Exhaust Waste Heat Recovery

Dr. HoSung Lee

February 18, 2015 (revised on 3/3/2016)

Thermoelectric Waste Heat Recovery Program for Passenger Vehicles• PI: Douglas T. Crane, BSST

• Presenter: John W. LaGrandeur, BSST

• May 18, 2012

• Project ID #ACE080

Overview

• Timeline: October 2004 – September 2011

• Budget: $11,874,538 DOE $7,156,109 and Contractor Share $4,718,429

• Partners:• Project Lead: BSST

• OEM Partners: BMW & Ford

• Tier 1 Partners: Faurecia, Visteon

• Universities/Federal Lab Partners: Caltech, JPL, NREL, VirginiaTech

BMW X6 and Ford Lincoln MKT

5

Crane and Lagrandeur (2010)-BSST

Crane et al. (2009)JEM, 38,7

Crane et al. (2009)JEM, 38,7

Cost-Competitive Advanced Thermoelectric Generators for Direct Conversion of Vehicle Waste Heat into Useful Electrical Power

• Gregory P. Meisner - General Motors Global Research & Development

• May 18, 2012

• Project ID #ACE081

Overview Project ID:ACE081

• Timeline: April 2012 – April 2016• Budget: $13,500,000• Partners:

• GM – project lead (GM Global R&D)• Marlow - TE module development & fabrication• Purdue - thermal interfaces, heat exchanger modeling and design• Dana, Inc.- heat exchanger design and fabrication• Eberspaecher - exhaust system design & fabrication• JPL – Modeling of TEG system, heat exchangers & modules; TE module testing &

durability studies• Delphi – TEG electronics, packaging, & assembly• Magnequench – TE material synthesis• MSU – Passivation/protection of TE materials• ORNL – High temperature transport & mechanical property measurements• BNL – TE material synthesis

Objectives

• Improve fuel economy by 5 %

• Develop low cost, commercially viable manufacturing processes and plan for scale-up TEG production (100k units/year)

• GM Suburban

GM report (1/29/2012)

GM report (1/29/2012)

Abstract

GM report (1/29/2012)

Salvador et al. (2013)

Salvador et al. (2013)

Kumar et al. (2013)

Kumar et al. (2013)

Kumar et al. (2013)

Kumar et al. (2013)

Kumar et al. (2013)

Kumar et al. (2013)

Kumar et al. (2013)

Kumar et al. (2013)

Kumar et al. (2013)

Develop Thermoelectric Technology for Automotive Waste Heat RecoveryDOE Grant#DE-FC26-04NT 42278

• Start date – May 2005, end date – August 31, 2011

• Budget: $11,172,983, DOEshare: $6.384,010, contractor: $4.824, 973

• Gregory P. Meisner – GM Global R&D, Waren MI

• James R. Salvador – Chemical Science and Materials System Laboratory

• Jan König – Fraunhofer, Freiburg Gemany

• Joshua Moczygemba and Jeffrey Sharp – Marlow, Dallas Texas

Overview• GM R&D Team: Gregory P. Meisner

• Collaborators:• Marlow• ORNL• University of Nevada• Future Tech• Heat Technology, Inc.• Emcon (Faurecia)• Shanghai Institute of Ceramics• University of Michigan• University of South Florida• BNL• MSU

Performance Analysis of a Waste Heat Recovery Thermoelectric Generation System for Automotive Application

• Wuhan University of Technology, Wuhan, China

• X, Liu, Y.D. Deng, C.Q. Su

• 2015

• Energy Conversion and Management, 90 (2015), 121-127

Liu et al. (2014)

Deng et al. (2014) the same group with Liu et al (2014)

Liu et al. (2014)

Frobenius et al. (2016)

Description GM Road Test(2012)

Wuhan Univ. Bench Test (China)

Max. power (W) 57 W 183 W

Exhaust volume flow rate (g/s) 35 (assumed) 20 g/s

TEG volume (m3) (W×L×H) 22.4 cm× 41.3 cm×3.8 cm =3.51×10-3 m3 (fr model)

Power per module (Skutt/BiTe) (at DTmax_junction)

1.6 W/1.05 W Road test9 W Module test

3 W

Power density (W/cm2)-calc. 0.064 W/cm2(Road test)0.36 W/cm2(Module test)

0.12 W/cm2

Number of modules (Skutt + BiTe) 24+18 = 42 60

Exhaust Thot_in / water Tcold_in (℃) 550 ℃/80 ℃ 350 ℃/ 90 ℃

Dpallow (Pa) 600 Pa at 35 g/s

TE material Skutterudite

Module size (W×L×H mm)-skutt. 50 × 50 × 7 mm 50 × 50 ×5 mm

Number of thermocouples 32

TE Element Ae (mm2) 2 mm × 2 mm =4 mm2

TE Element Le (mm) 4 mm

Heat sink fin thickness (mm) 3.3 mm (fr model)

Heat sink fin spacing (mm) 6.35 mm (fr model)

Description GM Road Test(2012)

BSSTBench Test

Max. power (W) 57 W 540 W

Exhaust volume flow rate (g/s) 35 (assumed)

TEG volume (m3) (W×L×H) 22.4 cm× 41.3 cm×3.8 cm =3.51×10-3 m3 (fr model)

Power per module (Skutt/BiTe) (at DTmax_junction)

1.6 W/1.05 W Road test9 W Module test

Power density (W/cm2)-calc. 0.064 W/cm2(Road test)0.36 W/cm2(Module test)

0.35 W/cm2 (Module Test)(16 cm×16cm-layer area)

Number of modules (Skutt + BiTe) 24+18 = 42

Exhaust Thot_in /water Tcold_in (℃) 550 ℃/80 ℃ 200 ℃/20 ℃

Dpallow (Pa) 600 Pa at 35 g/s

TE material Skutterudite

Module size (W×L×H mm)-skutt. 50 × 50 × 7 mm TE couple (4× 4 × 2)-Assume

Number of thermocouples 32 360 per layer (total 6 layer)

TE Element Ae (mm2) 2 mm × 2 mm =4 mm2

TE Element Le (mm) 4 mm

Heat sink fin thickness (mm) 3.3 mm (fr model)

Heat sink fin spacing (mm) 6.35 mm (fr model)

Fin