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

Lars Heber, Julian Schwab and Timo Knobelspies
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Lars Heber: German Aerospace Center (DLR), Institute of Vehicle Concepts, 70569 Stuttgart, Germany
Julian Schwab: German Aerospace Center (DLR), Institute of Vehicle Concepts, 70569 Stuttgart, Germany
Timo Knobelspies: German Aerospace Center (DLR), Institute of Vehicle Concepts, 70569 Stuttgart, Germany

Energies, 2021, vol. 15, issue 1, 1-16

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/dm 3 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.

Keywords: automotive thermoelectric generator; engine exhaust heat recovery; thermo-economic analysis; CFD in thermoelectrics (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2021
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