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DEER 2006
Progress in Thermoelectrical Energy Recovery from a Light
Truck Exhaust
E. F. Thacher, B. Helenbrook, M. A. Karri
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Topics
• Participants • Project Outline • Hardware • Highlights of Test Results
• Performance Prediction • Commercialization Plan
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Project Team • Technical
– Eric Thacher (PI) – Brian Helenbrook (Co-PI) – Madhav Karri (RA)
• Commercialization – Elmer (Stub) Estey (Consultant) – Brian Piotrowski (RA)
• Delphi, Inc.: test services • GM: test truck • Hi-Z Technology, Inc.,: design and construction• NYSERDA: funding
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Static Testing
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Exhaust inlet
Coolant inletsSeries connection
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rectifier
battery
by-pass valve(in pump housing)
radiator
thermostat valve (in pump housing)
PCHX
+
-
firewall
AETEG
alternator
14.5-V DC bus +
heater core
PCU
pump drive shaft
catalytic converter
coolant
belt
exhaust
+
+
engine
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PCU
FRONT
exhaust outlet pressuresensing tube
internaltemperature sensors
power wiresexhaust inlet pressuresensing tube
exhaust inlettemperaturesensor
exhaust outlet temperaturesensor
drive shaftFRONT drive shaft power wires
exhaust inlet pressure sensing tube Left side view
exhaust inlet temperature sensor
internal temperature sensors
exhaust outlet temperature sensor
exhaust outlet pressure sensing tube
PCU DC bus power wires FRONT
coolant out
Right side view AETEG power wires
coolant temperature sensors
coolant in
coolant pressure right side of frame sensing lines
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Test Matrix • Test configuration
• A: Baseline, No TEG • B: with TEG
• C: with TEG & Exhaust insulation
• D: with TEG, Exhaust insulation & PCHX
• Tunnel air inlet temperature
• 40o F
• 70o F
• 100o F
• Speeds • Idle
• 30 mph
• 50 mph
• 70 mph
• Electrical load
• Base
• Base+25 amps
• Base+50 amps
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Major Results from Testing -I• Power achieved: 255.1 W (design: 330 W)
– Climbing hill at 70 mph with city watercooling
– Power increases with speed (show later) – Thermal management important:
insulating exhaust & lowering coolanttemperature produced dramaticincreases in AETEG power
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Test Results - II
• Power limited by: – Available space for AETEG, – Exhaust and coolant heat exchangers’
UA, – Allowable continuous Th (250°C) readily
obtained
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Test Results - III
• Maximum Fuel economy increase of order 1%-2% – Best: Configuration D at 70 mph,
horizontal road
– Fuel savings increased with vehicle speed (but scatter large)
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Testing Results - IV • Effects on truck
– Parasitic losses: blow down power, pumping power, increased weight
– In some low speed tests, latter twolosses gave a reduction in the fuel economy
– Extra cooling load on vehicle coolingsystem not significant
• Submitted to J. Auto. Engineering
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Road Test
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Delphi PCHX 8/25/05 Road Test Data
200
150
100
50
0 0 10 20 30 40 50 60 70
generator voltage
pow
er (W
)po
wer
(W)
Pg (70 mph)
Pg(30 mph)
Pg(50 mph)
P, Delphi 30 mph, 21.1C P, Delphi 50 mph, 21.1C
-50 P, Delphi 70 mph, 21.1C
New PCHX 7/21/05 & 8/25/05 AETEG Road Test Data
200
150
-50 20.00 40.00 60.00
60 mph 100 50 mph
30 mph 50 70 mph 0
0.00 80.00
generator voltage
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Maximum Delphi and Road Test Powers (Road Test Average ambient: 25.35+1.28C)
0
50
100
150
200
pow
er (W
)
road tests
Delphi 70F
Delphi 40F
Delphi 100F
0 20 40 60 80
speed (mph)
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System Optimization
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Things to Improve -I
• Increase TH and decrease TC – Higher (UA)h and (UA)c – Better pre-cooling of engine coolant– Air cooling (lowest coolant inlet temp,
but must fix low hC )? – Better insulation
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Things to Improve - II• Reduce or eliminate parasitic losses
– Air cooling does (but maybe creates new ones)
– Reduce coolant pressure loss in coolant heat exchanger (CHX)
– Reduce exhaust gas heat exchanger (EGHX) pressure drop
– Reduce AETEG weight (mainly EGHX) • Increase PCU efficiency • Use quantum well TE material
– Yes, but all the foregoing must also be done
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New EGHX and CHX
• CHX – Increased number of fins – Flow-averaged UA increased about 50% – Pressure loss decreased
• EGHX – Impingement features – Flow-averaged UA increased about 55% – Pressure loss increased
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Performance Studies
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Studies
• Test truck – ADVISOR 2002 – Scaled library SUV engine map – Simulated test at 30, 50, and 70 mph
– QW & Baseline • Properties: Hi-Z Technology B4C/B9C (p) &
Si/SiGe (n) • Orion bus (a series hybrid) • Natural gas-fueled fixed generator
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Optimization at 70 mph
(L/A)opt = 5100 m-1
HZ20 = 107.6 m-1
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Test Truck Simulation
Delphi test
Hz20 modified
Optimized QW
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Fuel Economy Changes Relative Fuel Savings
-8
-6
-4
-2
0
2
4
20 40 60 80
speed (mph)
fu el
sav
in g s
(% )
QWTEG HZ20 TEST: WT&PCU CORR TEST
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QWTEG & Delphi Comparison
0
1
2
3
4
5
6
7
8
9
10
20 30 40 50 60 70 80
speed (mph)
effic
ienc
y (%
)
Delphi Configuration D Simulation
Efficiency Comparison
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Commercialization Conclusion
• Current thermoelectric generator technology is better suited to waste heat recovery from fixed engines where weight and size are not so constrained and operating conditions are more stable.
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Future Work• Develop new ideas for using radiator not
PCHX • Finite element analysis of AETEG • Bench test new EGHX in AETEG • Bench test new CHX • Redesign for lower weight • Run simulations using new EGHX • Project with Lockheed Martin Co.