Experimental investigation of a novel heat pipe thermoelectric generator for waste heat recovery and electricity generation

Waste heat recovery helps reduce energy consumption, decreases carbon emissions, and enhances sustainable energy development. In China, energy-intensive industries dominate the industrial sector and have significant potential for waste heat recovery. We propose a novel waste heat recovery system assisted by a heat pipe and thermoelectric generator (TEG) namely, heat pipe TEG (HPTEG)，to simultaneously recover waste heat and achieve electricity generation. Moreover, the HPTEG provides a good approach to bridging the mismatch between energy supply and demand. Based on the technical reserve on high-temperature heat pipe manufacturing and TEG device integration, a laboratory-scale HPTEG prototype was established to investigate the coupling performances of the heat pipes and TEGs. Static energy conversion and passive thermal transport were achieved with the assistance of skutterudite TEGs and potassium heat pipes. Based on the HPTEG prototype, the heat transfer and the thermoelectric conversion performances were investigated. Potassium heat pipes exhibited excellent heat transfer performance with 95% thermal efficiency. The isothermality of such a heat pipe was excellent, and the heat pipe temperature gradient was within 15°C. The TEG's thermoelectric conversion efficiency of 7.5% and HPTEG's prototype system thermoelectric conversion efficiency of 6.2% were achieved. When the TEG hot surface temperature reached 625°C, the maximum electrical output power of the TEG peaked at 183.2 W, and the open-circuit voltage reached 42.2 V. The high performances of the HPTEG prototype demonstrated the potential of the HPTEG for use in engineering applications.     

Performance effect on the TEG system for waste heat recovery in automobiles using ZnO and SiO2 nanofluid coolants

Enhancement in heat transfer of the cold side is vital to amplify the performance of a thermoelectric generator (TEG). With enriched thermophysical properties of nanofluids, significant improvement in heat transfer process can be obtained. The current study concerns the performance comparison of an automobile waste heat recovery system with EG‐water (EG‐W) mixture, ZnO, and SiO₂ nanofluid as coolants for the TEG system. The effects on performance parameters, that is, circuit voltage, conversion efficiency, and output power with exhaust inlet temperature, the total area of TEG, Reynolds number, and particle concentration of nanofluids for the TEG system have been investigated. A detailed performance analysis revealed an increase in voltage, power output, and conversion efficiency of the TEG system with SiO ₂ nanofluid, followed by ZnO and EG‐W coolants. The electric power and conversion efficiency for SiO ₂ nanofluid at an exhaust inlet temperature of 500K were enhanced by 11.80% and 11.39% respectively, in comparison with EG‐W coolants. Moreover, the model speculates that an optimal total area of TEGs exists for the maximum power output of the system. With SiO ₂ nanofluid as a coolant, the total area of TEGs can be diminished by up to 34% as compared with EG‐W, which brings significant convenience for the placement of TEGs and reduces the cost of the TEG system.     

Thermoelectric conversion of waste heat from IC engine‐driven vehicles: A review of its application,issues, and solutions

Thermoelectric generator (TEG) is a promising thermoelectric (TE) conversion technology to effectively recover and convert waste heat from vehicle exhaust into useful energy, ie, electricity. Exhaust TEG (ETEG) is a system that is incorporated into the exhaust manifold of a vehicle. Exhaust TEG comprises of a heat exchanger, TEG modules, heat sink, and power conditioning unit. The present work reviews different vehicular ETEGs based on engine type, engine‐rated power, type and number of TEG module, efficiency of ETEG and TEG, exhaust and coolant temperature, and power output of ETEG . In addition to these, the technical issues faced in these ETEGs are addressed under 2 categories, viz., primary (TEG with low ZT TE material and inefficient heat exchanger and heat sink) and secondary issues (low operating temperature TEG modules and installation position of ETEG). In addition to it, effects of vibration and thermal cycling of exhaust system on TEG modules that may arise in ETEG are also discussed. A review of preventive solutions to the issues is also presented. Finally, the economic aspects of an ETEG are also discussed. The review highlights the need of commercialization of TE materials with ZT > 2, high‐temperature operating range, and segmented TEG modules in large volumes so that their practice can be extended in vehicular applications. Heat exchanger modeling using computational fluid dynamics and interfacing with heat transfer theory is essential to maintain temperature uniformity across the TEG modules. Installation of ETEG in the exhaust pipe should be such that it does not affect the performance of the engine. It is also realized that sturdy TEG modules should be developed for long‐term operation to prevent degradation due to mechanical vibration and thermal cycling of the vehicle. Further, ETEG is economically beneficial in vehicles such as trucks owing to availability of high thermal energy in their exhaust stream.     

Evaluation of the power-generation capacity of wearable thermoelectric power generator

Employing thermoelectric generators (TEGs) to gather heat dissipating from the human body through the skin surface is a promising way to supply electronic power to wearable and pocket electronics. The uniqueness of this method lies in its direct utilization of the temperature difference between the environment and the human body, and complete elimination of power maintenance problems. However, most of the previous investigations on thermal energy harvesters are confined to the TEG and electronic system themselves because of the low quality of human energy. We evaluate the energy generation capacity of a wearable TEG subject to various conditions based on biological heat transfer theory. Through numerical simulation and corresponding parametric studies, we find that the temperature distribution in the thermopiles affects the criterion of the voltage output, suggesting that the temperature difference in a single point can be adopted as the criterion for uniform temperature distribution. However, the criterion has to be shifted to the sum of temperature difference on each thermocouple when the temperature distribution is inconsistent. In addition, the performance of the thermal energy harvester can be easily influenced by environmental conditions, as well as the physiological state and physical characteristics of the human body. To further validate the calculation results for the wearable TEG, a series of conceptual experiments are performed on a number of typical cases. The numerical simulation provides a good overview of the electricity generation capability of the TEG, which may prove useful in the design of future thermal energy harvesters.     

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.     

Numerical simulation of nanostructured thermoelectric generator considering surface to surrounding convection

Thermoelectric systems (TE) can directly convert heat to electricity and vice-versa by using semiconductor materials. Therefore, coupling between heat transfer and electric field potential is important to predict the performance of thermoelectric generator (TEG) systems. This paper develops a general two-dimensional numerical model of a TEG system using nanostructured thermoelectric semiconductor materials. A TEG with p-type nanostructured material of Bismuth Antimony Telluride (BiSbTe) and n-type Bismuth Telluride (Bi₂Te₃) with 0.1 vol.% Silicon Carbide (SiC) nanoparticles is considered for performance evaluations. Coupled TE equations with temperature dependant transport properties are used after incorporating Fourier heat conduction, Joule heating, Seebeck effect, Peltier effect, and Thomson effect. The effects of temperature difference between the hot and cold junctions and surface to surrounding convective on different output parameters (e.g., thermal and electric fields, power generation, thermal efficiency, and current) are studied. Selected results obtained from current numerical analysis are compared with the results obtained from analytical model available in the literature. There is a good agreement between the numerical and analytical results. The numerical results show that as temperature difference increases output power and amount of current generated increase. Moreover, it is quite apparent that convective boundary condition deteriorates the performance of TEG.     

Experimental investigation of thermoelectric power generation versus coolant pumping power in a microchannel heat sink

The coolant heat sinks in thermoelectric generators (TEG) play an important role in order to power generation in the energy systems. This paper explores the effective pumping power required for the TEGs cooling at five temperature difference of the hot and cold sides of the TEG. In addition, the temperature distribution and the pressure drop in sample microchannels are considered at four sample coolant flow rates. The heat sink contains twenty plate-fin microchannels with hydraulic diameter equal to 0.93 mm. The experimental results show that there is a unique flow rate that gives maximum net-power in the system at the each temperature difference.     

Evaluation of the power-generation capacity of wearable thermoelectric power generator

Employing thermoelectric generators (TEGs) to gather heat dissipating from the human body through the skin surface is a promising way to supply electronic power to wearable and pocket electronics. The uniqueness of this method lies in its direct utilization of the temperature difference between the environment and the human body, and complete elimination of power maintenance problems. However, most of the previous investigations on thermal energy harvesters are confined to the TEG and electronic system themselves because of the low quality of human energy. We evaluate the energy generation capacity of a wearable TEG subject to various conditions based on biological heat transfer theory. Through numerical simulation and corresponding parametric studies, we find that the temperature distribution in the thermopiles affects the criterion of the voltage output, suggesting that the temperature difference in a single point can be adopted as the criterion for uniform temperature distribution. However, the criterion has to be shifted to the sum of temperature difference on each thermocouple when the temperature distribution is inconsistent. In addition, the performance of the thermal energy harvester can be easily influenced by environmental conditions, as well as the physiological state and physical characteristics of the human body. To further validate the calculation results for the wearable TEG, a series of conceptual experiments are performed on a number of typical cases. The numerical simulation provides a good overview of the electricity generation capability of the TEG, which may prove useful in the design of future thermal energy harvesters.     

Design of innovative power conditioning system for the grid integration of thermoelectric generators

Recently, thermoelectric generators (TEGs) have emerged as a potential alternative for clean energy generation, due mainly to the technology innovation and the marked cost reduction of modules, as well as their distinctive advantages. In a TEG system, the electronic power conditioning system (PCS) plays a vital role in ensuring the effective power grid integration, since it is subject to requirements related not only to the variable thermal source itself but also to its effects on the grid operation. This paper proposes an enhanced structure of PCS for the grid integration of TEG arrays to maximize the energy capture from a variable heat source. The innovative topology employed consists of a Z-source inverter that allows the flexible, efficient and reliable generation of high quality electric power from the TEG array. A full detailed model is described and its control scheme is designed. The dynamic performance of the proposed systems is fully validated by computer simulation and experimental studies.     

On the volume power density of radial thermoelectric generators

We examine the volume power density of radial thermoelectric generators (TEGs). Radial, or tubular, TEGs have been considered as an alternative to the usual flat-plate TEGs due to its improved geometric match to typical curved heat sources and high surface power density. However, surface power density is not the only important performance index in realistic situations. Especially for TEGs with inorganic materials that have high raw material prices, volume power density can be important as well. In this note, an analytic model of a radial TEG is studied with a numerical trial-and-error approach for investigating its volume power density. At the same time, an alternative, approximate method of estimating the maximum power of the radial TEG is presented. Using these two approaches, we estimate the volume power density of a skutterudite-based radial TEG and compare the results to those of a flat-plate TEG. The volume power density of the radial TEG is significantly lower than that of the flat-plate TEG. For example, our calculation for a representative case with free convection on the cold side shows that the volume power density of the radial TEG will be 107 W/m³ at best. The result improves with forced convection, and our calculation for a representative case with forced convection on the cold side exhibits the maximum volume power density of 24 100 W/m³ . All these values turn out to be smaller roughly by one order of magnitude than the maximum volume power densities of comparable flat-plate TEGs. Such a low volume power density indicates lower economic feasibility of the radial TEG with expensive inorganic thermoelectric materials. This is also explicitly discussed by presenting the high cost per watt of the radial TEG. It is therefore suggested that radial TEGs with less expensive organic materials may be more acceptable than those with inorganic ones.     

Experiments and simulations on low-temperature waste heat harvesting system by thermoelectric power generators

In this case study, a system to recover waste heat comprised 24 thermoelectric generators (TEG) to convert heat from the exhaust pipe of an automobile to electrical energy has been constructed. Simulations and experiments for the thermoelectric module in this system are undertaken to assess the feasibility of these applications. A slopping block is designed on the basis of simulation results to uniform the interior thermal field that improves the performance of TEG modules. Besides simulations, the system is designed and assembled. Measurements followed the connection of the system to the middle of an exhaust pipe. Open circuit voltage and maximum power output of the system are characterized as a function of temperature difference. Through these simulations and experiments, the power generated with a commercial TEG module is presented. Overview this case study and our previous work, the results establish the fundamental development of low-temperature waste heat thermoelectric generator system that enhances the TEG efficiency for vehicles.     

Modeling, experimental study on the heat transfer characteristics of thermoelectric generator

This paper investigates the heat transfer characteristics of a thermoelectric generator. The influence of heat dissipation intensity to the sub-thermal resistances distribution is experimentally studied. Based on the thermal network analysis and finite time thermodynamics, an analytical model including all thermal resistances (in both thermocouples and external heat exchangers) is developed to predict the performance of the generator. The results show that the computed values of output power agree well with the experimental values. The heat transfer enhancement on the generator cold side greatly reduces the cold side temperature and thermal resistance, and obviously improves the output power. Compare with air natural convection cooling, the main thermal resistance changes from the resistance between the fins and the ambient to the thermal contact resistances between the generator and the heat sink at the conditions of forced convection and water cooling. This study may be guide the optimization of generator structure.     

Numerical model of a thermoelectric generator with compact plate-fin heat exchanger for high temperature PEM fuel cell exhaust heat recovery

This paper presents a numerical model of an exhaust heat recovery system for a high temperature polymer electrolyte membrane fuel cell (HTPEMFC) stack. The system is designed as thermoelectric generators (TEGs) sandwiched in the walls of a compact plate-fin heat exchanger. Its model is based on a finite-element approach. On each discretized segment, fluid properties, heat transfer process and TEG performance are locally calculated for higher model precision. To benefit both the system design and fabrication, the way to model TEG modules is herein reconsidered; a database of commercialized compact plate-fin heat exchangers is adopted. Then the model is validated against experimental data and the main variables are identified by means of a sensitivity analysis. Finally, the system configuration is optimized for recovering heat from the exhaust gas. The results exhibit the crucial importance of the model accuracy and the optimization on system configuration. Future studies will concentrate on heat exchanger structures.     

Numerical study on nonuniform segmented enhancement method for thermoelectric power generator

Thermoelectric power generators (TEGs) have received considerable attention in the vehicular waste heat recovery. Large temperature difference between hot-side end and cold-side end of TE modules should be maintained to keep large power generation. However, the scaling-up problem of inevitably temperature drop of exhaust gas along the flow direction of vehicles is introduced when multiple TE modules are assembled. In this work, a three-dimensional fluid–thermal–electric multiphysics model with equivalent properties of TE modules is established. The influencing mechanism of longitudinal vortex generator (LVG) pair number and distribution in the hot-side heat exchanger on the local power generation performance of the TEGs is examined. It is found that the extent of the local power generation enhancement gets smaller or even deteriorates at the downstream TE modules by uniformly increasing the LVG pair number along the flow direction. Hence, to make the heat flux efficiently utilized, a nonuniform segmented enhancement method is used for the hot-side heat exchanger. The results show that compared with the TEG with a uniform heat exchanger or a downstream-denser heat exchanger, the total Seebeck voltage generated by the TEG with an upstream-denser heat exchanger is 28% higher, and its output power is 64.4% higher at the matched load resistance. The TEG with the upstream-denser heat exchanger significantly improves the overall power generation performance without additional pumping power.     

Power-optimization of non-ideal energy converters under generalized convective heat transfer law via Hamilton-Jacobi-Bellman theory

A multistage irreversible Carnot heat engine system operating between a finite thermal capacity high-temperature fluid reservoir and an infinite thermal capacity low-temperature environment with generalized convective heat transfer law [q∝m(ΔT)] and the irreversibility of heat resistance and internal dissipation is investigated in this paper. Optimal control theory is applied to derive the continuous Hamilton-Jacobi-Bellman (HJB) equations, which determine optimal fluid temperature configurations for maximum power output under the conditions of fixed duration and fixed initial temperature of the driving fluid. Based on general optimization results, the analytical solution for the case with Newtonian heat transfer law (m=1) is further obtained. Since there are no analytical solutions for the other heat transfer laws (m≠1), the continuous HJB equations are discretized and dynamic programming (DP) algorithm is adopted to obtain complete numerical solutions of the optimization problem, and the relationships among the maximum power output of the system, the process period and the fluid temperature are discussed in detail.     

Analytical model of parallel thermoelectric generator

The paper studied the performances of parallel thermoelectric generator (TEG) by theoretical analysis and experimental test. An analytical model of parallel TEG was developed by theoretical analysis and calculation, based on thermodynamics theory, semiconductor thermoelectric theory and law of conservation of energy. Approximate expressions of output power and current of parallel TEG were deduced by the analytical model. An experimental system was built to verify the model. The results indicate that only when all of the thermoelectric modules (TE modules) in the parallel TEG have the same inherent parameters and working conditions, the parallel properties of the TEG are the same as that of common DC power. The existence of contact resistance is just like the increase of the TE module’s internal resistance, which leads to the deceases of output power. The thermal contact resistance reduces the output power by reducing the temperature difference between the two sides of the thermocouples. The results derived from the model are basically consistent with the experimental results, the model is suitable for the performance researching and designing of parallel TEG.     

Parametrical analysis of the design and performance of a solar heat pipe thermoelectric generator unit

This paper describes a solar heat pipe thermoelectric generator (SHP-TEG) unit comprising an evacuated double-skin glass tube, a finned heat pipe and a TEG module. The system takes the advantage of heat pipe to convert the absorbed solar irradiation to a high heat flux to meet the TEG operating requirement. An analytical model of the SHP-TEG unit is presented for the condition of constant solar irradiation, which may lead to different performance characteristics and optimal design parameters compared with the condition of constant temperature difference usually dealt with in other studies. The analytical model presents the complex influence of basic parameters such as solar irradiation, cooling water temperature, thermoelement length and cross-section area and number of thermoelements, etc. on the maximum power output and conversion efficiency of the SHP-TEG. Simulation based on the analytical model has been carried out to study the performance and design optimization of the SHP-TEG.     

Coupled thermal model of photovoltaic-thermoelectric hybrid panel for sample cities in Europe

In general, modeling of photovoltaic-thermoelectric (PV/TEG) hybrid panels have been mostly simplified and disconnected from the actual ambient conditions and thermal losses from the panel. In this study, a thermally coupled model of PV/TEG panel is established to precisely predict performance of the hybrid system under different weather conditions. The model takes into account solar irradiation, wind speed and ambient temperature as well as convective and radiated heat losses from the front and rear surfaces of the panel. The model is developed for three sample cities in Europe with different weather conditions. The results show that radiated heat loss from the front surface and the convective heat loss due to the wind speed are the most critical parameters on performance of the hybrid panel performance. The results also indicate that, with existing thermoelectric materials, the power generation by the TEG is insignificant compared to electrical output by the PV panel, and the TEG plays only a small role on power generation in the hybrid PV/TEG panel. However, contribution of the TEG in the power generation can be improved via higher ZT thermoelectric materials and geometry optimization of the TEG.     

A 500 W low-temperature thermoelectric generator: Design and experimental study

Most of the current thermal power-generation technologies must first convert thermal energy to mechanical work before producing electricity. In this study, a direct heat to electricity (DHE) technology using the thermoelectric effect, without the need to change through mechanical energy, was applied to harvest low-enthalpy thermal work. Such a power generation system has been designed and built using thermoelectric generator (TEG) modules. Experiments have been conducted to measure the output power at different conditions: different inlet temperature and temperature differences between hot and cold sides. TEG modules manufactured with different materials have also been tested. The power generator assembled with 96 TEG modules had an installed power of 500 W at a temperature difference of around 200 °C. An output power of over 160 W has been generated with a temperature difference of 80 °C. The power generated by the thermoelectric system is almost directly proportional to the temperature difference between the hot and the cold sides. The cost of the DHE power generator is lower than that of photovoltaics (PV) in terms of equivalent energy generated.     

Numerical study of a solar thermoelectric generator with nanofluids based microcooling system

Abstract

Nanofluids have been recently gaining ever-increasing attention in solar thermoelectric applications due to their promising potentials as heat transfer fluids. This research investigates numerically the performance of a thermoelectric generator (TEG) that is cooled by Al₂O₃/water nanofluid flows in zigzag microchannel heat sinks (ZMCHS). The one-way fluid–structure interaction (FSI) tool was used to couple the thermal-electric and fluid flow tools in ANSYS 15.0. The present study focused on the effects of heat flux (2–50?kW/m²), laminar Reynolds number (5–1500), inlet flow temperature (293–303?K) and the nanoparticle concentration (1–6%) on the output electric power and the efficiency of the TEG module. The applied heat flux limitations and its relation to the thermal limitations of thermoelectric materials were considered. The results indicated that the increase of heat flux increased the output power and the efficiency of TEG. Higher Reynolds numbers (Re > 400), inlet temperature and nanofluid concentration had an insignificant impact on the TEG performance.