Browsing by Subject "Waste heat recovery"

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Analysis of a novel thermoelectric generator in the built environment
(2011-08) Lozano, Adolfo; Webber, Michael E., 1971-; Schmidt, Philip S.
This study centered on a novel thermoelectric generator (TEG) integrated into the built environment. Designed by Watts Thermoelectric LLC, the TEG is essentially a novel assembly of thermoelectric modules whose required temperature differential is supplied by hot and cold streams of water flowing through the TEG. Per its recommended operating conditions, the TEG nominally generates 83 Watts of electrical power. In its default configuration in the built environment, solar-thermal energy serves as the TEG’s hot stream source and geothermal energy serves as its cold stream source. Two systems-level, thermodynamic analyses were performed, which were based on the TEG’s upcoming characterization testing, scheduled to occur later in 2011 in Detroit, Michigan. The first analysis considered the TEG coupled with a solar collector system. A numerical model of the coupled system was constructed in order to estimate the system’s annual energetic performance. It was determined numerically that over the course of a sample year, the solar collector system could deliver 39.73 megawatt-hours (MWh) of thermal energy to the TEG. The TEG converted that thermal energy into a net of 266.5 kilowatt-hours of electricity in that year. The second analysis focused on the TEG itself during operation with the purpose of providing a preliminary thermodynamic characterization of the TEG. Using experimental data, this analysis found the TEG’s operating efficiency to be 1.72%. Next, the annual emissions that would be avoided by implementing the zero-emission TEG were considered. The emission factor of Michigan’s electric grid, RFCM, was calculated to be 0.830 tons of carbon dioxide-equivalent (CO2e) per MWh, and with the TEG’s annual energy output, it was concluded that 0.221 tons CO2e would be avoided each year with the TEG. It is important to note that the TEG can be linearly scaled up by including additional modules. Thus, these benefits can be multiplied through the incorporation of more TEG units. Finally, the levelized cost of electricity (LCOE) of the TEG integrated into the built environment with the solar-thermal hot source and passive ground-based cold source was considered. The LCOE of the system was estimated to be approximately $8,404/MWh, which is substantially greater than current generation technologies. Note that this calculation was based on one particular configuration with a particular and narrow set of assumptions, and is not intended to be a general conclusion about TEG systems overall. It was concluded that while solar-thermal energy systems can sustain the TEG, they are capital-intensive and therefore not economically suitable for the TEG given the assumptions of this analysis. In the end, because of the large costs associated with the solar-thermal system, waste heat recovery is proposed as a potentially more cost-effective provider of the TEG’s hot stream source.
Heat waste recovery system from exhaust gas of diesel engine to a reciprocal steam engine
(2011-08) Duong, Tai Anh; Matthews, Ronald D.; Hall, Matthew J.
This research project was about the combined organic Rankine cycle which extracted energy from the exhaust gas of a diesel engine. There was a study about significant properties of suitable working fluids. The chosen working fluid, R134a, was used to operate at the dry condition when it exited the steam piston engine. Furthermore, R134a is environmentally friendly with low environmental impact. It was also compatible with sealing materials. There were calibrations for the components of the combined Rankine cycle. The efficiency of the heat exchanger converting exhaust heat from the diesel engine to vaporize R134a was 89%. The average efficiency of the generator was 50%. The hydraulic pump used for the combined Rankine cycle showed a transporting problem, as vapor-lock occurred when the pump ran for about 1 minute. The output of the combined Rankine cycle was normalized to compensate for the parasitic losses of a virtual vane pump used in hydraulic systems for the 6 liter diesel engines. There were three different vane pump widths from different pumps to compare frictional loss. The pump with the smallest vane width presented the least frictional mean effective pressure (fmep) (0.26 kPa) when scaled with the displacement of the GMC Sierra 6 liter diesel engine. The power output of the Rankine cycle was scaled to brake mean effective pressure (bmep) to compare with the frictional mean effective pressure. The maximum bmep was at 0.071 kPa when diesel engine had rotational speed at 2190 RPM. The power outputs of the organic Rankine compensated partially the frictional loss of the vane pumps in the 6 liter diesel engine. By using R134a, the condensing pressure was 0.8 MPa; hence, the power outputs from steam engine were limited. Therefore, refrigerants with lower condensing pressure were needed. There were proposal for improvement of the organic Rankine by substituting R134a by R123 (0.1 MPa), R21 (0.2 MPa), and R114 (0.25 MPa) .
Modeling and measurements of thermoelectric waste heat recovery devices for motor vehicles
(2013-12) Fateh, Haiyan Z.; Hall, M. J. (Matthew John)
This study is centered on modeling and experimental efforts to simulate and optimize the performance of thermoelectric generators (TEGs) for waste heat recovery systems for use in motor vehicles. TEGs are being studied and developed for applications in which waste heat, for example, from the exhaust of motor vehicles is converted into usable electricity. TEGs consisting of TE elements integrated with an exhaust heat exchanger require optimization to produce the maximum possible power output. Important optimization parameters include TE element leg length, fill fraction, leg area ratio between n- and p-type legs, and load resistance. A finite difference model was developed to study the interdependencies among these optimization parameters for thermoelectric elements integrated with an exhaust gas heat exchanger. The present study was carried out for TE devices made from n-type Mg₂Si and p-type MnSi[subscript 1.8] based silicides, which are promising TE materials for use at high temperatures associated with some exhaust heat recovery systems. The model uses specified convection boundary conditions instead of specified temperature boundary conditions to duplicate realistic operating conditions for a waste heat recovery system installed in the exhaust of a vehicle. A numerical model for a new waste heat recovery system configuration was proposed which showed an improvement of 40% in net power output over the conventional systems while using approximately 60% more TEG modules. The 1st generation, and an improved 2nd generation TEG module using n-type Mg₂Si and p-type MnSi[subscritp 1.8] based silicides were fabricated and tested to compare and correlate TE power generation with the numerical model. Important results include parameter values for maximum power output per unit area and the interdependencies among those parameters. Heat transfer through the void areas was neglected in the numerical model. When thermal contact resistance between the TE element and the heat exchangers is considered negligible, the numerical model predicts that any volume of TE material can produce the same power per unit area, given the parameters are accurately optimized. Incorporating the thermal contact resistance, the numerical model predicts that the peak power output is greater for longer TE elements with larger leg areas. The optimization results present strategies to improve the performance of TEG modules used for waste heat recovery systems.
Simulation, design, and experimental characterization of catalytic and thermoelectric systems for removing emissions and recovering waste energy from engine exhaust
(2012-12) Baker, Chad Allan; Shi, Li, Ph. D.; Hall, M. J. (Matthew John); Matthews, Ronald D.; Ezekoye, Ofodike A.; Raja, Laxminarayan L.
An analytical transport/reaction model was developed to simulate the catalytic performance of ZnO nanowires as a catalyst support. ZnO nanowires were chosen because they have easily characterized, controllable features and a spatially uniform morphology. The analytical model couples convection in the catalyst flow channel with reaction and diffusion in the porous substrate material; it was developed to show that a simple analytical model with physics-based mass transport and empirical kinetics can be used to capture the essential physics involved in catalytic conversion of hydrocarbons. The model was effective at predicting species conversion efficiency over a range of temperature and flow rate. The model clarifies the relationship between advection, bulk diffusion, pore diffusion, and kinetics. The model was used to optimize the geometry of the experimental catalyst for which it predicted that maximum species conversion density for fixed catalyst surface occurred at a channel height of 520 [mu]m. A modeling study of thermoelectric (TE) vehicle waste heat recovery was conducted based on abundant and inexpensive Mg₂ Si[subscript 0.5] Sn[subscript 0.5] and MnSi[subscript 1.75] TE materials with consideration of performance at the system and TE device levels. The modeling study identified a critical TE design space of fill fraction, leg length, n-/p-type leg area ratio, and current; these parameters needed to be optimized simultaneously for positive TE power output. The TE power output was sensitive to this design space, and the optimal design point was sensitive to engine operating conditions. The maximum net TE power for a 29.5 L strip fin heat exchanger with an 800 K exhaust flow at 7.9 kg/min was 2.25 kW. This work also includes two generations of TE waste heat recovery systems that were built and tested in the exhaust system of a Cummins 6.7 L turbo Diesel engine. The first generation was a small scale heat exchanger intended for concept validation, and the second generation was a full scale heat exchanger that used the entire exhaust flow at high speed and torque. The second generation heat exchanger showed that the model could accurately predict heat transfer, and the maximum experimental heat transfer rate was 15.3 kW for exhaust flow at 7.0 kg/min and 740 K.