanged when operating the SOEC stack around the thermoneutral condition.     

Theoretical Investigation of Waste Heat Recovery from an IC Engine Using Vapor Absorption Refrigeration System and Thermoelectric Converter

This study proposes the preliminary simulation of a single cylinder spark ignition engine with waste heat recovery system. To harvest waste heat energy from the engine exhaust a thermoelectric generator coupled to a vapor absorption refrigeration (VAR) system was proposed in this simulation work. Parametric simulation of engine, thermoelectric generator and VAR using thermodynamic relations was carried out in MATLAB – Simulink software. An attempt has been made mathematically to integrate engine, thermoelectric generator and VAR system to study the effect of engine load, speed, equivalence ratio on thermoelectric output and coefficient of performance (COP) of a VAR system. In this study, the VAR system runs by taking heat energy from the exhaust gas and the electric power produced by a thermoelectric generator was utilized to run the pump of the refrigeration system. It was found that COP of the absorption refrigeration system depends on engine load, speed and air fuel equivalence ratio. The study also reveals that about 10% to 15% of the total exhaust energy can be harvested using this system.     

Study on waste heat recovery from exhaust smoke in cogeneration system using woody biomass fuels

In recent years, fossil fuels such as petroleum, coal, and natural gas have become limited resources. In addition, bad effects caused by excessive carbon dioxide (CO₂) emissions have now begun destroying our global environment seriously. Since current living and economical standards depend strongly on the fossil fuels, it is necessary to realize a new society that utilizes biomass as one of major sources of energy. In this background, we manufactured a practical Stirling engine using woody biomass fuels for the first time in Japan in 2005. Further we proposed a unique cogeneration system with the Stirling engine that uses woody biomass fuels such as sawdust, firewood, and wood pellets. In this cogeneration system, 43% of the input energy is wasted as heat loss from the exhaust smoke into the atmosphere. Therefore we tried to recover the waste heat by using a thermoelectric conversion module in this study. In this report, the results of basic performance test and demonstration experiment as a cogeneration system combined the waste heat recovery with a power generating system are reported. © 2011 Wiley Periodicals, Inc. Heat Trans Asian Res; Published online in Wiley Online Library ( wileyonlinelibrary.com/journal/htj ). DOI 10.1002/htj.20390     

千瓦级空间堆热离子—碱金属混合式热电转换系统设计及性能

针对空间核电转换系统静态热电转换发电效率低的问题，设计开发了一种新型的热离子-碱金属混合发电系统，即利用热离子转换系统的余热作为碱金属转换器的热源，利用余热进行二次发电以提高转换系统效率，通过建立热离子-碱金属混合发电系统数理模型，研究了热离子热电转换系统接收极功函数和系统电流密度对混合发电系统功率效率的影响，得到了两个参数的最优区间，计算结果表明热离子-碱金属混合发电系统相比于热离子热电转换系统效率约6％~10％，为静态热电转换系统的效率优化提供了理论依据。     

Heat transfer modelling of a plate radiator for district heating applications

The paper presents a heat transfer model of a plate radiator for district heating applications, developed by the authors. A microcomputer program based on the model was implemented for use in design and simulation of radiator space heating systems. The theoretical model is compared with a model based on experimental data. Results from using the new model to evaluate the accuracy of the German standard DIN 4703 (Q/Q_o = (LMTD/LMTD₀)^1.3) for Icelandic geothermal district heating are presented. Conclusions are drawn on the basis of the results.     

汽车发动机尾气余热温差发电装置结构研究

半导体温差发电技术在低品位余热回收技术领域具有重要的应用价值。汽车尾气温度高,带走的热量约占发动机总量的40%,温差发电技术能直接将废热能量转化为电能回收利用。介绍温差发电装置的设计原理,结构参数对性能影响以及装置输出性能参数,并结合试验对温差发电装置的传热性能和电功率输出性能进行分析以及提出有效的改进方案。     

Thermoelectric water-cooling device applied to electronic equipment

This article investigates the thermal performance of a thermoelectric water-cooling device for electronic equipment. The influences of heat load and the thermoelectric cooler's current on the cooling performance of the thermoelectric device are experimentally and theoretically determined. This study develops a novel analytical model of thermal analogy network to predict the thermal capability of the thermoelectric device. The model's prediction agrees well with the experimental data. The experimental result shows that when heat load increases from 20 W to 100 W, the lowest overall thermal indicator increases from − 0.75 KW^− 1 to 0.62 KW^− 1 at the optimal electric current of 7 A. Besides, this study verifies that the thermal performance of the conventional water-cooling device can be effectively enhanced by integrating it with the thermoelectric cooler when the heat load is below 57 W.     

Effect of heat exchanger material and fouling on thermoelectric exhaust heat recovery

Thermoelectric devices are being investigated as a means of improving fuel economy for diesel and gasoline vehicles through the conversion of wasted fuel energy, in the form of heat, to useable electricity. By capturing a small portion of the energy that is available with thermoelectric devices can reduce engine loads thus decreasing pollutant emissions, fuel consumption, and CO₂ to further reduce green house gas emissions. This study is conducted in an effort to better understand and improve the performance of thermoelectric heat recovery systems for automotive use. For this purpose an experimental investigation of thermoelectrics in contact with clean and fouled heat exchangers of different materials is performed. The thermoelectric devices are tested on a bench-scale thermoelectric heat recovery apparatus that simulates automotive exhaust. It is observed that for higher exhaust gas flowrates, thermoelectric power output increases from 2 to 3.8 W while overall system efficiency decreases from 0.95% to 0.6%. Degradation of the effectiveness of the EGR-type heat exchangers over a period of driving is also simulated by exposing the heat exchangers to diesel engine exhaust under thermophoretic conditions to form a deposit layer. For the fouled EGR-type heat exchangers, power output and system efficiency is observed to be 5-10% lower for all conditions tested.     

Improving power density and efficiency of miniature radioisotopic thermoelectric generators

We have built and tested a prototype miniaturized thermoelectric power source that generates 450 μW of electrical power in a system volume of 4.3 cm³. The measured power density of 104 μW cm⁻³ exceeds that of any previously reported thermoelectric power system of equivalent size. This improvement was achieved by implementing a novel thermopile design in which wagon wheel-shaped thermoelectric elements contact the entire circumference of the heat source whereas traditional approaches utilize only one heat source surface. The thermopile consists of 22 wagon wheel-shaped elements (11 P–N thermocouples) fabricated from 215-μm thick bismuth–telluride wafers having ZT = 0.97 at 30 °C. The power source operates on a 150 mW thermal input provided by an electrical resistance heater that simulates a capsule containing 0.4 g of ²³⁸PuO₂ located at the center of the device. Our primary research objective was to develop and demonstrate a prototype thermopile and radioisotopic thermoelectric generator (RTG) architecture with improved power density at small scales. Output power from this device, while optimized for efficiency, was not optimized for output voltage, and the maximum power was delivered at 41 mV. We also discuss modifications to our prototype design that result in significantly improved voltage and power. Numerical predictions show that a power output of 1.4 mW, power density of 329 μW cm⁻³, and voltage of 362 mV, is possible in the same package size.     

Improvement of a Turbulence Model for Conjugate Heat Transfer Simulation

For the conjugate heat transfer simulation, two-equation turbulence models will predict an anomalously large growth of turbulent kinetic energy in high strain rate flows, and then the flow and heat transfer will be unreasonable. The current study improved the low Reynolds number Chien k-? two-equation model using the “realizability” based C _μ limiter and the production term P _k limiter. This study was conducted based on a developed preconditioned density-based conjugate heat transfer algorithm. Calculations are presented for the flat plate turbulence flow and the conjugate heat transfer of the MarkII cooling turbine blade using the improved model. The results were analyzed and compared with semi-empirical formula and experimental data. Significant improvement in the turbulent kinetic energy anomaly was obtained using both limiters. The prediction accuracy of the Chien k-? model for the flow and heat transfer in the conjugate heat transfer simulation was significantly enhanced. The changes in the model are guaranteed to not have unfavorable influence on the simulation of low strain rate flows.     

A comparative study of the carbon dioxide transcritical power cycle compared with an organic rankine cycle with R123 as working fluid in waste heat recovery

The organic rankine cycle (ORC) as a bottoming cycle¹ to convert low-grade waste heat into useful work has been widely investigated for many years. The CO₂ transcritical power cycle, on the other hand, is scarcely treated in the open literature. A CO₂ transcritical power cycle (CO₂ TPC) shows a higher potential than an ORC when taking the behavior of the heat source and the heat transfer between heat source and working fluid in the main heat exchanger into account. This is mainly due to better temperature glide matching between heat source and working fluid. The CO₂ cycle also shows no pinch limitation in the heat exchanger. This study treats the performance of the CO₂ transcritical power cycle utilizing energy from low-grade waste heat to produce useful work in comparison to an ORC using R123 as working fluid.Due to the temperature gradients for the heat source and heat sink the thermodynamic mean temperature has been used as a reference temperature when comparing both cycles. The thermodynamic models have been developed in EES² The relative efficiencies have been calculated for both cycles. The results obtained show that when utilizing the low-grade waste heat with the same thermodynamic mean heat rejection temperature, a transcritical carbon dioxide power system gives a slightly higher power output than the organic rankine cycle.