Currently, the automotive industry faces challenges to implement solutions that provide reductions in energy consumption, pollutants and greenhouse-gas (GHG) emissions. Exhaust heat recovery employing Thermoelectric generators (TEGs) enables the direct conversion of heat into electric energy without moving parts and little to no maintenance. On-board electrical production is especially useful given the growing electrification trend of road vehicles. The present work assesses the performance of a novel temperature-controlled thermoelectric generator (TCTG) concept in a light duty vehicle and its impact on fuel economy and GHG emissions under realistic driving conditions. The novel exhaust heat exchanger (HE) concept consists of corrugated pipes embedded in a cast aluminium matrix along with variable conductance heat pipes (VCHPs) acting as spreaders of excess heat along the longitudinal direction. This concept seems to have a quite good potential for highly variable thermal load applications, as it is able to avoid overheating by spreading heat instead of wasting it through bypass systems. Furthermore, when compared to previous concepts by the group, it does not need gravity assistance and has a form factor similar to conventional generators. It also appears to be capable of delivering a breakthrough electric output for TEG systems in such light vehicles, with as much as 572 W and 1538 W of average and maximum electric powers during a driving cycle, respectively, and showing a quite promising reduction of 5.4% in fuel consumption and CO2 emissions.

One of the main obstacles for the use of thermoelectric generators (TEGs) in vehicles is the highly variable thermal loads typical of driving cycles. Under these conditions it will be virtually impossible for a conventional heat exchanger to avoid both thermal dilution under low thermal loads and TEG overheating under high thermal loads. The authors have been exploring an original heat exchanger concept able to address the aforementioned problems. It uses a variable conductance thermosiphon-based phase-change buffer between the heat source and the TEGs so that a nearly constant, optimized temperature is obtained regardless of operating conditions. To the best of the authors' knowledge, the thermal control feature of the system is unique among existing TEG concepts. The novelty of the present work is the actual computation of operating pressure and temperature and the corresponding vaporization and condensation rates inside the thermosiphon system during driving cycles along with the assessment of the influence of the volumes and pre-charge pressure on electrical output. The global energy and emission savings were also computed for a typical yearly driving profile. It was observed that indeed the concept has unparalleled potential for improving the efficiency of vehicles using TEGs, with around 6% fuel and CO2 emissions savings using the system. This seems a breakthrough for such light duty applications since the efficiency of conventional (passive) systems is strongly deprecated by thermal dilution under low thermal loads and the need to bypass high thermal load events to avoid overheating. On the contrary, the present concept allows the control of the hot face temperature of the TEGs even under highly variable thermal load (i.e. driving cycle) environments.

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