Advanced Thermoelectric Solutions

Combustion Exhaust Gas Heat to Power using Thermoelectric Engines

John LaGrandeur October 5, 2011

Advanced Thermoelectric Solutions - 1 -

Market motivation based on CO2 penalty cost avoidance1

First WHR products fielded (Faurecia, Valeo, et al) capture waste heat to improve engine cold start and increase occupant comfort in cold climes.

Many technology options implemented and underway to meet the new requirements:

October 5, 2011

Sour

ce:

IAV

GM

BH, D

. Jae

nsch

, ICT

200

9

1. Regulation (EC) No 443/2009 of the European Parliament and of the Council of 23 April 2009 setting emission performance standards for new passenger cars

Advanced Thermoelectric Solutions - 2 - October 5,

2011

Advanced Thermoelectric Solutions - 3 -

Blower

Gas heaters

TEG under test

October 5, 2011

Advanced Thermoelectric Solutions - 4 -

Argon ports

Instrumentation feedthroughs

Bypass Valve

Liquid circuit in

Variable Electrical Load

October 5, 2011

Advanced Thermoelectric Solutions - 5 -

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current (A)

TEG Performance - Test 11(hot inlet temperature = 620C, cold inlet temperature = 20C)

(hot mass flow = 45 g/s, cold mass flow = 250 g/s)(6/29/11)

measured voltage

measured power

Linear (measured voltage)

Poly. (measured power)

Liquid mass flow ↑ 32%

0.0%0.5%1.0%1.5%2.0%2.5%3.0%3.5%4.0%4.5%5.0%

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effi

cien

cy (%

)

current (A)

TEG Performance - Test 11(hot inlet temperature = 620C, cold inlet temperature = 20C)

(hot mass flow = 45 g/s, cold mass flow = 250 g/s)(6/29/11)

hot heat flow = hot mass flow*hot specific heat*(hot inlet temp -hot outlet temp)

hot heat flow = cold heat flow + power output

hot heat flow = hot mass flow*hot specific heat*(hot inlet temp -ambient temp)

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current (A)

TEG Performance - Test 12(hot inlet temperature = 620C, cold inlet temperature = 20C)

(hot mass flow = 45 g/s, cold mass flow = 330 g/s)(6/29/11)

measured voltage

measured power

Linear (measured voltage)

Poly. (measured power)

0.0%0.5%1.0%1.5%2.0%2.5%3.0%3.5%4.0%4.5%5.0%

0 200 400 600 800

effi

cien

cy (%

)

current (A)

TEG Performance - Test 12(hot inlet temperature = 620C, cold inlet temperature = 20C)

(hot mass flow = 45 g/s, cold mass flow = 330 g/s)(6/29/11)

hot heat flow = hot mass flow*hot specific heat*(hot inlet temp -hot outlet temp)

hot heat flow = cold heat flow + power output

hot heat flow = hot mass flow *hot specific heat*(hot inlet temp -ambient temp)

October 5, 2011

Advanced Thermoelectric Solutions - 6 -

The three runs were performed over a period of two weeks (over 25 hours of testing) and show good repeatability.

• There is a 9% decrease in electrical resistance from run 1 to run 2 due to “settling in” of the device interfaces

• This reduction in electrical resistance caused a 5% increase in peak power

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volt

age

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current (A)

Test 11hot inlet temperature = 620C, cold inlet temperature = 20C

hot mass flow = 45 g/s, cold mass flow = 250 g/s

1st run

2nd run

3rd run

Linear (1st run)

Linear (2nd run)

Linear (3rd run)

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pow

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current (A)

Test 11hot inlet temperature = 620C, cold inlet temperature = 20C

hot mass flow = 45 g/s, cold mass flow = 250 g/s

1st run

2nd run

3rd run

Poly. (1st run)

Poly. (2nd run)

Poly. (3rd run)

October 5, 2011

Advanced Thermoelectric Solutions - 7 - October 5,

2011

Advanced Thermoelectric Solutions - 8 -

Power & Voltage Validation

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TEG Performance - Test 11(hot inlet temperature = 620C, cold inlet temperature = 20C)

(hot mass flow = 45 g/s, cold mass flow = 250 g/s)(6/29/11)

measured voltage

simulated voltage

measured power

simulated power

Poly. (simulated power)

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TEG Performance - Test 19 (no first & last ring)(hot inlet temperature = 510C, cold inlet temperature = 40C)

(hot mass flow = 30.1 g/s, cold mass flow = 170 g/s)(6/29/11)

measured voltage

simulated voltage

measured power

simulated power

Poly. (simulated power)

October 5, 2011

Advanced Thermoelectric Solutions - 9 -

Medium Temperature TEG Transient Model Validation

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pow

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time (s)

Medium Temperature TEG Transient Test(changing electrical load, Test 11)

measured

simulated

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pow

er (W

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time (s)

Medium Temperature TEG Transient Test(changing hot and cold temperatures and flows)

measured

simulated

October 5, 2011

Page 10

BMW THERMOELECTRIC WASTE HEAT RECOVERY. KEY ASPECTS OF THE SYSTEM INTEGRATION.

Vehicle Power Supply

Exhaust System Cooling System

Package

Page 11

BMW THERMOELECTRIC WASTE HEAT RECOVERY. BMW X6 PROTOTYPE VEHICLE.

Fully integrated in vehicle exhaust and cooling system.

Automated control strategy for auxiliary water pump and exhaust valve.

TEG visualization concept integrated into the central information display.

Research & Advanced Engineering

Test Platform: Lincoln MKT AWD 3.5L V6 GTDI Engine

October 5, 2011 12

Research & Advanced Engineering

TEG & Exhaust System Packaging

Electrical Connections

Underfloor Catalyst

Flex Couplings

Electric Pump

TEG

Coolant Lines

October 5, 2011 13

Research & Advanced Engineering

65mph Freeway Cruise

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TEG

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Exh. Temp. into TEG

Vehicle Speed

Bypass Opened Bypass Closed

October 5, 2011 14

Research & Advanced Engineering

Lincoln MKT, 3.5L GTDI City Driving

October 5, 2011 15

Advanced Thermoelectric Solutions - 16 -

A cylindrical TEG incorporating segmented TE engines and coaxial gas bypass has been modeled, designed, built and tested at Amerigon.

• The TEG is compatible with inlet gas in the 6000C range with thermoelectric material surface temperatures in the 5000C range.

• Peak power produced in bench testing at Amerigon was over 700 watts. Power produced during vehicle operation will be lower as the cold side circuit will be hotter than in bench testing.

Vehicle level TEG system evaluations are underway at BMW and Ford.

The DOE sponsored Amerigon TEG program has formally concluded. Final results will be reported in November this year.

Amerigon, BMW, Ford and Faurecia will continue in a new program funded by the DOE to make implementation ready TE materials and engines over a four year program period.

October 5, 2011

Advanced Thermoelectric Solutions - 17 - October 5,

2011

John Fairbanks, US DOE Office of Vehicle Technologies

Carl Maronde, DOE NETL

Robin Willats and Rita Fehle, Faurecia

Boris Mazar, the BMW Group

Clay Maranville, Ford Motor Company Amerigon’s Team