PNNL

Abstract

Abstract: Large amounts of waste heat are generated worldwide in industrial processes, automotive transportation, diesel engine exhaust, military generators, and incinerators because 60-70% of the fuel energy is typically lost in these processes. There is a strong need to develop technologies that recover this waste heat to increase fuel efficiency and minimize fuel requirements in these industrial processes, automotive and heavy vehicle engines, diesel generators, and incinerators. There are additional requirements to reduce CO2 production and environmental footprints in many of these applications. Recent work with the Strategic Environmental Research and Development Program office has investigated new thermoelectric (TE) materials and systems that can operate at higher performance levels and show a viable pathway to lightweight, small form-factor, advanced thermoelectric generator (TEG) systems to recover waste heat in many of these applications. New TE materials include nano-composite materials such as lead-antimony-silver-telluride (LAST) and lead-antimony-silver-tin-telluride (LASTT) compounds. These new materials have created opportunities for high-performance, segmented-element TE devices. New higher-performance TE devices segmenting LAST/LASTT materials with bismuth telluride have been designed and fabricated. Sectioned TEG systems using these new TE devices and materials have been designed. Integrated heat exchanger/TE device system analyses of sectioned TE system designs have been performed creating unique efficiency-power maps that provide better understandings and comparisons of design tradeoffs and nominal and off-nominal system performance conditions. New design perspectives in optimization of sectioned TE design approaches are discussed that provide insight on how to optimize such sectioned TE systems. System performance analyses using ANSYS® TE modeling capabilities have integrated heat exchanger performance models with ANSYS® TE models to extend its analysis capabilities beyond simple constant hot-side and cold-side temperature conditions . Analysis results portray external resistance effects, matched load conditions, maximum power vs. maximum efficiency points simultaneously.