Recent developments of high performance thermoelectric (TE) materials have increased the interest of using this technology to directly convert waste heat into electricity. In the automotive sector, many automotive thermoelectric generators (ATEGs) designs use TE modules (TEMs) with high hot side temperatures to cope with high engine load regimes. Here, we develop a new concept of a radial ATEG that is specifically designed to work with low temperature TEMs, which enables the use of Pb-free modules and reduces the thermal stress of the device. A prototype is built and tested at different regimes in an engine test bench. A numerical model of the ATEG is developed and validated. The consequences of modifying (1) the exchange area between the heat absorber and the exhaust gases and (2) the effective figure of merit of TEMs on the electrical output power and fuel economy are investigated by means of simulations. Results indicate that the maximum fuel economy (1.3%) is not attained at the point of maximum output power (228 W). In terms of fuel economy, the back pressure at the exhaust penalizes high mass flow regimes. We use a dimensionless parameter to analyze the potential of the ATEG for reducing fuel consumption.
The need for more sustainable mobility promoted research into the use of waste heat to reduce emissions and fuel consumption. As such, thermoelectric generation is a promising technique thanks to its robustness and simplicity. Automotive thermoelectric generators (ATEGs) are installed in the tailpipe and convert heat directly into electricity. Previous works on ATEGs mainly focused on extracting the maximum amount of electrical power. However, the back pressure caused by the ATEG heavily influences fuel consumption. Here, an ATEG numerical model was first validated with experimental data and then applied to investigate the effects that modifying the main ATEG design parameters had on both fuel economy and output power. The cooling flow rate and the geometrical dimensions of the heat exchanger on the hot side and the cold side of the ATEG were varied. The design that produced the maximum output power differed from that which maximized fuel economy. Back pressure was the most limiting factor in attaining fuel savings. Back pressure values lower than 5 mbar led to a < 0.2% increase in fuel consumption. In the ATEG design analyzed here, the generation of electrical output power reduced fuel consumption by a maximum of 0.5%.
Automotive thermoelectric generators (ATEGs) are devices used to harvest waste energy from the exhaust gases of internal combustion engines. An ATEG is essentially formed by three main elements: (1) heat absorber in contact with exhaust gases; (2) thermoelectric modules that directly convert heat into electricity; (3) heat sink to increase the heat transfer through the system. Thermoelectric modules (TEM) are commonly based on small-scale commercial units, with tenths of them needed to assemble a full ATEG device. Thus, several thermal and electrical connections between TEMs can be implemented. Previous studies focused on the implications on the output power. Here, we investigated the effects of using different module connections on the energy efficiency and on the electrical outputs (voltage and current). The study was carried out numerically with ATEGs that used from 4 to 100 individual TEMs. Series, parallel and square connections were investigated under two different engine operating points. The maximum output power was obtained with overall energy conversion efficiencies on the order of 3%. Though the series connection provided the highest output power, the square configuration was the best compromise between output power and electrical characteristics (voltage and current) to successfully integrate the ATEG into the vehicle management system.
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