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The Growth Potential of Thermoelectrics John W. Fairbanks Department of Energy Washington, DC Thermoelectric Applications Workshop Del Coronado Hotel San Diego, California September 29, 2009 Vehicle Technologies Program

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Page 1: The Growth Potential of Thermoelectrics...Thermoelectric Air Conditioner/Heaters (HVAC) Scheduled for ... In Bangladesh, at just over 3. feet of rise, 70. million people . could be

Program Name or Ancillary Text eere.energy.gov

The Growth Potential of Thermoelectrics

John W. FairbanksDepartment of Energy

Washington, DC

Thermoelectric Applications WorkshopDel Coronado HotelSan Diego, CaliforniaSeptember 29, 2009

Vehicle Technologies Program

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Vehicle Technologies Program eere.energy.gov

Workshop Overview

Thermoelectric Material Efficiency is being Improved

Thermoelectric Technology and Applications are in Accelerated Development World-Wide

Every Major Automotive Vehicle OEM is investigating Thermoelectric Applications

Thermoelectric Generators will be Commercially Introduced in Autos in a Limited Number as early as 2013

Thermoelectric Air Conditioner/Heaters (HVAC) Scheduled for Commercial Introduction on or about 2015 in Autos

Historically Semiconductor Costs Come Down with Large Increased Volume

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Vehicle Technologies Program eere.energy.gov

Opportunities for Thermoelectrics

Increased Availability and Lower Costs of High Efficiency Thermoelectric Modules Should Stimulate Opportunities for Thermoelectric Direct Conversion of Waste Heat to Electricity for:

Industrial Processes,

Stationary Power Plants,

Marine, Rail and Aircraft

Off-Highway Engines,

Geothermal

Wide Range of Military Applications

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Vehicle Technologies Program eere.energy.gov

Petroleum Market Forecast

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Vehicle Technologies Program eere.energy.gov

Opportunities for Thermoelectrics

Massive Quantity of “Waste”

Energy

97% Oil Dependent

Imported Oil

“Waste Heat”

Can Be Directly Converted to Electricity

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Vehicle Technologies Program eere.energy.gov

International Perspective

The World uses 83,700,000 barrels of non- renewable

petroleum daily

When does demand for petroleum exceed supply ?

Transportation is going more electric

Thermoelectrics can have a significant role

o

Also in other waste heat producing technologies

Page 7: The Growth Potential of Thermoelectrics...Thermoelectric Air Conditioner/Heaters (HVAC) Scheduled for ... In Bangladesh, at just over 3. feet of rise, 70. million people . could be

Vehicle Technologies Program eere.energy.gov

Modular HVACVariable speed compressor more efficient and serviceable3X more reliable compressor no belts,

no valves, no hoses leak-proof refrigerant lines instant electric heat

StarterGenerator

MotorBeltless engine

product differentiation improve systems design flexibility more efficient & reliable accessories

Shore Powerand InverterSupplies DC Bus Voltage from 120/240 Vac 50/60 Hz Input Supplies 120 Vac outlets from battery or generator power

Down ConverterSupplies 12 V Battery from DC Bus

AuxiliaryPower Unit

Supplies DC Bus Voltage when engine is not

running - fulfills hotel loads without idling main engine

overnight

Compressed Air ModuleSupplies compressed air for brakes and ride control

Electric WaterPump

Electric Oil PumpVariable speed

Higher efficiency

Truck Electrification

Electrify accessories

decouple them from engine

Match power demand to real time need

Enable use of alternative power sources

Beltless or More Electric Engine

Higher reliability variable speedfaster warm-up less white smoke

lower cold weather emissions

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Vehicle Technologies Program eere.energy.gov

Heating Up… Melting Down…

NATIONAL GEOGRAPHIC CHANNEL’S MOST AMAZING DISCOVERIES, SEPT. 6-10 AT 9 P.M. ET/PT

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Vehicle Technologies Program eere.energy.gov

Carbon Balance Through Internal Combustion Engine

Carbon

PM

HC

Unburned

Fuel, Lube Oil

CO

CO2

Gasoline C7

H16

Diesel C18

H30

Methanol CH3

OH

Ethanol C2

H5

OH

Natural Gas (Primarily Methane, CH4

)

Propane C3

H8

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Vehicle Technologies Program eere.energy.gov

0

1

2

3

. . . . . .

2000 2020 2040 2060 2080 2100

feet

1

0

2

3

Best-case ScenarioCO2

at478 ppm

Worst-case ScenarioCO2

at971 ppm

In Bangladesh,at just over 3feet of rise, 70million people could be dis-placed.

75 percentof coastal Loui-siana wetlandswould be de-stroyed at justover 1.5 feet.

Many low-Lying South Sea islands areat further riskof flooding at about 4 inches.

Rise Above 1900 sea level (global average)

Source: National Geographic, September 2004

Sea Level Rising

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Vehicle Technologies Program eere.energy.gov

Global Warming

Worst Case Scenario

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Vehicle Technologies Program eere.energy.gov

Available Energy in Auto Engine Exhaust

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Vehicle Technologies Program eere.energy.gov

Com

bust

ion 30%

Engine

Vehicle Operation10

0%

40% Exhaust

Gas

30%Coolant

5% Friction & Radiated

25Mobility &

AccessoriesGas

olin

e

Gas

olin

ega

solin

e

Potential Thermoelectric Heat Sources

Spark Assisted Gasoline internal Combustion Engine (Light Truck or Passenger Vehicle)

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Vehicle Technologies Program eere.energy.gov

Organic Rankine Bottoming Cycle for Heavy-Duty Diesel Engine Waste Heat Recovery (Cummins Engine Co.)

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Vehicle Technologies Program eere.energy.gov

Power Turbine

Transmission

Turbocharger

Compressor

Motor/Generator (+Power Conversion)

Turbine

Mechanical System Electrical System

ETC system has been designed and analyzed

5% -

10% fuel economy improvement potential

Opportunity for reduced emissions and improved driveability

Turbocompounding

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Vehicle Technologies Program eere.energy.gov

ETC: Prototype Design

Turbine

Bearing Housing

Water Cooling

Compressor

Rotor/ Stator

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Vehicle Technologies Program eere.energy.gov

Turbo-Compound System for Engine Waste Heat Recovery

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Vehicle Technologies Program eere.energy.gov

Thermoelectric Generator and HVAC

Page 19: The Growth Potential of Thermoelectrics...Thermoelectric Air Conditioner/Heaters (HVAC) Scheduled for ... In Bangladesh, at just over 3. feet of rise, 70. million people . could be

Vehicle Technologies Program eere.energy.gov

U.S. Spacecraft Using Radioisotope Thermoelectric Power Generators

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Vehicle Technologies Program eere.energy.gov

TE Power Generation from Engine Waste Heat (Clemson)

Heat RejectionWaste Heat > 60%

Waste Heat RecoveryGoal > 10% Increase in fuel economy

Carnot Efficiency

C TH TC

TH

TH TC

TH

1ZT 1

1ZT TCTH

TE EfficiencyExhaust ≈

500˚C

TH

500˚C

TC ≈

110˚C

TE Devices

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Vehicle Technologies Program eere.energy.gov

Installed Thermoelectric Generator on Heavy Duty Truck

Front View Rear View

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Vehicle Technologies Program eere.energy.gov

First Vehicle with Thermoelectric Generator

Engine –

Caterpillar 3406E, 550 HP Diesel Engine Heavy Duty TruckPACCAR’s 50 to 1 test track

Standard test protocols used each evaluationHeavy loaded (over 75,000 lbs)

Hi-Z Technology’s Nominal 1 kW Bi2

Te3

TEG installed in exhaust gas path after turbocharger and emissions reduction system

Survived equivalence of 550,000 highway miles

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Vehicle Technologies Program eere.energy.gov

DOE Vehicular Thermoelectric Generator Projects Competitive Award Selections

(March 2004 RFP)

Awardees Additional Team Members

General Motor Corporation and General Electric

University of Michigan, University of South Florida, Oak Ridge National

Laboratory, RTI International, Marlow Industries

BSST, LLC. Visteon, BMW-NA, Ford, ZT Plus

Michigan State University NASA Jet Propulsion Laboratory,

Cummins Engine Company, Tellurex, Iowa State

High Efficiency Thermoelectrics

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Vehicle Technologies Program eere.energy.gov

1017 1018 1019 1020 1021

Carrier Concentration

Tota

l ZT

insu

lato

r

met

al

semiconductor

Unusual Combinationof Properties

TE materials performance: Figure of Merit (ZT)

2

ZT e

L

) T

Seebeck coefficientor thermopower

(V/T)

Electrical conductivity

Total thermal conductivity

ZTmax

L

e

Power Factor

electrical conductivity

electrical resistivity

[courtesy of Oregon State]

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Nanoscale Effects for Thermoelectrics

Phonons=10-100 nm

=1 nm

Electrons=10-100 nm=10-50 nm

Electron Phonon

Interfaces that Scatter Phonons but not Electrons

Mean Free Path Wavelength

[Courtesy of Millie Dresselhaus, MIT]

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Crystal Structure of Skutterudites

Cobalt atoms form a fcc

cubic latticeAntimony atoms are arranged as square planar ringsThere are 8 spaces for the Sb4 units6 are filled and 2 are empty

CoSb3 [Co8

(Sb4

)6

]

Rx

CoSb3

Atoms can be inserted into Atoms can be inserted into empty sites. Atoms can empty sites. Atoms can ““rattlerattle””

in these sites in these sites ––

scatter phonons scatter phonons and lower the lattice thermal and lower the lattice thermal conductivity. conductivity.

[Courtesy of Oregon State]

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R: La, Ce, Nd, Er, Yb,Rattlers

Mn, Fe, Ni, Cu, Pd, Pt, Rh, RuCo

High Temperature TE based on Skutterudites: In0.15

R0.10

Co4

Sb12

Rx

Co4

Sb12

Page 28: The Growth Potential of Thermoelectrics...Thermoelectric Air Conditioner/Heaters (HVAC) Scheduled for ... In Bangladesh, at just over 3. feet of rise, 70. million people . could be

Vehicle Technologies Program eere.energy.gov

TEG Candidate Materials –

2005

Exhaust gas temperature of an internal combustion engine

Page 29: The Growth Potential of Thermoelectrics...Thermoelectric Air Conditioner/Heaters (HVAC) Scheduled for ... In Bangladesh, at just over 3. feet of rise, 70. million people . could be

Vehicle Technologies Program eere.energy.gov

Zone 1Zone 2

Zone 3

Thermoelectric Modules Optimized for Thermal Zones

Page 30: The Growth Potential of Thermoelectrics...Thermoelectric Air Conditioner/Heaters (HVAC) Scheduled for ... In Bangladesh, at just over 3. feet of rise, 70. million people . could be

Vehicle Technologies Program eere.energy.gov

T (K)200 400 600 800 1000 1200 1400

ZT

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

Bi2Te3

PbTe SiGe

Ba0.24Co4Sb12

Ba0.08Yb0.09Co4Sb12

Triple-filled

Yb0.12Co4Sb12

ZTave

= 1.2

• Ba0.08

La0.05

Yb0.04

Co4

Sb12.05 Ba0.10

La0.05

Yb0.07

Co4

Sb12.16

Highest ZT Achievedin Triple-filled Skutterudites

1.

X. Shi, et al. Appl. Phys. Lett. 92, 182101 (2008)2.

X. Shi, et al., submitted (2009)

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Prototype Modules

Page 32: The Growth Potential of Thermoelectrics...Thermoelectric Air Conditioner/Heaters (HVAC) Scheduled for ... In Bangladesh, at just over 3. feet of rise, 70. million people . could be

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Current TE Materials

P-type TE materialN-type TE material

Ref: http://www.its.caltech.edu/~jsnyder/thermoelectrics/

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BSST Y Segmented TE Configuration

Traditional configuration

BSST “Y”

configuration

heat

heat heat

p-TAGS

p-CeFe3RuSb12

p-Bi2Te3

current

n-CoSb3

n-PbTe

n-Bi2Te3current

heat

heat heat

p-TAGS

p-CeFe3RuSb12

p-Bi2Te3

p-TAGS

p-CeFe3RuSb12

p-Bi2Te3

current

n-CoSb3

n-PbTe

n-Bi2Te3

n-CoSb3

n-PbTe

n-Bi2Te3current

p-CeFe3RuSb12

heat

heat

heat

p-TAGS

p-Bi2Te3

n-CoSb3

n-PbTe

n-Bi2Te3

current

p-CeFe3RuSb12

heat

heat

heat

p-TAGS

p-Bi2Te3

n-CoSb3

n-PbTe

n-Bi2Te3

current

heatheat

heatheat

heatheat

p-TAGS

p-Bi2Te3

n-CoSb3

n-PbTe

n-Bi2Te3

current

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High Temperature 2nd-Stage

Segmented Element Subassembly

Gas heat exchanger interface

Cold heat exchanger interface

TE elementsSegmented

Segmented TE elements

Page 35: The Growth Potential of Thermoelectrics...Thermoelectric Air Conditioner/Heaters (HVAC) Scheduled for ... In Bangladesh, at just over 3. feet of rise, 70. million people . could be

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Segmented Couple TAGS/PbTe-Bi2

Te3

BiTe (0.6 mm)

PbTe (2mm)

TAGS (2mm)

BiTe (0.6 mm)

BSST Phase 3 Waste Heat Recovery Program Review

2 December, 2008

BSST Proprietary and Confidential

Page 36: The Growth Potential of Thermoelectrics...Thermoelectric Air Conditioner/Heaters (HVAC) Scheduled for ... In Bangladesh, at just over 3. feet of rise, 70. million people . could be

Vehicle Technologies Program eere.energy.gov

Exhaust Flow and Temperatures for a 4-

Cylinder Engine

0.00

0.01

0.02

0.03

0.04

0.05

0.06

0 500 1000 1500 2000 2500 3000

TIME (SEC)

EXH

AUST

GAS

FLO

W R

ATE

(kg/

s)

0

200

400

600

800

1000

1200

TEM

PE

RAT

UR

E (K

)

EXHAUST MASS FLOW

EXHAUST GAS TEMPERATURE

COOLANT TEMPERATURE

LD9 ENGINE -- EPA FTP CYCLE

There are tens of kW heat energy in the exhaust & coolant

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BMW’s Electric Water Pump Improves Fuel Economy 1.5 to 2.0 %

Page 38: The Growth Potential of Thermoelectrics...Thermoelectric Air Conditioner/Heaters (HVAC) Scheduled for ... In Bangladesh, at just over 3. feet of rise, 70. million people . could be

Vehicle Technologies Program eere.energy.gov

BMW Series 5 , Model Year 2011, 3.0 Liter Gasoline Engine w/ Thermoelectric Generator

Page 39: The Growth Potential of Thermoelectrics...Thermoelectric Air Conditioner/Heaters (HVAC) Scheduled for ... In Bangladesh, at just over 3. feet of rise, 70. million people . could be

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Computer Controlled Butterfly Valve to Optimize Vehicular TEG Performance

Exhaust gas enters a diffusor upstream from the multi-layer TEG

The number of TEG layers exposed to exhaust gas is proportional to total mass flow

An exhaust gas valve controls gas distribution to layers downstream from the TEG

Bypass section

Multilayer TEG

Exhaust inlet

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Vehicle Technologies Program eere.energy.gov

ZT

0.1

0.2

1

700

500

300

Temperature [°

C]

exhaust gas temperature

10

0.10

1.00

10.00

100.00

500 1000 1500 2000 2500 3000 3500 4000 4500

-

750

-

550

-

350

-

150

50

250

450

650

0.5

400

600

ZT (1000W)

ZT (500W)

Distance behind three way catalyst [mm]500 1000 1500 2000 2500 3000 3500 4000 45000

0

Vehicle 530iA at 130 km/h, Exhaust gas back pressure limited to 30mbar at 130km/h

Max hot side temperature of a module

TEG SI Engine Waste Heat Recovery. Need High ZT Material & By-pass (BMW)

Slide courtesy of BSST

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TEG is Ideally Compatible with Regenerative Braking (BMW)

BSST TEG (prognosis)

BMW TEG 2007

Slide courtesy of BSST

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TEG Demonstrator Installed on BMW Series 5 Test Vehicle

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TEG Installed in BMW Series 5 Sedan

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BSST/BMW TEG Test Instrumentation

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116i 530dA 750iA

190 W2%

330 W3,5%

390 W4%

750 W6%

1000 W8%

Ave

rage

dem

and

for e

lect

ric p

ower

Frac

tion

of e

lect

ricity

on

tota

l FC

.

NEDC customer NEDC customer NEDC customer

Thermoelectric Generator Performance BMW Sedans

Slide courtesy of BSST

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Ford’s Transient Modeling of a TEG for a HEV Application

2.5L Atkinson Engine in Ford Escape Hybrid Vehicle •

Major Design Constraints: TE Mass, Exhaust P, Response Time

TEG

Exhaust Mass flowTemperature

Coolant

To Muffler

BSST TGM Model

HEV EscapeSystem Model

Backpressure

Engine Model

Radiator Model

PumpModel

P, V, I

Fuel ConsumptionEngine

Load

Drive Cycle

Mass flowTemperature

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150 Watt TGM Integrated Buck/Boost Converter

The PCS produces a positive output voltage that is greater than, equal to or less than the input voltage in a single stage.Minimizes cost, size and weight while maximizing power conversion efficiency.Supports Maximum Power Point Tracking.

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Power Converter Efficiency

Converter Efficiency vs. Input Voltage at Maximum Achievable Power

0.820

0.840

0.860

0.880

0.900

0.920

0.940

0.960

0.980

24.03V,158W

21.81V,148W

19.70V,149W

18.00V,149W

15.91V,150W

13.95V,150W

11.98V,149W

10.00V,151W

7.95V,148W

6.00V,116W

4.00V,54W

3.01V,34W

Converter Input Voltage and Input Power

Effic

ienc

y

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Program Flow Chart

Exhaust:TH, TC, flow & fluidproperties

Radiator:TH, TC, flow & fluidproperties

Elec. Load:Effective R, Vreq,

GM’s Inputs GE’s System Model

Device config.• Structure / designHeat transfer• Hot & cold exchangers• InterfacesPower conditioning• DC/DC converter

Requirements:Cost, Power, Life

Outputcost

mass, P,power

% FE Savings

GM’s FE Tools

Materials Dev.•(T),(T),(T)•Cost & mass•Geom. req.

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GM Thermoelectric Generator Analytical Predicts from Early Tests

Average output ~ 350 W and max. output ~ 914 W for city cycle

Average output ~ 600 W for highway cycle

An additional ~ 5% fuel economy improvement is expected

Case 08

Power vs. Time - Urban drive cycle

0

200

400

600

800

1000

1200

0 500 1000 1500 2000 2500 3000

time [s]

Pow

er [W

]

Quasi-steady analysis - EES Transient analysis - ANSYS

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GM TE Generator on a Chevy Suburban

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TEG Installation in Chevy Suburban

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Climate Control Seat

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Automotive TE HVAC (Thermoelectric Heating, Ventilating, and Air Conditioning)

Competitive Awards to Ford and GM

Co-Funded with the California Energy Commission

Develop TE Zonal or Distributed Cooling/Heating System

Maintain Occupant Comfort without Cooling Entire Cabin

Reduce Energy used in Automotive HVAC’s by >50%

Eliminate all Toxic, Greenhouse and FlammableGases Associated with Automotive HVAC

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Vehicular TE HVAC

No substance release

Therefore no

ozone depletion, greenhouse gases, toxicity or flammability problems

No moving parts

other than fan and coolant recirculation pump

Minimal maintenance cost

Fuel Consumption

Zonal Concept cools/heats each occupant

independently; not whole cabin

630 Watts to cool single occupant; current A/C’s 3500 to 4500 watts cool entire cabin

Lighter weight

Large potential savings -

73 percent of personal vehicle miles driven with driver only

First Approximation –

Cost competitive

Semiconductor costs are significantly reduced with volume

Converts Air Conditioner to Heater by reversing DC polarity

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Greenhouse Gas Emissions from Vehicular Compressed Refrigerant Gas Air Conditioners

Current Vehicular Air Conditioner (A/C) uses Compressed R134-a Refrigerant Gas

--

Vehicles leak 110 g/year R134-a --

R134-a Has 1300 times the “Greenhouse Gas Effect”

as

Carbon Dioxide (CO2)--

That is 143 kg/year CO2 equivalent per vehicle/year or34 Million Metric Tons of CO2 equivalents/year from

personal vehicles in the US from operating air conditionersPlus additional 11Million Metric tons of CO2

equivalents/year released to atmosphere from vehicle accidents in the US

Total of 45 Million Metric Tons of CO2 equivalents/year from regular and irregular leakage

in the US enter the

atmosphere--

EU is proscribing use of R134-a

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Thermoelectric HVAC Advantages for Plug-in Hybrids and Electric Cars

Occupant Heating During Battery Propulsion(No Engine Heat)

Inefficient Resistance HeatingOccupant Cooling

Electric Compressor Refrigerant Gases> Need R134-a Replacement

Thermoelectric HVAC Zonal Concept> Cooling COP 1.5

Augment or Replace Compressed Gas Unit> Heating COP 2.5

Replace Resistive Heaters Typical COP 1.0

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Zonal or Disbursed HVAC System

Zonal TE devices located in the dashboard, headliner,A&B pillars and seats / seatbacks

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Zonal or Distributed Cooling with High Efficiency Vehicular TE HVAC (NREL)

• Reduce onboard AC without sacrifice passenger comfort level• Improve fuel economy and reduce CO2

emission

Loads Reduction Project.

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Vehicular TE HVAC

While TE HVAC is beneficial to all vehicles, it is especially advantageous for:•

Plug-in Hybrids,

Hybrids, •

Electric Cars,

Fuel Cell Powered Vehicles and •

Vehicles with Small, High-Efficiency, Low-

Temperature Exhaust Engineso

Inadequate heating first 20 something miles

o

Augment Occupant Comfort w/PCH Ceramic Resistive Heaters

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Vehicular Solid State Thermoelectric HVAC Development Program

Approach: Develop Zonal Thermoelectric based heating and cooling systems for cars, light trucks (SUV’s, Pick-ups, Mini vans) and Heavy Duty Trucks which provides :•

Reduced fuel consumption

Reduced Greenhouse Gases•

Reduced toxic emissions (NOx & Particulates)

Increased engine-off comfort •

Faster heating and cooling to comfort at start-up

Reduced maintenance costso

No moving parts

o

(Except for fans and heat transfer fluid circulating pump)

o

No refrigerant gas recharging

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Battery Temperature Impacts HEV/EV Performance

Temperature affects battery operation 24/7

Round trip efficiency and charge acceptance

Power and energy

Safety and reliability

Life and life cycle cost

Battery temperature impacts vehicle performance, reliability, safety, and life cycle cost

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A Battery Temperature Control System

Battery

ThermoelectricHeater/cooler

TempBattery

Temperature Control

UnitPower Control

Battery Temperature

Cooling or Heat Collection Fins

BatteryThermal

Enclosure

Optional Heat Vents

With ControlsVent Control

Battery toThermoelectricUnit Thermal

Interface

Battery

ThermoelectricHeater/cooler

TempBattery

Temperature Control

UnitPower Control

Battery Temperature

Cooling or Heat Collection Fins

BatteryThermal

Enclosure

Optional Heat Vents

With ControlsVent Control

Battery toThermoelectricUnit Thermal

Interface

significant warranty cost savings

improved battery reliability

improved battery efficiency & performance

enables more flexible packaging

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Embedded Semiconductor Cooling Remove Heat From Die to Heat Sink

Heat Sink

Thermal Interface Material 2

Silicon DieSubstrate

Thermal Interface Material 1

Heat SpreaderResolveCritical

Path

Nextreme’s solution

Embedded Thermoelectric in IC• Active micro-cooling of hotspot• Reduces total power cooled• Simplifies package

Hotspots effect

Reliability

Performance

Package cost

100 m thickness

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Thermoelectric Generator on a Fishing Vessel’s Engine Exhaust

Keel Coolers

Maine Maritime Academy’s “Fishing Vessel”

R/V Friendship 47 Feet LOA

Seawater Cooled Exhaust

Stack TE Generator

Engine

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Advanced Thermal Comfort Management

for Soldier of Tomorrow

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USS DOLPHIN AGSS 555 Thermoelectric Air Conditioning Test for Silent Running

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Thermoelectric Wristwatch

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Recent Advances in Efficiency of Thermoelectric Materials

H

CH

CH

TT

ZT

ZTT

TT

1

11

Efficiency:

Year1940 1950 1960 1970 1980 1990 2000 2010

ZT

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

ZnSbPbTe

Bi2Te3 Zn4Sb3

filled skutterudites

Bi2Te3/Sb2Te3 superlattices

PbSeTe/PbTe quantum dots

AgPb18SbTe20

Many recent thermoelectric material advances are nano-based

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Vehicular Multi-Fuel Thermoelectric Hybrid Electric Powertrain

AirCompressor

CoolantPump

Fuel Pump:Solid,

liquid, gas

Exhaust

Thermoelectric

Multi-Fuel

CombustorElectric

PropulsionMotor

TransmissionGear Box

&Differential

Rad

iato

r

Electric PowerConditioning &

Control Electrical Energy Storage

(Batteries orUltracapacitors) Vehicle Electrical

SystemDriverDemand

12V

12V

Thermoelectric

440V

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Thermoelectric Generators (TEG’s) providing nominal 10% fuel economy gain augmenting smaller alternator

“Beltless”

or more electric engines

Thermoelectric HVAC augmenting reduced size A/C

TEG’s installed in diesel or gasoline engine exhaust

55% efficient heavy duty truck engine

50% efficient light truck, auto

2nd

Generation TEG’s and TE HVAC w/o alternators or A/C

Aluminum/Magnesium engine, frame & body replacing steel(Process waste heat recovery) mass market cars

30% efficient Thermoelectrics w/ 500 0C ∆T

Replace Internal Combustion Engine (ICE)

Dedicated combustor burns any fuel

Terrestrial RTG TEG powered busses, light rail

{

Near Term(3-6 yrs)

Mid Term(7-15 yrs)

{

Long Term(16-50 yrs) {

Vehicular Thermoelectric Application Possibilities

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Vehicle Technologies Program eere.energy.gov

TE Materials Performance Objective

max

1

11

hot

coldhot

coldhot

TTZT

ZTT

TT

Carnot TE Materials

TE conversion efficiency as a function of hot junction temperature and ZT

0%

5%

10%

15%

20%

25%

200 400 600 800 1000 1200T (K)

Effic

ienc

y (%

)

ZT=0.5

ZT=1

ZT=2 TE Materials for Vehicular TE GeneratorsFirst

Generation

SecondGeneration

Tcold

= 380 K

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DOE VTP Program Objectives & Potential Spin -Offs

DOE/VT R&D Objectives

Commercially viable ZTavg

> 1.7, 320K –

820K

Program Planning

DOE/NSF Non-Telluride TE materials development

DOE/VT Scale-up advanced materials & Increase production capability

Develop 2nd Generation Vehicular TEG’s and TE HVAC

Potential Spin-off Applications

Industrial Processes

Rail–

Stationary Power

Marine–

Geothermal

Spacecraft–

Aircraft

Military

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If the 220 M Personal Vehicles in the US had Thermoelectric Generators powering

Thermoelectric Coolers/Heaters (HVAC)

Save 4.5 Billion gals/year of fuelReduce Greenhouse Gases by 69.5

Million Metric Tons of CO2

/year

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THERMOELECTRIC GENERATORS COULD SAVE YOU 10% OF CAR/LIGHT TRUCK FUEL

CONSUMPTION

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Thermoelectrics –

They Are Not Just For Outer Space!!!

Thank You!!

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Possible Venues: 2010 Thermoelectric Applications Workshop

Monterey

San Diego

Detroit, MI

Newport, RI

Castine, ME

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DOE SBIR call for proposals Advanced cooling technologies

Looking for advanced thermoelectric technology for applications in building, industry and vehicles for:

Phase I proposals should include:

a preliminary design•

a characterization of laboratory-scale devices

using the best measurements available, including a description of the measurement methods

a road map showing major milestones

that would lead to a system that would be built and tested in Phase II

Cooling applications Waste heat recovery

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DOE SBIR call for proposals Advanced cooling technologies

The targeted areas or cooling and waste heat recovery are:•

new thermoelectric materials

that have•

a high figure of merit

(ZT) and the potential •

for large-scale production, •

at costs competitive

with conventional technologies•

considering the full system over its lifetime;•

modules to house

thermoelectric materials that mitigate thermal expansion

issuesthat can cause failure; and

thermoelectric systems

that address all of the•

thermal interface, •

materials compatibility, and•

thermal management

issues of the integrated system.

Proposals that address all three of the above subjects are preferred. Collaborations with OEM’s (Original Equipment Manufacturer) are encouraged.

Contact: Dr. Sam Baldwin, [email protected],202-586-0927

http://www.science.doe.gov/SBIR