high temperature thermoelectric heat exchanger and...
TRANSCRIPT
HIGH TEMPERATURE THERMOELECTRIC HEAT EXCHANGER AND OPTIMIZATION OF DISSIPATIVE SYSTEMS APPLIED IN AUTOMOTIVE
Pasadena CA3rd August 2017
Fabio PugliaC. Fanciulli, V. Ottolina, F. Riva and A. Mari
Zeus: how it works
Truck: Boat:
To charge the batteries of camper, trucks and boats when they are exhausted
Camper:
First Prototype : 6 modules
First prototype: Results
150
175
200
225
250
275
0.00.00 0.08.38 0.17.17 0.25.55 0.34.34 0.43.12
T [°
C]
time [hh:mm:ss]
Hot side temperature (corner)
Temperature
Power increase
25
30
35
40
45
50
0.00.00 0.14.24 0.28.48 0.43.12
T [
°C]
time [hh:mm:ss]
Water temperature
Inletwatertemperature
40
50
60
70
0.15.50 0.23.02 0.30.14 0.37.26 0.44.38
Po
we
r [W
]
Time [hh:mm:ss]
Output Power
Power output
Power increase
First Prototype: CFD + Heat Transfer Simulation
Combustion chamber: Cooling system:
CFD model was created and verified on experiment dataAt steady state
Temperature hot side TEG 231 °C Temperature cold side TEG 54 °C
Experiment Simulation
T gas outlet 280/300 °C 302 °C
T corner TEG
257 °C 252 °C
Experiment Simulation
T water outlet
45,3 °C 45,5 °C
T external 47,8 °C 48,4°C
Laminar flow
DeltaT=177°C
First Prototype: Output Power and Electrical Consumption
Auxiliary devices Consumption [W]
Water pump 12,6
Airfan 18
Total 30,6
Maximum output power [W]
Prototype (6 TEGs) 64
Net power output: 33,4 W
First Prototype: Conclusions
▪ Maximum Net Output Power < 55 W
Not enough for a commercial product
▪ Cannot be commercialized: weight, gas supply, dimensions…
Needs to be engineered
✓The Prototype produces electric power using LGP in a silent and reliable way
What needs to be improve?
What did we achieve?
Second prototype
Specifications:
✓ Gasoline/Diesel supply (burner)
✓ Silent ( 32 dB)
✓ Net output power: 100/150 W
✓ Maximum height: 260 mm
✓ Maximum weight: 40 Kg
✓ Competitive price: <3.000,00 $
✓ Compatible for automotive application (vibrations…)
Second prototype: geometry
• 12 TEG (modules with maximum output power 28W)
• Increased the inlet power: burner 5 kWCombustion chamber:
Inlet burner
Outlet burner
Water cooling system
Second prototype: characteristics
Materials:• Combustion chamber: cast iron• Cooling system: aluminum
Dimensions: 450 x 390 x 260 mm
Weight: 40 kg
Pressing force: 1 MPa
Thermocouples to check temperatures
Power: 150 W
Heat Exchanger Optimization
2 lines of thermoelectric modules: 6 each
Medium flux for first line: 16 W/cmq
Medium flux for second line: 11 W/cmq
24 We output
16 We output
Second prototype: issues and challanges
• Combustion chamber cannot be made using shell molding technology
adapted the geometry
• Auxiliary device consumption
Auxiliary devices Consumption [W]
Burner eletronics 30
Water pump 12,6
Airfan 60
Total 102,6
Optimization of the air fan
Fan shape opt.:
1 prototype: 85 W - 75 dB 1m
2 prototype: 50 W - 52 dB 1m
Optimitazion of the cold side exchanger
0
5
10
15
20
25
10 15 20
W IN FUNZIONE DELLA PORTATA
Temperature opt. On the cold faceElectrical output vs. Water flux l/min
Conclusions and Future Work
✓ Designed a silent prototype with diesel supply, compact, compatible to automotive application.
✓ Increase the net power output reduce the consumption of auxiliary devices
✓ Adapt the system to burners of different sizes (campers and trucks)✓ Adapt the system to work with sea water as cooling system (boats)
THANK YOU FOR YOUR KIND ATTENTION
Pasadena CA3rd August 2017
Fabio PugliaC. Fanciulli, V. Ottolina, F. Riva and A. Mari