development of a 100-watt high temperature thermoelectric

Development of a 100Development of a 100--Watt Watt High Temperature High Temperature

Thermoelectric Generator Thermoelectric Generator J. LaGrandeur, D. Crane, L. Bell

DEER Conference, Detroit, MIAugust 6, 2008

Development of a 100 watt High Temperature TE GeneratorDEER 2008

2

BSST OverviewBSST OverviewBSST is a subsidiary of Amerigon

and is located in Irwindale, CA (near Los Angeles)

BSST is developing advanced thermoelectric engines for heating, cooling and power generation

Sales & Technical SupportSales & Technical Support

Amerigon IncAmerigon Inc..Engineering, R&D CenterEngineering, R&D Center

Amerigon Inc. DetroitAmerigon Inc. DetroitWorld Headquarters World Headquarters Sales & Technical Support Sales & Technical Support

Amerigon Inc. Amerigon Inc. -- AsiaAsiaSales, Technical SupportSales, Technical Support

Amerigon Serves the Global Automotive Industry


Amerigon Inc. Amerigon Inc. -- EuropeEuropeSales, Technical Support GermanySales, Technical Support Germany

Amerigon Inc. Amerigon Inc. -- EuropeEuropeSales, Technical Support EnglandSales, Technical Support England

Manufacturing Manufacturing ChinaChina

Amerigon Inc. Amerigon Inc. -- ChinaChinaSales, Technical SupportSales, Technical SupportManufacturing MexicoManufacturing Mexico

Sales & Technical SupportSales & Technical Support

Amerigon IncAmerigon Inc..Engineering, R&D CenterEngineering, R&D Center

Amerigon Inc. DetroitAmerigon Inc. DetroitWorld Headquarters World Headquarters Sales & Technical Support Sales & Technical Support

Amerigon Inc. Amerigon Inc. -- AsiaAsiaSales, Technical SupportSales, Technical Support



Amerigon Inc. Amerigon Inc. -- EuropeEuropeSales, Technical Support GermanySales, Technical Support Germany

Amerigon Inc. Amerigon Inc. -- EuropeEuropeSales, Technical Support EnglandSales, Technical Support England

Manufacturing Manufacturing ChinaChina

Amerigon Inc. Amerigon Inc. -- ChinaChinaSales, Technical SupportSales, Technical SupportManufacturing MexicoManufacturing Mexico

2007 Escalade (ESV, EXT) Cadillac (XLR,DTS)

2006 Buick Lucerne

2006 Lincoln Zephyr Mercury Monterey

Lincoln LS

Lincoln Navigator Ford Expedition

* Four Seat Systems

Infiniti (Q45, M45)

Nissan Cima

Nissan Fuga

Hyundai Equus*

Lexus LS 430*

Toyota Celsior*

Toyota Century

2007 Range Rover

2007 Escalade (ESV, EXT)2007 Escalade (ESV, EXT) Cadillac (XLR,DTS)

2006 Buick Lucerne

2006 Lincoln Zephyr Mercury Monterey

Lincoln LS

Lincoln Navigator Ford Expedition

* Four Seat Systems

Infiniti (Q45, M45)

Nissan Cima

Nissan Fuga

Hyundai Equus*

Lexus LS 430*

Toyota Celsior*

Toyota Century

2007 Range Rover

Cadillac (XLR,DTS) Cadillac (XLR,DTS)

2006 Buick Lucerne2006 Buick Lucerne

2006 Lincoln Zephyr2006 Lincoln Zephyr Mercury MontereyMercury Monterey

Lincoln LSLincoln LS

Lincoln NavigatorLincoln Navigator Ford ExpeditionFord Expedition

* Four Seat Systems

Infiniti (Q45, M45)Infiniti (Q45, M45)

Nissan CimaNissan Cima

Nissan FugaNissan Fuga

Hyundai Equus*Hyundai Equus*

Lexus LS 430*Lexus LS 430*

Toyota Celsior*Toyota Celsior*

Toyota CenturyToyota Century

2007 Range Rover

Amerigon CCS Customers include most major OEMs


3

In Q4 2004 the US DOE Office of Vehicle Technologies started 4 Thermoelectric Waste Heat Recovery Programs

The Program objectives include:•

10% fuel efficiency improvement

•

Reduced emissions

•

A demonstrated path to commercialization and economic feasibility assessment


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BSST Waste Heat Recovery BSST Waste Heat Recovery Program OverviewProgram Overview

The program is organized into 4 development phases:•

Phase 1

(Q3 04 thru Q2 05) A system architecture was created and bumper

to bumper model created using ADVISOR. Initial system FE savings were shown to reach 12%

•

Phase 2

(Q3 05 thru Q4 06) Key subsystems (Primary Exhaust Gas Heat Exchanger, Thermoelectric Generator Module TGM), Power Conversion Electronics) were built and tested. BMW converted the bumper to bumper model to a Gamma Technologies modeling platform

•

Phase 3

(Q1 07 thru Q3 08) Low and high temp TEGs are being built and tested with other key subsystems:

−

A BiTe TGM, has been built and tested demonstrating > 500 watts electrical power output.

−

A high temperature TEG will be built and tested in Q3 2008 (>100

watts)

−

The Waste Heat Recovery System will be operated on a test bench using a hot gas torch in Q3 2008

•

Phase 4

(Q4 2008 –

Q1 2009) A 500 watt high temperature TEG will be integrated and

tested with BMW’s in line 6 cylinder engine on an engine dynamometer at the Federal Laboratory in NREL Colorado

4


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BSST TE EngineBSST TE EngineBSST stack design allows:

•

Optimum compressive loads for thermal and electrical interfaces

•

Tailored n and p type element geometries for highest efficiency


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BiTe TEGBiTe TEG

n-type Bi2Te3n-type Bi2Te3

160 mm

TE Circuit (Bi2Te3 subassemblies)

160 mm160 mm

TE Circuit (Bi2Te3 subassemblies)

500W Generator (Delta T = 207°C)

0

100

200

300

400

500

600

0 5 10 15 20 25 30 35 40Current (Amps)

Pow

er (W

atts

)

0

10

20

30

40

50

60

Vol

tage

(V)

PowerV-I

5 Sept 2007

160 mm


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Single plate(interfacial resistance = 2μΩcm2,

hot volume flow = 8 gpm (Xceltherm 600),cold volume flow = 8.85 lpm (water or glycol/water))

0102030405060708090

100110120130140150160170180

0 20 40 60 80 100 120 140 160 180 200 220 240 260

hot fluid inlet temperature (C)

pow

er (W

)

cold water inlet = 5C



cold glycol/water inlet = -5C

cold glycol/water inlet = 5C



cold water inlet = 4.68C, 8.85 lpm, hot oilflow = 4.3 gpmcold water inlet = 5.12C, 8.85 lpm, hot oilflow = 3.8gpmcold water inlet = 5.33C, 8.85 lpm, hot oilflow = 4.2 gpmcold water inlet = 6.60C, 8.85 lpm, hot oilflow = 7.5 gpmcold water inlet = 14.13C, 8.85 lpm, hot oilflow = 7.9 gpmcold water inlet = 24.51C, 8.85 lpm, hot oilflow = 8 gpmcold glycol/water inlet = -3.23C, 11.0 lpm,hot oil flow = 6.1 gpmcold glycol/water inlet = -6.02C, 10.9 lpm,hot oil flow = 6.0 gpmcold glycol/water inlet = -6.62C, 10.9 lpm,hot oil flow = 7.0 gpmcold glycol/water inlet = -5.68C, 10.9 lpm,hot oil flow = 6.9 gpmcold glycol/water inlet = -6.60C, 10.8 lpm,h t il fl 6 8

Peak Test Results Compared to SimulationsPeak Test Results Compared to Simulations Measured to simulated values vary by < 5%Measured to simulated values vary by < 5%


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TEG Power ManagementTEG Power ManagementThe 100 watt BiTe TEG was tested with a prototype Power Control System (PCS) and resistive load.

The prototype PCS includes:•

Boost and buck converters with microprocessor control to provide a maximum voltage of 12.8 VDC (resistive load maximum operating voltage)

•

Serial data interface to report input and output voltage, current, power and converter efficiency

Three 50 watt automotive headlamps were used to test the PCS with the TEG.


9

PCS PerformancePCS Performance--

BiTe 100 Watt TEGBiTe 100 Watt TEGPower Control System (PCS) Performance

0.0

10.0

20.0

30.0

40.0

50.0

60.0

70.0

80.0

0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0

TEG Power to the Converter

Con

vert

er P

ower

Out

93.0%

94.0%

95.0%

96.0%

97.0%

98.0%

99.0%

100.0%

Con

vert

er E

ffici

ency

Output Power Converter Efficiency


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High Temperature TEG Design SummaryHigh Temperature TEG Design Summary

Hot side heat exchanger redesigned for 5000C exhaust gas (BiTe TEG used liquid heat exchangers with 2000C oil)

Three different TE subassemblies designed to match exhaust gas temperature gradient in the direction of flow to provide maximum TE material performance

TEG thermal and electrical interfaces modified to withstand high temperature environment


11

Prototype Exhaust Gas Heat Prototype Exhaust Gas Heat ExchangerExchanger

Stainless steel brazed construction with wavy fin

Diamond surface coating for electrical isolation


12

Prototype Cold Side Heat Prototype Cold Side Heat ExchangerExchanger

Lytron off the shelf aluminum cold plate

Surface finish: clear anodized for electrical isolation (blue die for anodize coating confirmation)


13

100 Watt High Temperature TEG100 Watt High Temperature TEG

Counter flow design

Three configurations of TE subassemblies designed to match the temperature gradient in the heat exchanger for maximum TE performance

TE Bank 1High Temp

TE Bank 2Medium Temp

TE Bank 3Low Temp

Gas flow Coolant flow


14

TE Subassembly Design and TE Subassembly Design and ConstructionConstruction

Hot and cold “T Shunts”

provide electrical and thermal connections to TE elements

T shunts and elements designed to match thermal flux to optimize

TE conversion efficiency

Proprietary Matlab Simulink computer tool simultaneously solves non linear equations to optimize performance and selected design parameters


15

TE Subassembly Design and TE Subassembly Design and ConstructionConstruction

TE subassemblies fabricated by BSST

High and medium temperature sections include Half Heusler and BiTe segmented elements

Low temperature TE subassemblies use BiTe only

TE Subassembly Thermal TE Subassembly Thermal Cycling ResultsCycling Results


17

Segmented Half-Heusler/Bi2Te3 Subassembly(heater = 470C, water bath = 70C, I = 9.0A)

0.00.10.20.30.40.50.60.70.80.91.01.11.21.31.41.5

0 10 20 30 40 50

cycles

pow

er (W

)


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Segmented Half-Heusler/Bi2Te3 Subassembly(heater = 350C, water bath = 70C, I = 10.0A)

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1.0

0 10 20 30 40 50 60 70 80 90 100 110

cycles

pow

er (W

)


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Bi2Te3 Generator Thermal Cycling1181 cycles, Th = 190C, water bath = 20C

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1.0

0 200 400 600 800 1000 1200 1400

cycles

pow

er (W

)


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Summary and Further WorkSummary and Further Work

A low temperature TEG has been built and tested providing over 500 watts electric power at a ∆T of 2000C

Prototype TE subassemblies for a high temperature TEG have been designed, built and tested•

A 100 watt high temperature TEG will be completed in Q3 2008

•

A 500 watt high temperature TEG will be completed in Q4 2008 with Engine Dynamometer testing in Q1 2009

Testing of a low temperature TEG in a diesel engine vehicle is underway with results finalized in Q4 2008


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AcknowledgementsAcknowledgements

John Fairbanks and the US DOE Office of Vehicle Technologies (OVT)

Aaron Yokum

and Carl Maronde of the DOE NETL

Andreas Eder and Boris Mazar of BMW

Steve Newton of Visteon

development of a 100-watt high temperature thermoelectric

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