Identifying Cost Effective Routes To Optimised Energy Recovery For The Fuel Economy Of Vehicles
Lead Research Organisation:
Loughborough University
Department Name: Aeronautical and Automotive Engineering
Abstract
The internal combustion engine which is in everyday use in a wide variety of applications remains one of the most cost effective means of generating power. A typical engine however loses substantial amounts of energy in its normal operation and there is clear potential to utilise this energy. The largest flow is in the exhaust system of the vehicle, and it is here that the proposed research is focussed.
The main objective of the project is the realisation of an efficient method of energy recovery using a thermoelectric generator and utilising a new type of material known as a skutterudite. By adopting the same internal structure, skutterudites simulate a naturally occurring mineral which has the vital properties of low thermal conductivity with low electrical resistance. The principal advantage of these materials is their potential for cost reduction by utilising low cost metals in their structure. A second and important advantage is the future potential for novel manufacturing techniques in which the active elements of the thermoelectric generator are made using additive methods to build up the kind of complex shapes that are required.
The project brings together three universities that can cover the range of capabilities from the chemistry of materials through to systems integration methods.
The Heriot-Watt team will synthesise new materials using progressively lower cost materials to demonstrate that the required thermoelectric performance can be obtained using low cost materials. The Cardiff team will integrate modules, incorporating protective coatings to ensure the durability of the generator. At Loughborough, the scope to integrate thermo-electric (TE) generators with other functions such as after-treatment will be explored. The Loughborough team will work with the Cardiff team to identify novel methods of integrating the TE modules into a heat exchange device, regarding the requirements imposed by different types of engine.
The project concludes with the practical demonstration of TE generators and a portfolio of simulation results that demonstrate how the cost path and the path to levels of commercial performance will be realised.
The main objective of the project is the realisation of an efficient method of energy recovery using a thermoelectric generator and utilising a new type of material known as a skutterudite. By adopting the same internal structure, skutterudites simulate a naturally occurring mineral which has the vital properties of low thermal conductivity with low electrical resistance. The principal advantage of these materials is their potential for cost reduction by utilising low cost metals in their structure. A second and important advantage is the future potential for novel manufacturing techniques in which the active elements of the thermoelectric generator are made using additive methods to build up the kind of complex shapes that are required.
The project brings together three universities that can cover the range of capabilities from the chemistry of materials through to systems integration methods.
The Heriot-Watt team will synthesise new materials using progressively lower cost materials to demonstrate that the required thermoelectric performance can be obtained using low cost materials. The Cardiff team will integrate modules, incorporating protective coatings to ensure the durability of the generator. At Loughborough, the scope to integrate thermo-electric (TE) generators with other functions such as after-treatment will be explored. The Loughborough team will work with the Cardiff team to identify novel methods of integrating the TE modules into a heat exchange device, regarding the requirements imposed by different types of engine.
The project concludes with the practical demonstration of TE generators and a portfolio of simulation results that demonstrate how the cost path and the path to levels of commercial performance will be realised.
Planned Impact
The aim of the project is the confirmation of a set of technologies as being the firm basis for energy recovery techniques. Energy recovery contributes to the fuel efficiency of vehicle propulsion and power generation, and will contribute to carbon dioxide (CO2) emissions targets. The primary impact is in the availability of the technologies to potential users. Those users for the most part will be suppliers to the automotive, marine and industrial machinery sectors. For the manufacturers of machinery and engines, the immediate impact of the research will be an understanding of the scope and cost of energy recovery equipment. For their suppliers, the technology, its manufacturing implications, and cost of production will be understood.
For legislators and policy makers the availability of information about a cost effective route to energy efficiency is a major contribution to their assessment of feasible policy routes to lower energy usage.
The proposed path for materials development has the potential to initiate a wholly new supply chain. Skutterudite materials are not currently manufactured in bulk and their incorporation into TE modules is simply done in the lab. While a large company like JM will be in a strong position to develop the manufacture of skutterudites, because of their existing process expertise, module manufacture may well develop in SMEs and start-up companies. ETL is an example of an SME which has a niche interest in cooling that has begun to grow a business in TE module production for energy harvesting from waste heat.
There is a strong process aspect to the proposal and the successful demonstration of component in the loop techniques will allow their dissemination to the wider community. The modelling methods and test architecture will be made available through an open source arrangement as the first step to building an academic community to refine and develop these techniques. Modelling and optimisation methods are particularly important in this application. A wider dissemination of methods will enhance research efficiency while academic groups can continue to explore in confidence their own component and system technologies
For those with a broad interest in the feasibility of TE methods, we are proposing also to offer an open source application toolkit that will allow the investigation of operating conditions, material choices, and system configuration in relation to fuel economy gains. We believe that this kind of access will broaden interest and permit rational judgements to be made by potential users.
The proposal to explore the exhaust system as a single concept complete with its own operating environment (pressure and temperature) where key functions (energy recovery and after-treatment typically) are integrated is novel. This objective has the potential to open up new research agendas for academic colleagues in after-treatment, heat transfer and the application of turbocharging methods.
Outside of the ground vehicle sector, there is the potential for applications in the Aero sector in both power generation and temperature management of key components. The investigators have already had some discussions in this area with an Aero engine company. This initial interest sets the agenda for a wider discussion in other sectors. The involvement of Caterpillar with their large portfolio of products represents a strong potential.
For legislators and policy makers the availability of information about a cost effective route to energy efficiency is a major contribution to their assessment of feasible policy routes to lower energy usage.
The proposed path for materials development has the potential to initiate a wholly new supply chain. Skutterudite materials are not currently manufactured in bulk and their incorporation into TE modules is simply done in the lab. While a large company like JM will be in a strong position to develop the manufacture of skutterudites, because of their existing process expertise, module manufacture may well develop in SMEs and start-up companies. ETL is an example of an SME which has a niche interest in cooling that has begun to grow a business in TE module production for energy harvesting from waste heat.
There is a strong process aspect to the proposal and the successful demonstration of component in the loop techniques will allow their dissemination to the wider community. The modelling methods and test architecture will be made available through an open source arrangement as the first step to building an academic community to refine and develop these techniques. Modelling and optimisation methods are particularly important in this application. A wider dissemination of methods will enhance research efficiency while academic groups can continue to explore in confidence their own component and system technologies
For those with a broad interest in the feasibility of TE methods, we are proposing also to offer an open source application toolkit that will allow the investigation of operating conditions, material choices, and system configuration in relation to fuel economy gains. We believe that this kind of access will broaden interest and permit rational judgements to be made by potential users.
The proposal to explore the exhaust system as a single concept complete with its own operating environment (pressure and temperature) where key functions (energy recovery and after-treatment typically) are integrated is novel. This objective has the potential to open up new research agendas for academic colleagues in after-treatment, heat transfer and the application of turbocharging methods.
Outside of the ground vehicle sector, there is the potential for applications in the Aero sector in both power generation and temperature management of key components. The investigators have already had some discussions in this area with an Aero engine company. This initial interest sets the agenda for a wider discussion in other sectors. The involvement of Caterpillar with their large portfolio of products represents a strong potential.
Organisations
- Loughborough University (Lead Research Organisation)
- Dana Incorporated (Collaboration)
- Cardiff University (Collaboration)
- UNIVERSITY OF READING (Collaboration)
- Johnson Matthey (United Kingdom) (Collaboration, Project Partner)
- Ricardo UK Ltd (Collaboration)
- European Thermodynamics (United Kingdom) (Project Partner)
- Ricardo (United Kingdom) (Project Partner)
- Dana (Canada) (Project Partner)
- Caterpillar (United States) (Project Partner)
Publications
Stobart R
(2016)
Thermoelectric Materials and Devices
Lan S
(2018)
Prediction of the fuel economy potential for a skutterudite thermoelectric generator in light-duty vehicle applications
in Applied Energy
Lan S
(2022)
Performance comparison of a thermoelectric generator applied in conventional vehicles and extended-range electric vehicles
in Energy Conversion and Management
Description | A new thermal electric materials to convert waste heat energy into electricity at high temperature has been developed from this project. The materials was made into the thermal electricity generation unit, and has been experimentally evaluated on a conventional automotive diesel engine. The results shoed that the new thermal electricity generation unit can work at high temperature and convert energy at higher efficiency than conventional ones. |
Exploitation Route | There are two ways that the outcomes of this project have been taken forward. 1. The industrial partner has take the developed material for trial production. It provided the possibility for the new materials to be used by automotive industries and beyond. 2. The output of the project showed that over 300W of electricity can be generated from a conventional engine. The industrial partner Ricardo is working on the commercialization. |
Sectors | Aerospace, Defence and Marine,Agriculture, Food and Drink,Electronics,Energy,Environment,Financial Services, and Management Consultancy,Transport |
Title | Driving cycle-vehicle-engine-TEG modelling |
Description | The model developed provided a systematic analysis of automobile exhaust waste heat energy recovery through TEG technologies in real-world driving. |
Type Of Material | Improvements to research infrastructure |
Year Produced | 2016 |
Provided To Others? | Yes |
Impact | Ricardo has used the model and developed a full vehicle energy saving and financial analysis of using TEG in real-world driving. |
Title | Dynamic TEG system model |
Description | The model simulates the transient thermal and electric behaviour of the TEG unit. |
Type Of Material | Computer model/algorithm |
Year Produced | 2016 |
Provided To Others? | Yes |
Impact | The model assisted the TEG development by the team at Cardiff University. |
Title | TEG automotive business model |
Description | The model provide a tool for financial analysis of implementing the TEG technology into various vehicle platforms, delivers the costs and energy benefit analysis. |
Type Of Material | Computer model/algorithm |
Year Produced | 2016 |
Provided To Others? | Yes |
Impact | In collaboration with Ricardo, the model provides automotive industry an insight view of the TEG technology of future implementation strategy development. |
Title | Thermal electrical module model |
Description | The model provides a validated simulation of TEG unit includes thermal heat transfer and electricity generation. |
Type Of Material | Computer model/algorithm |
Year Produced | 2016 |
Provided To Others? | Yes |
Impact | The model assisted the research team at Cardiff University in developing the new TEG units. |
Title | Vehicle TEG system model |
Description | The model provides a validated simulation of the energy generation through TEG units quipped onto vehicle exhaust system. |
Type Of Material | Computer model/algorithm |
Year Produced | 2016 |
Provided To Others? | Yes |
Impact | The model is in collaboration with Prof. Lars Eriksson at Linköpings Universitet in Sweden. It provides the energy recovered from real world driving. |
Description | Automotive economy analysis |
Organisation | Ricardo UK Ltd |
Country | United Kingdom |
Sector | Private |
PI Contribution | The research team at Loughborough employed the financial data provided by Ricardo into our TEG model, and developed a full-scale financial analysis of the TEG technology of this project. |
Collaborator Contribution | Ricardo provided the project with automotive market analysis. These information were applied to the TEG and vehicle driving cycle model and developed the potential financial analysis of the TEG technology. |
Impact | TEG financial costing model. |
Start Year | 2020 |
Description | New TEG materials development |
Organisation | University of Reading |
Department | Department of Chemistry |
Country | United Kingdom |
Sector | Academic/University |
PI Contribution | Team at Loughborough evaluated the performances of the TEG units built using the new novel materials developed by the Reading research team. |
Collaborator Contribution | The Reading team developed the new materials for the high temperature TEG units of this project. |
Impact | Engine performance using the new TEG materials. |
Start Year | 2013 |
Description | New heat exchanger development |
Organisation | Dana Incorporated |
Country | United States |
Sector | Private |
PI Contribution | The research team at Loughborough has applied the newly developed TEG units through this project onto the purposely designed and manufactured heat exchanger provided by Dana Incorporated |
Collaborator Contribution | Dana Incorporated designed and manufactured a new heat exchanger for the project to demonstrate the performance of the TEG units developed by this research project. |
Impact | Heat exchanger development; |
Start Year | 2014 |
Description | TEG development and electrics |
Organisation | Cardiff University |
Department | School of Engineering |
Country | United Kingdom |
Sector | Academic/University |
PI Contribution | The Loughborough team experimentally evaluated the TEG units developed by Cardiff team. Design criteria were developed through the modelling and experimental studies at Loughborough. |
Collaborator Contribution | The Cardiff team developed the new TEG units using the newly developed novel materials of this project. Significantly improved the new TEG performance. |
Impact | Joint paper publicationsn. |
Start Year | 2013 |
Description | TEG material development and automotive applications |
Organisation | Johnson Matthey |
Country | United Kingdom |
Sector | Private |
PI Contribution | Research team at Loughborough provided Johnson Matthey the TEG performance data on engine operations, provided the system design criteria and future market analysis. |
Collaborator Contribution | Johnson Matthey provided the vehicle and the engine data and requirements. prepared the TEG materials. |
Impact | Economy analysis report of TEG for automotive applications. |
Start Year | 2014 |
Title | Engine TEG prototype demonstration |
Description | The project integrated the new TEG using the newly developed materials into a production internal combustion engine, demonstrated the engine system, and proved the potential of future real-world applications. |
Type Of Technology | Systems, Materials & Instrumental Engineering |
Year Produced | 2016 |
Impact | The demonstration proved the concept of the technology, the material, and potential energy efficiency improvement. The demonstration highlighted the need of further research on operation, optimisation and control. |
Title | Skutterudites thermoelectric materials |
Description | This project developed a new thermoelectric material, Skutterudites. |
Type Of Technology | New Material/Compound |
Year Produced | 2015 |
Impact | The new material significantly improves the TEG performance, at high temperature suitable form engine exhaust heat energy in particular. |
Title | Skutterudites thermoelectric modules |
Description | The project developed new material processing technique to build high temperature Skutterudites thermoelectric modules. |
Type Of Technology | New/Improved Technique/Technology |
Year Produced | 2015 |
Impact | In this project, we developed a new material processing technique, to process the newly developed Skutterudites into high efficient thermoelectric modules. |
Description | Waste heat energy recovery |
Form Of Engagement Activity | A talk or presentation |
Part Of Official Scheme? | No |
Geographic Reach | Local |
Primary Audience | Schools |
Results and Impact | Introduce high-school student the future low CO2 automotive propulsion. Waste heat energy recovery will play a significant role in achieving such target. |
Year(s) Of Engagement Activity | 2016 |