C. Q. Su

Multi-Scale Microstructural Thermoelectric Materials: Transport Behavior, Non-Equilibrium Preparation, and Applications

Considering only about one third of the worlds energy consumption is effectively utilized for functional uses, and the remaining is dissipated as waste heat, thermoelectric (TE) materials, which offer a direct and clean thermal-to-electric conversion pathway, have generated a tremendous worldwide interest. The last two decades have witnessed a remarkable development in TE materials. This Review summarizes the efforts devoted to the study of non-equilibrium synthesis of TE materials with multi-scale structures, their transport behavior, and areas of applications. Studies that work towards the ultimate goal of developing highly efficient TE materials possessing multi-scale architectures are highlighted, encompassing the optimization of TE performance via engineering the structures with different dimensional aspects spanning from the atomic and molecular scales, to nanometer sizes, and to the mesoscale. In consideration of the practical applications of high-performance TE materials, the non-equilibrium approaches offer a fast and controllable fabrication of multi-scale microstructures, and their scale up to industrial-size manufacturing is emphasized here. Finally, the design of two integrated power generating TE systems are described-a solar thermoelectric-photovoltaic hybrid system and a vehicle waste heat harvesting system-that represent perhaps the most important applications of thermoelectricity in the energy conversion area.

Research on the Compatibility of the Cooling Unitin an Automotive Exhaust-based Thermoelectric Generatorand Engine Cooling System

The temperature difference between the hot and cold sides of thermoelectric modules is a key factor affecting the conversion efficiency of an automotive exhaust-based thermoelectric generator (TEG). In the work discussed in this paper the compatibility of TEG cooling unit and engine cooling system was studied on the basis of the heat transfer characteristics of the TEG. A new engine-cooling system in which a TEG cooling unit was inserted was simulated at high power and high vehicle speed, and at high power and low vehicle speed, to obtain temperatures and flow rates of critical inlets and outlets. The results show that coolant temperature exceeds its boiling point at high power and low vehicle speed, so the new system cannot meet cooling requirements under these conditions. Measures for improvement to optimize the cooling system are proposed, and provide a basis for future research.

A 42-V Electrical and Hybrid Driving System Basedon a Vehicular Waste-Heat Thermoelectric Generator

A 42-V powernet has been recognized as the next generation of vehicle electrical systems, and the waste-heat thermoelectric generator is becoming the future of vehicular energy conservation and emission reduction technologies. In this paper, effective utilization of vehicular waste-heat energy is proposed by introducing an electrical and hybrid driving system, which is an assemblage of a waste-heat thermoelectric generator, a 42-V powernet, and an integrated starter and generator (ISG). A vehicle model and the submodels for the new system have been built on the ADVISOR platform based on MATLAB/Simulink, and the dynamic performance of the vehicle model tested using the Economic Commission for Europe–Europe Urban Dynamometer Cycle driving cycle. The simulation results indicate that application of a 42-V waste-heat thermoelectric vehicle could be an integrated approach for fuel economy improvement and emission reduction, compared with a conventional internal combustion engine vehicle and an ISG-type 42-V vehicle.

Experiments and Simulations on a Heat Exchanger of an Automotive Exhaust Thermoelectric Generation System Under Coupling Conditions

The present experimental and computational study investigates an exhaust gas waste heat recovery system for vehicles, using thermoelectric modules and a heat exchanger to produce electric power. It proposes a new plane heat exchanger of a thermoelectric generation (TEG) system, producing electricity from a limited hot surface area. To investigate the new plane heat exchanger, we make a coupling condition of heat-flow and flow-solid coupling analysis on it to obtain the temperature, heat, and pressure field of the heat exchanger, and compared it with the old heat exchanger. These fields couple together to solve the multi-field coupling of the flow, solid, and heat, and then the simulation result is compared with the test bench experiment of TEG, providing a theoretical and experimental basis for the present exhaust gas waste heat recovery system.

Simulation and Optimization of the Heat Exchanger for Automotive Exhaust-Based Thermoelectric Generators

In order to enhance the exhaust waste heat recovery efficiency of the automotive exhaust-based thermoelectric generator (TEG) system, a three-segment heat exchanger with folded-shaped internal structure for the TEG system is investigated in this study. As the major effect factors of the performance for the TEG system, surface temperature, and thermal uniformity of the heat exchanger are analyzed in this research, pressure drop along the heat exchanger is also considered. Based on computational fluid dynamics simulations and temperature distribution, the pressure drop along the heat exchanger is obtained. By considering variable length and thickness of folded plates in each segment of the heat exchanger, response surface methodology and optimization by a multi-objective genetic algorithm is applied for surface temperature, thermal uniformity, and pressure drop for the folded-shaped heat exchanger. An optimum design based on the optimization is proposed to improve the overall performance of the TEG system. The performance of the optimized heat exchanger in different engine conditions is discussed.

Experimental Investigation of Exhaust Thermoelectric System and Application for Vehicle

In this case study, an energy harvesting system using a thermoelectric power generator (TEG) has been constructed. Experimental investigation of the hot and cold sides of the thermoelectric modules (TMs) in this system has been undertaken to assess the feasibility for automotive applications. Two test benches have been developed to analyze the TM performance and the TEG system characteristics, especially the temperature difference, open-circuit voltage, and maximum power output of the TM and TEG system. As the performance of a TM is most influenced by the applied pressure and the temperature difference, a thermostatic heater, thermostatic water tank, and clamping devices are used in our experimental apparatus, increasing the output power of the TEG system. Based on the test bench, a new system called the “four-TEGs” system was designed and assembled into a prototype vehicle called “Warrior,” and the characteristics of the system such as the maximum power output have been studied in road tests. The results show great potential for application of this technology in future vehicles.

Control Strategy for a 42-V Waste-Heat Thermoelectric Vehicle

A 42-V waste-heat thermoelectric vehicle is employed as a potential application of thermoelectric generators for fuel economy improvement and emissions reduction. The 42-V waste-heat thermoelectric vehicle currently in development employs an assemblage driving system consisting of a waste-heat thermoelectric generator, a 42-V powernet, and an integrated starter and generator (ISG). The waste-heat thermoelectric generator also functions as a power supply. To optimize the utilization of the waste-heat energy generated by the thermoelectric generator, an electric assist control strategy and a torque split control strategy are proposed herein. Through the development of relevant systems and strategies, including the thermoelectric generator and an electric bus system, two vehicle models are established and compared using the ADVISOR platform based on MATLAB/Simulink. The calculation results show improved fuel economy and emissions performance resulting from the integration of the torque split control strategy into the 42-V waste-heat thermoelectric vehicle.

Multi-Objective Optimization Design for Cooling Unit of Automotive Exhaust-Based Thermoelectric Generators

In order to improve the performance of cooling units for automotive thermoelectric generators, a study is carried out to optimize the cold side and the fin distributions arranged on its inner faces. Based on the experimental measurements and numerical simulations, a response surface model of different internal structures is built to analyze the heat transfer and pressure drop characteristics of fluid flow in the cooling unit. For the fin distributions, five independent variables including height, length, thickness, space and distance from walls are considered. An experimental study design incorporating the central composite design method is used to assess the influence of fin distributions on the temperature field and the pressure drop in the cooling units. The archive-based micro genetic algorithm (AMGA) is used for multi-objective optimization to analyze the sensitivity of the design variables and to build a database from which to construct the surrogate model. Finally, improvement measures are proposed for optimization of the cooling system and guidelines are provided for future research.

Optimization of Cooling Unit Design for Automotive Exhaust-Based Thermoelectric Generators

Integrating a thermoelectric cooler (TEC) into the engine cooling system has various advantages including reducing additional mechanical parts, and saving energy and space for automotive applications. Based on performance parameters of the engine and thermoelectric modules, three different TEC configurations called plate-shape, stripe-shape, and diamond-shape are constructed with development of simulations of the different TECs and the performance of the circulating coolant. Based on these simulations, the velocity, pressure, and temperature fields of the coolant are obtained for further research. Besides, the temperature of the TEC and the output power of the thermoelectric generator (TEG) are acquired experimentally. Comparing the working performance of the different TECs, the simulation and experimental results show that the TEG using the diamond-shaped TEC achieves a relatively ideal performance. Finally, some measures are proposed to improve the cooling system, providing guidelines for future research.

Acoustic Optimization of Automotive Exhaust Heat Thermoelectric Generator

The potential for thermoelectric exhaust heat recovery in vehicles has been increasing with recent advances in the efficiency of thermoelectric generators (TEGs). This study analyzes the acoustic attenuation performance of exhaust-based TEGs. The acoustic characteristics of two different thermal designs of exhaust gas heat exchanger in TEGs are discussed in terms of transmission loss and acoustic insertion loss. GT-Power simulations and bench tests on a dynamometer with a high-performance production engine are carried out. Results indicate that the acoustic attenuation of TEGs could be determined and optimized. In addition, the feasibility of integration of exhaust-based TEGs and engine mufflers into the exhaust line is tested, which can help to reduce space and improve vehicle integration.