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Waste Heat Recovery Using Thermoelectric Generators

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A special issue of Energies (ISSN 1996-1073). This special issue belongs to the section "B: Energy and Environment".

Deadline for manuscript submissions: closed (30 April 2022) | Viewed by 18990

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Special Issue Editor

Prof. Dr. Francisco P. Brito

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Guest Editor

Mechanical Engineering and Resource Sustainability Center (MEtRICs), University of Minho, School of Engineering, Campus Azurem, 4800-058 Guimaraes, Portugal
Interests: energy efficiency; internal combustion engines; thermoelectric generation; heat pipes; thermosiphons; heat exchangers; electronics cooling; energy assessment; alternative fuels, waste-to-energy; electric mobility technologies; hydrodynamic journal bearings

Special Issue Information

Dear Colleagues,

The extensive research and the recent advances in affordable, performing thermoelectric (TE) materials is increasing the attractiveness of thermoelectric generators (TEGs) for the recovery of the large amounts of heat wasted in areas such as transportation, buildings, and industrial processes. After decades of research, TEGs might soon become a solution not just for important niche markets such as space exploration and remote autonomous applications but also for extensive adoption as an increasingly affordable solution for small- to large-scale WHR applications. Cutting down primary energy usage in transportation, industry, and buildings and harvesting thermal energy from waste or renewable thermal sources is an endeavor that is especially valuable in a time where sustainability and energy efficiency have become one of the main drives of R&D in academia and the industry.

The present Special Issue aims to highlight recent research done in the area of waste heat recovery (WHR) and renewable energy harvesting using thermoelectric generators (TEGs).

As you are a recognized expert in the area, we invite you to contribute to this Special Issue with a research or review article. Topics include but are not limited to:

Analysis, development, manufacturing, and testing of TEG WHR in conventional/hybrid light, medium, and heavy-duty land, naval, aerospace vehicles, engines, power generation using the exhaust, cooling circuit, radiating heat; in industrial processes; in commercial and domestic buildings; in domestic appliances, infrastructure and renewable energy technologies, solar, geothermal;
TEG heat exchangers, exhaust heat exchangers, coolers, high-performance heat exchangers including phase change processes, micro-finned coolers, thermal management, and thermal control in WHR TEGs;
Power electronics of WHR TEGs, TE energy harvesting for autonomous devices;
Energy, thermo-economic, life cycle analysis of WHR TEGs, improvement of engine, vehicle, device efficiency;
Assessment of materials, interfaces, bondings, coatings, reliability, manufacturing and assembly processes of TEG systems, modules, and components for WHR (preferably, not limited to materials research);
Heat transfer, fluid dynamics, electrical, solid mechanics, multiphysics analysis, and optimization of TEGs and WHR systems.

Prof. Dr. Francisco Brito
Guest Editor

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Keywords

Thermoelectric generators
Waste heat recovery
Engine exhaust heat recovery
Internal combustion engine efficiency
Automotive thermoelectric generator
Industrial process heat recovery
Renewable energy harvesting
Heat exchangers for thermoelectric generators
Electronics cooling
Heat sinks
Heat pipes
Thermosiphons
Heat transfer in thermoelectrics
CFD in thermoelectrics
Multiphysics analysis in thermoelectrics
Mechanical behavior of thermoelectric generators
Thermal management and control
Thermoelectric materials
Thermo-economic analysis
Life cycle analysis of thermoelectrics
Solar thermoelectric generator
Hybrid solar thermoelectric generator
Combined heat and power
Thermoelectric modules
Thermoelectric module design
Thermoelectric module manufacture
Thermoelectric module testing
MPPT
Energy efficiency
Energy conversion
Radioisotope TEG

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Published Papers (7 papers)

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Research

19 pages, 3030 KiB

Open AccessArticle

Assessment of an Exhaust Thermoelectric Generator Incorporating Thermal Control Applied to a Heavy Duty Vehicle

by Carolina Clasen Sousa, Jorge Martins, Óscar Carvalho, Miguel Coelho, Ana Sofia Moita and Francisco P. Brito

Energies 2022, 15(13), 4787; https://doi.org/10.3390/en15134787 - 29 Jun 2022

Cited by 4 | Viewed by 2211

Abstract

The road transport industry faces the need to develop its fleet for lower energy consumption, pollutants and CO₂ emissions. Waste heat recovery systems with Thermoelectric Generators (TEGs) can directly convert the exhaust heat into electric energy, aiding the electrical needs of the vehicle, thus reducing its dependency on fuel energy. The present work assesses the optimisation and evaluation of a temperature-controlled thermoelectric generator (TCTG) concept to be used in a commercial heavy-duty vehicle (HDV). The system consists of a heat exchanger with wavy fins (WFs) embedded in an aluminium matrix along with vapour chambers (VCs), machined directly into the matrix, that grant the thermal control based on the spreading of local excess heat by phase change, as proposed by the authors in previous publications and patents. The TCTG concept behaviour was analysed under realistic driving conditions. An HDV with a 16 L Diesel engine was simulated in AVL Cruise to obtain the exhaust gas temperature and mass flow rate for each point of two cycle runs. A model proposed in previous publications was adapted to the new fin geometry and vapour chamber configuration and used the AVL Cruise data as input. It was possible to predict the thermal and thermoelectric performance of the TCTG along the corresponding driving cycles. The developed system proved to have a good capacity for applications with highly variable thermal loads since it was able to uncouple the maximisation of heat absorption from the regulation of the thermal level at the hot face of the TEG modules, avoiding both thermal dilution and overheating. This was achieved by the controlled phase change temperature of the heat spreader, that would ensure the spreading of the excess heat from overheated to underheated areas of the generator instead of wasting excess heat. A maximum average electrical production of 2.4 kW was predicted, which resulted in fuel savings of about 2% and CO₂ emissions reduction of around 37 g/km. Full article

(This article belongs to the Special Issue Waste Heat Recovery Using Thermoelectric Generators)

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16 pages, 4297 KiB

Open AccessArticle

Design of a Thermoelectric Device for Power Generation through Waste Heat Recovery from Marine Internal Combustion Engines

by Georgios Konstantinou, Theodora Kyratsi and Loucas S. Louca

Energies 2022, 15(11), 4075; https://doi.org/10.3390/en15114075 - 1 Jun 2022

Cited by 5 | Viewed by 2567

Abstract

Modern ships discharge large amounts of energy into the environment. More specifically, internal combustion engines (ICE) of commercial and passenger ships waste significant amounts of thermal energy at high temperature through their exhaust gases that are discharged to the atmosphere. A practical approach of recovering some amount of this energy is by using thermoelectric generator systems, which can convert thermal into electrical energy, given that there is a significant temperature difference. It is the aim of this work to propose a thermoelectric generator to recover energy from the exhaust gases of marine ICEs. The proposed thermoelectric generator uses the outside surface of the ICE manifold as the hot side of the thermoelectric module, while the cold side is maintained at a low temperature through a heat sink and induced water flow. The goal of this work is to design this thermoelectric generator and identify the configuration that produces the maximum electric power. The analysis and design are performed with the use of modeling and simulation, while commercial software is employed to study the 3-dimensional coupled fluid flow and heat transfer at a steady state. A sensitivity analysis is carried out to identify the parameters with the highest influence on power production. In addition to a full factorial sensitivity analysis, the more efficient Latin hypercube sampling is used. The analysis shows that significant energy of the exhaust gases can be converted into electric power with the use of an optimized heatsink, which creates the highest temperature difference between the two sides of the thermoelectric module. Full article

(This article belongs to the Special Issue Waste Heat Recovery Using Thermoelectric Generators)

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16 pages, 7414 KiB

Open AccessEditor’s ChoiceArticle

3 kW Thermoelectric Generator for Natural Gas-Powered Heavy-Duty Vehicles—Holistic Development, Optimization and Validation

by Lars Heber, Julian Schwab and Timo Knobelspies

Energies 2022, 15(1), 15; https://doi.org/10.3390/en15010015 - 21 Dec 2021

Cited by 11 | Viewed by 3397

Abstract

Emissions from heavy-duty vehicles need to be reduced to decrease their impact on the climate and to meet future regulatory requirements. The use of a cost-optimized thermoelectric generator based on total cost of ownership is proposed for this vehicle class with natural gas engines. A holistic model environment is presented that includes all vehicle interactions. Simultaneous optimization of the heat exchanger and thermoelectric modules is required to enable high system efficiency. A generator design combining high electrical power (peak power of about 3000 W) with low negative effects was selected as a result. Numerical CFD and segmented high-temperature thermoelectric modules are used. For the first time, the possibility of an economical use of the system in the amortization period of significantly less than 2 years is available, with a fuel reduction in a conventional vehicle topology of already up to 2.8%. A significant improvement in technology maturity was achieved, and the power density of the system was significantly improved to 298 W/kg and 568 W/dm³ compared to the state of the art. A functional model successfully validated the simulation results with an average deviation of less than 6%. An electrical output power of up to 2700 W was measured. Full article

(This article belongs to the Special Issue Waste Heat Recovery Using Thermoelectric Generators)

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17 pages, 3855 KiB

Open AccessArticle

Performance Assessment of Using Thermoelectric Generators for Waste Heat Recovery from Vapor Compression Refrigeration Systems

by Alaa Attar, Mohamed Rady, Abdullah Abuhabaya, Faisal Albatati, Abdelkarim Hegab and Eydhah Almatrafi

Energies 2021, 14(23), 8192; https://doi.org/10.3390/en14238192 - 6 Dec 2021

Cited by 5 | Viewed by 2847

Abstract

This article reports on an experimental analysis and performance assessment of using thermoelectric generators (TEGs) for waste heat recovery from residential vapor compression refrigeration systems. The analysis shows that there is a good opportunity for waste heat recovery using TEGs by de-superheating refrigerant after the compressor. Design and manufacturing of a de-superheater unit consisting of a tube and plate heat exchanger and thermoelectric generator modules (HE-TEGs) have been performed and integrated in an experimental test rig of R134a refrigeration cycle. Experimental assessment of the performance parameters, as compared to the basic refrigeration system, reveals that the overall coefficient of performance (COP) using HE-TEGs desuperheater unit increases by values ranging from 17% to 32% depending on the condenser and evaporator loads. Exergy analysis shows that the enhancement is attributed to reduction in the exergy destruction in the condenser and compressor due to lower values of condenser pressure and pressure ratio of the compressor. The output power of the HE-TEGs unit is found to be sufficient for driving the TEGs heat sinks air cooling fan, thus providing a passive de-superheating system without an additional external source of electricity. Further enhancement of the refrigeration cycle performance can be achieved by installation of additional HE-TEGs units. Full article

(This article belongs to the Special Issue Waste Heat Recovery Using Thermoelectric Generators)

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16 pages, 3664 KiB

Open AccessArticle

Heat Flux Based Optimization of Combined Heat and Power Thermoelectric Heat Exchanger

by Kazuaki Yazawa and Ali Shakouri

Energies 2021, 14(22), 7791; https://doi.org/10.3390/en14227791 - 21 Nov 2021

Cited by 1 | Viewed by 1508

Abstract

We analyzed the potential of thermoelectrics for electricity generation in a combined heat and power (CHP) waste heat recovery system. The state-of-the-art organic Rankine cycle CHP system provides hot water and space heating while electricity is also generated with an efficiency of up to 12% at the MW scale. Thermoelectrics, in contrast, will serve smaller and distributed systems. Considering the limited heat flux from the waste heat source, we investigated a counterflow heat exchanger with an integrated thermoelectric module for maximum power, high efficiency, or low cost. Irreversible thermal resistances connected to the thermoelectric legs determine the energy conversion performance. The exit temperatures of fluids through the heat exchanger are important for the system efficiency to match the applications. Based on the analytic model for the thermoelectric integrated subsystem, the design for maximum power output with a given heat flux requires thermoelectric legs 40–70% longer than the case of fixed temperature reservoir boundary conditions. With existing thermoelectric materials, 300–400 W/m² electrical energy can be generated at a material cost of $3–4 per watt. The prospects of improvements in thermoelectric materials were also studied. While the combined system efficiency is nearly 100%, the balance between the hot and cold flow rates needs to be adjusted for the heat recovery applications. Full article

(This article belongs to the Special Issue Waste Heat Recovery Using Thermoelectric Generators)

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19 pages, 4243 KiB

Open AccessArticle

Thermoelectric Generator with Passive Biphasic Thermosyphon Heat Exchanger for Waste Heat Recovery: Design and Experimentation

by Miguel Araiz, Álvaro Casi, Leyre Catalán, Patricia Aranguren and David Astrain

Energies 2021, 14(18), 5815; https://doi.org/10.3390/en14185815 - 14 Sep 2021

Cited by 4 | Viewed by 2435

Abstract

One of the measures to fight against the current energy situation and reduce the energy consumption at an industrial process is to recover waste heat and transform it into electric power. Thermoelectric generators can be used for that purpose but there is a lack of experimental studies that can bring this technology closer to reality. This work presents the design, optimizations and development of two devices that are experimented and compared under the same working conditions. The hot side heat exchanger of both generators has been designed using a computational fluid dynamics software and for the cold side of the generators two technologies have been analysed: a finned dissipater that uses a fan and free convection biphasic thermosyphon. The results obtained show a maximum net generation of

6.9

W

in the thermoelectric generator with the finned dissipater; and

10.6

W

of power output in the generator with the biphasic thermosyphon. These results remark the importance of a proper design of the heat exchangers, trying to get low thermal resistances at both sides of the thermoelectric modules, as well as, the necessity of considering the auxiliary consumption of the equipment employed. Full article

(This article belongs to the Special Issue Waste Heat Recovery Using Thermoelectric Generators)

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21 pages, 71784 KiB

Open AccessArticle

Analysis and Design of a Silicide-Tetrahedrite Thermoelectric Generator Concept Suitable for Large-Scale Industrial Waste Heat Recovery

by F. P. Brito, João Silva Peixoto, Jorge Martins, António P. Gonçalves, Loucas Louca, Nikolaos Vlachos and Theodora Kyratsi

Energies 2021, 14(18), 5655; https://doi.org/10.3390/en14185655 - 8 Sep 2021

Cited by 8 | Viewed by 2181

Abstract

Industrial Waste Heat Recovery (IWHR) is one of the areas with strong potential for energy efficiency and emissions reductions in industry. Thermoelectric (TE) generators (TEGs) are among the few technologies that are intrinsically modular and can convert heat directly into electricity without moving parts, so they are nearly maintenance-free and can work unattended for long periods of time. However, most existing TEGs are only suitable for small-scale niche applications because they typically display a cost per unit power and a conversion efficiency that is not competitive with competing technologies, and they also tend to rely on rare and/or toxic materials. Moreover, their geometric configuration, manufacturing methods and heat exchangers are often not suitable for large-scale applications. The present analysis aims to tackle several of these challenges. A module incorporating constructive solutions suitable for upscaling, namely, using larger than usual TE elements (up to 24 mm in diameter) made from affordable p-tetrahedrite and n-magnesium silicide materials, was assessed with a multiphysics tool for conditions typical of IWHR. Geometric configurations optimized for efficiency, power per pair and power density, as well as an efficiency/power balanced solution, were extracted from these simulations. A balanced solution provided 0.62 kWe/m² with a 3.9% efficiency. Good prospects for large-scale IWHR with TEGs are anticipated if these figures could be replicated in a real-world application and implemented with constructive solutions suitable for large-scale systems. Full article

(This article belongs to the Special Issue Waste Heat Recovery Using Thermoelectric Generators)

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