A Thermoelectric Generator Using Engine Coolant for Light-Duty Internal Combustion Engine-Powered Vehicles

We proposed and fabricated a thermoelectric generator (TEG) using the engine water coolant of passenger vehicles. The experimental results revealed that the maximum output power from the proposed thermoelectric generator was ~75 W, the calculated thermoelectric module efficiency of the TEG was ~2.1%, and the overall efficiency of electric power generation from the waste heat of the engine coolant was ~0.3% in the driving mode at 80 km/h. The conventional radiator can thus be replaced by the proposed TEG without additional devices or redesign of the engine water cooling system of the existing radiator.     

Electric Power Generation from Thermoelectric Cells Using a Solar Dish Concentrator

In this paper, design details, theoretical analysis, and outcomes of a preliminary experimental investigation on a concentrator thermoelectric generator (CTEG) utilizing solar thermal energy are presented. The designed CTEG system consisted of a parabolic dish collector with an aperture diameter of 1.8 m used to concentrate sunlight onto a copper receiver plate with 260 mm diameter. Four BiTe-based thermoelectric cells (TEC) installed on the receiver plate were used to convert the concentrated solar thermal energy directly into electric energy. A microchannel heat sink was used to remove waste heat from the TEC cold side, and a two-axis tracking system was used to track the sun continuously. Experimental tests were conducted on individual cells and on the overall CTEG system under different heating rates. Under maximum heat flux, a single TEC generator was able to produce 4.9 W for a temperature difference of 109°C, corresponding to 2.9% electrical efficiency. The overall CTEG system was able to produce electric power of up to 5.9 W for a 35°C temperature difference with a hot-side temperature of 68°C. The results of the investigation help to estimate the potential of the CTEG system and show concentrated thermoelectric generation to be one of the potential options for production of electric power from renewable energy sources.     

Model for Increasing the Power Obtained from a Thermoelectric Generator Module

We have developed a model for finding the most efficient way of increasing the power obtained from a thermoelectric generator (TEG) module with a variety of operating conditions and limitations. The model is based on both thermoelectric principles and thermal resistance circuits, because a TEG converts heat into electricity consistent with these two theories. It is essential to take into account thermal contact resistance when estimating power generation. Thermal contact resistance causes overestimation of the measured temperature difference between the hot and cold sides of a TEG in calculation of the theoretical power generated, i.e. the theoretical power is larger than the experimental power. The ratio of the experimental open-loop voltage to the measured temperature difference, the effective Seebeck coefficient, can be used to estimate the thermal contact resistance in the model. The ratio of the effective Seebeck coefficient to the theoretical Seebeck coefficient, the Seebeck coefficient ratio, represents the contact conditions. From this ratio, a relationship between performance and different variables can be developed. The measured power generated by a TEG module (TMH400302055; Wise Life Technology, Taiwan) is consistent with the result obtained by use of the model; the relative deviation is 10%. Use of this model to evaluate the most efficient means of increasing the generated power reveals that the TEG module generates 0.14 W when the temperature difference is 25°C and the Seebeck coefficient ratio is 0.4. Several methods can be used triple the amount of power generated. For example, increasing the temperature difference to 43°C generates 0.41 W power; improving the Seebeck coefficient ratio to 0.65 increases the power to 0.39 W; simultaneously increasing the temperature difference to 34°C and improving the Seebeck coefficient ratio to 0.5 increases the power to 0.41 W. Choice of the appropriate method depends on the limitations of system, the cost, and the environment.     

Thermoelectricity in Self-Contained Heating and Boiler Systems

The use of thermoelectric generators (TEGs) in heating systems enables autonomous supply of power to automatic safety devices, creation of optimized gas mixtures, and automation and precise temperature control of exhaust gas and heat carriers. It is particularly important to make heating systems independent of the district electric grid. Results of research and development efforts on a TEG for supplying power to electric devices of self-contained heating and boiler systems are presented. A TEG physical model is proposed, and results of computer simulation and optimization of its basic power and design parameters are given. Two TEG design variants (single and double sided) are considered. Their advantages and shortcomings are discussed. On the basis of theoretical calculations, a prototype TEG for a 10.5-kW boiler is built. At water heating system temperatures from 35°C to 80°C, the TEG electric power is 50 W to 65 W, which is used to supply a circulation pump for forced liquid heat carrier delivery (30 W to 40 W) and a fan for removal of fuel combustion products from the boiler’s smoke chamber (5 W to 7 W).     

Design of a Miniaturized Thermoelectric Generator Using Micromachined Silicon Substrates

This paper presents the design of a compact (~1 cm³) thermoelectric (TE) generator intended to generate power locally for sensor/electronic device applications using hot gases (~100°C to 400°C). The design employs 13-mm-diameter, ~0.36-mm-thick (48 mm³) silicon-micromachined TE modules that are stacked to form a cylindrical, finned heat exchanger. The stacked structure is intended to establish a large, uniform temperature gradient across radially oriented thermopiles in each module. Analytical heat transfer and electrical circuit models are used to design and optimize the thermopile for maximum output power under microfabrication and system-level constraints. Optimized structures using PbTe and Bi₂Te₃ thin films are predicted to achieve output power levels of 1.3 mW per module (26.7 mW/cm³) and 0.83 mW per module (17.4 mW/cm³), respectively, for hot gas at 400°C.     

Heat-Pipe-Associated Localized Thermoelectric Power Generation System

The present study focused on how to improve the maximum power output of a thermoelectric generator (TEG) system and move heat to any suitable space using a TEG associated with a loop thermosyphon (loop-type heat pipe). An experimental study was carried out to investigate the power output, the temperature difference of the thermoelectric module (TEM), and the heat transfer performance associated with the characteristic of the researched heat pipe. Currently, internal combustion engines lose more than 35% of their fuel energy as recyclable heat in the exhaust gas, but it is not easy to recycle waste heat using TEGs because of the limited space in vehicles. There are various advantages to use of TEGs over other power sources, such as the absence of moving parts, a long lifetime, and a compact system configuration. The present study presents a novel TEG concept to transfer heat from the heat source to the sink. This technology can transfer waste heat to any location. This simple and novel design for a TEG can be applied to future hybrid cars. The present TEG system with a heat pipe can transfer heat and generate power of around 1.8 V with T _TEM = 58°C. The heat transfer performance of a loop-type heat pipe with various working fluids was investigated, with water at high heat flux (90 W) and 0.05% TiO₂ nanofluid at low heat flux (30 W to 70 W) showing the best performance in terms of power generation. The heat pipe can transfer the heat to any location where the TEM is installed.     

Thermoelectric Power Generation System for Future Hybrid Vehicles Using Hot Exhaust Gas

The present experimental and computational study investigates a new exhaust gas waste heat recovery system for hybrid vehicles, using a thermoelectric module (TEM) and heat pipes to produce electric power. It proposes a new thermoelectric generation (TEG) system, working with heat pipes to produce electricity from a limited hot surface area. The current TEG system is directly connected to the exhaust pipe, and the amount of electricity generated by the TEMs is directly proportional to their heated area. Current exhaust pipes fail to offer a sufficiently large hot surface area for the high-efficiency waste heat recovery required. To overcome this, a new TEG system has been designed to have an enlarged hot surface area by the addition of ten heat pipes, which act as highly efficient heat transfer devices and can transmit the heat to many TEMs. As designed, this new waste heat recovery system produces a maximum 350 W when the hot exhaust gas heats the evaporator surface of the heat pipe to 170°C; this promises great possibilities for application of this technology in future energy-efficient hybrid vehicles.     

Evaluation of Power Conditioning Architectures for Energy Production Enhancement in Thermoelectric Generator Systems

A large-scale thermoelectric generator (TEG) system has an unbalanced temperature distribution among the TEG modules, which leads to power mismatch among the modules and decreases the power output of the TEG system. To maximize the power output and minimize the power conversion loss, a centralized–distributed hybrid power conditioning architecture is presented, analyzed, and evaluated for a TEG system. The novel architecture is a combination of a conventional centralized architecture and a fully distributed architecture. By using the proposed architecture, most of the harvested power is processed by the centralized stage while only the mismatched power among the TEG modules is processed by the distributed stages. As a result, accurate and distributed maximum-power-point tracking (MPPT) for each TEG module and single-stage power conversion between the modules and load can be achieved. It offers the benefit of implementing high MPPT efficiency and high conversion efficiency simultaneously. A 50-W TEG system composed of two TEG modules is built and tested. Experimental results show that the proposed hybrid power conditioning architecture generates up to 5% more energy for a temperature difference between the two modules of only 10°C.     

Studies on Effective Utilization of SOFC Exhaust Heat Using Thermoelectric Power Generation Technology

Solid oxide fuel cells (SOFCs) are being researched around the world. In Japan, a compact SOFC system with rated alternative current (AC) power of 700 W has become available on the market, since the base load electricity demand for a standard home is said to be less than 700 W AC. To improve the generating efficiency of SOFC systems in the 700-W class, we focused on thermoelectric generation (TEG) technology, since there are a lot of temperature gradients in the system. Analysis based on simulations indicated the possibility of introducing thermoelectric generation at the air preheater, steam generator, and exhaust outlet. Among these options, incorporating a TEG heat exchanger comprising multiple CoSb₃/SiGe-based TEG modules into the air preheater had potential to produce additional output of 37.5 W and an improvement in generating efficiency from 46% to 48.5%. Furthermore, by introducing thermoelectric generation at the other two locations, an increase in maximum output of more than 50 W and generating efficiency of 50% can be anticipated.     

Thermoelectric Generation Using Waste Heat in Steel Works

The steelmaking industry in Japan has significantly reduced its energy use for the past several decades and has kept the highest energy efficiency in the world. However, the steelmaking industry is strongly required to develop new technologies for further energy conservation in view of energy security, high and volatile energy prices, and climate change. One of the key technologies to achieve the requirement is waste heat recovery. This paper describes the thermoelectric generation (TEG) system using the waste heat in the steelmaking process. In this system, the TEG unit, which consists of 16 thermoelectric modules made of Bi-Te thermoelectric materials, generates the electrical power directly by converting the radiant heat released from hot steel products. Each thermoelectric module, whose size is 50 mm × 50 mm × 4.2 mm, generates 18 W when the hot-side temperature is 523 K and the cold-side is 303 K. Therefore, the output of the TEG unit is over 250 W. The performance and the durability of the system have been investigated under various operating conditions in steel works. The results of the verification tests in the JFE steel Corporation’s continuous casting line will be discussed.     

Efficiency Study of a Commercial Thermoelectric Power Generator (TEG) Under Thermal Cycling

Thermoelectric generators (TEGs) make use of the Seebeck effect in semiconductors for the direct conversion of heat to electrical energy. The possible use of a device consisting of numerous TEG modules for waste heat recovery from an internal combustion (IC) engine could considerably help worldwide efforts towards energy saving. However, commercially available TEGs operate at temperatures much lower than the actual operating temperature range in the exhaust pipe of an automobile, which could cause structural failure of the thermoelectric elements. Furthermore, continuous thermal cycling could lead to reduced efficiency and lifetime of the TEG. In this work we investigate the long-term performance and stability of a commercially available TEG under temperature and power cycling. The module was subjected to sequential hot-side heating (at 200°C) and cooling for long times (3000 h) in order to measure changes in the TEG’s performance. A reduction in Seebeck coefficient and an increase in resistivity were observed. Alternating-current (AC) impedance measurements and scanning electron microscope (SEM) observations were performed on the module, and results are presented and discussed.     

Synthesis and Characterization of New Ceramic Thermoelectrics Implemented in a Thermoelectric Oxide Module

Novel thermoelectric oxides were developed, produced, and characterized to demonstrate their promising thermoelectric conversion potential in a thermoelectric converter. Four-leg thermoelectric oxide modules were fabricated by combining p- and n-type oxide thermoelements made of pressed polycrystalline GdCo_0.95Ni_0.05O₃ and CaMn_0.98Nb_0.02O₃, respectively. In these modules, the p- and n-type thermoelements were connected electrically in series and thermally in parallel. The materials were joined by electrical contacts consisting of a Ag/CuO composite material. Fairly good thermal contacts were ensured by pressing the thermoelements between alumina substrates. Cross-sections of the alumina/Ag–CuO mixture/thermoelement interface were investigated by scanning electron microscopy. The temperature distribution across the module was monitored using K-type thermocouples and a micro-infrared (IR) camera. The open-circuit voltage and the load voltages of the module were measured up to a temperature difference of ΔT = 500 K while keeping the temperature of the cold side at 300 K. The output power and internal resistance were calculated. The characteristics of the module evaluated from electrical measurements were compared with respective values of the p- and n-type leg materials. An output power of 0.04 W at ΔT = 500 K led to a power density of ~0.125 W/cm³, where the volume of thermoelectric material was determined by a cross-section of 4 mm × 4 mm and a leg length of 5 mm.     

Individual Module Maximum Power Point Tracking for Thermoelectric Generator Systems

In a thermoelectric generator (TEG) system the DC/DC converter is under the control of a maximum power point tracker which ensures that the TEG system outputs the maximum possible power to the load. However, if the conditions, e.g., temperature, health, etc., of the TEG modules are different, each TEG module will not produce its maximum power. If each TEG module is controlled individually, each TEG module can be operated at its maximum power point and the TEG system output power will therefore be higher. In this work a power converter based on noninverting buck–boost converters capable of handling four TEG modules is presented. It is shown that, when each module in the TEG system is operated under individual maximum power point tracking, the system output power for this specific application can be increased by up to 8.4% relative to the situation when the modules are connected in series and 16.7% relative to the situation when the modules are connected in parallel.     

High-Temperature High-Efficiency Solar Thermoelectric Generators

Inspired by recent high-efficiency thermoelectric modules, we consider thermoelectrics for terrestrial applications in concentrated solar thermoelectric generators (STEGs). The STEG is modeled as two subsystems: a TEG, and a solar absorber that efficiently captures the concentrated sunlight and limits radiative losses from the system. The TEG subsystem is modeled using thermoelectric compatibility theory; this model does not constrain the material properties to be constant with temperature. Considering a three-stage TEG based on current record modules, this model suggests that 18% efficiency could be experimentally expected with a temperature gradient of 1000°C to 100°C. Achieving 15% overall STEG efficiency thus requires an absorber efficiency above 85%, and we consider two methods to achieve this: solar-selective absorbers and thermally insulating cavities. When the TEG and absorber subsystem models are combined, we expect that the STEG modeled here could achieve 15% efficiency with optical concentration between 250 and 300 suns.     

Progress Report on BSST-Led US Department of Energy Automotive Waste Heat Recovery Program

As global consumption of energy continues to increase at an exponential rate, the need to find technologies that can help reduce this rate of consumption, particularly in passenger vehicles, is imperative. This paper provides a progress report on the BSST-led US Department of Energy-sponsored automotive thermoelectric waste heat recovery project, which has transitioned from phase 3 and is completing phase 4. Thermoelectric generator (TEG) development will be discussed, including modeling and thermal cycling of subassemblies. The design includes the division of the TEG into different temperature zones, where the subassembly materials and aspect ratios are optimized to match the temperature gradients for the particular zone. Test results for a phase 3 quarter-scale device of the phase 4 high-temperature TEG will be discussed, where power outputs of up to 125 W were achieved on a 600°C hot-air test bench. The design of the TEG, which uses high-power-density segmented thermoelectric elements, has evolved from a planar design in phase 3 to a cylindrical design in phase 4. The culmination of phase 4 includes testing of the generator on a dynamometer at the National Renewable Energy Laboratory with a high-performance production engine.     

Performance Results of a High-Power-Density Thermoelectric Generator: Beyond the Couple

This paper describes the development of a high-power-density thermoelectric generator (TEG) with a power output of greater than 100 W. Previous papers have described the development of the generator made of high-power-density TE couples. In this discussion, initial thermal cycling results for the TE couples are described. The building blocks are then scaled and integrated into a complete TEG. The design, build, and test of the TEG are discussed. The high-power-density design produces power at greater than 250 W/L and 80 W/kg. Test results are shown for varying flow rates, temperatures, and electrical loads.     

Weight Penalty Incurred in Thermoelectric Recovery of Automobile Exhaust Heat

Thermoelectric recovery of automobile waste exhaust heat has been identified as having potential for reducing fuel consumption and environmentally unfriendly emissions. Around 35% of combustion energy is discharged as heat through the exhaust system, at temperatures which depend upon the engine’s operation and range from 800°C to 900°C at the outlet port to less than 50°C at the tail-pipe. Beneficial reduction in fuel consumption of 5% to 10% is widely quoted in the literature. However, comparison between claims is difficult due to nonuniformity of driving conditions. In this paper the available waste exhaust heat energy produced by a 1.5 L family car when undergoing the new European drive cycle was measured and the potential thermoelectric output estimated. The work required to power the vehicle through the drive cycle was also determined and used to evaluate key parameters. This enabled an estimate to be made of the engine efficiency and additional work required by the engine to meet the load of a thermoelectric generating system. It is concluded that incorporating a thermoelectric generator would attract a penalty of around 12 W/kg. Employing thermoelectric modules fabricated from low-density material such as magnesium silicide would considerably reduce the generator weight penalty.     

Power-Generation Performance and Durability of a Skutterudite Thermoelectric Generator

By using a p-type (La, Ba, Ga, Ti)₁(Fe, Co)₄Sb₁₂ skutterudite with a dimensionless figure of merit, ZT, = 0.75 at 500°C and an n-type (Yb, Ca, Al, Ga, In)_0.7(Co, Fe)₄Sb₁₂ skutterudite with ZT = 1.0 at 500°C, we fabricated a thermoelectric power-generation module capable of working at high temperatures (up to 600°C). When its hot and cold sides were at 600°C and 30°C, respectively, the power output of a 50 mm × 50 mm × 7.6 mm skutterudite module was 34 W and its thermoelectric conversion efficiency was 8%. In a durability test with the module’s hot and cold sides continuously maintained at 600°C and 80°C, respectively, for 8000 h, power generation first decreased by approximately 6% in the initial 300 h then remained constant.     

Thin-Film Thermoelectric Modules for Power Generation Using Focused Solar Light

We demonstrated the fabrication of thin-film thermoelectric generators and evaluated their generation properties using solar light as a thermal source. Thin-film elements of Bi_0.5Sb_1.5Te₃ (p-type) and Bi₂Te_2.7Se_0.3 (n-type), which were patterned using the lift-off technique, were deposited on glass substrates using radiofrequency magnetron sputtering. After annealing at 300°C, the average Seebeck coefficients of p- and n-type films were 150???V/K and ?104???V/K, respectively, at 50°C to 75°C. A cylindrical lens was used to focus solar light to a line shape onto the hot side of the thin-film thermoelectric module with 15 p?Cn junctions. The minimum width of line-shaped solar light was 0.8?mm with solar concentration of 12.5 suns. We studied the properties of thermoelectric modules with different-sized p?Cn junctions on the hot side, and obtained maximum open voltage and power values of 140?mV and 0.7???W, respectively, for a module with 0.5-mm p?Cn junctions. The conversion efficiency was 8.75?×?10^?4%, which was approximately equal to the value estimated by the finite-element method.     

Skutterudites: Thermoelectric Materials for Automotive Applications?

The power output of a thermoelectric generator (TEG) was investigated under engine partial-load operation based on measured exhaust gas temperatures and mass flow rates. Materials with properties required for highend temperature TE couples (>500°C) were evaluated. Various possible material combinations for p- and n-legs of these couples as well as the conflicting targets of high efficiency and low cost as required for automotive mass production are discussed. New skutterudite materials for both p- and n-legs as identified during a joint research project are presented, which can help to overcome this conflict. Efficiencies >10% were achieved with these new materials, which have potentially twofold lower production costs than telluride-based materials due to the price of their elements. Some potential for improvement in efficiency and costs has been identified by developing highly integrated TEG units, specifically designed for automotive applications. These initial results of the material development and the evaluation of different integration concepts will be applied in a subsequent step for the fabrication of a pilot number of TEG modules/units.