HeatReCar. Reduced Energy Consumption by Massive Thermoelectric Waste Heat Recovery in Light Duty Trucks

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1 HeatReCar Reduced Energy Consumption by Massive Thermoelectric Waste Heat Recovery in Light Duty Trucks SST Vehicle/vessel and infrastructure technologies for optimal use of energy Daniela Magnetto, Mauro Brignone, Alessandro Ziggiotti 20 Novembre, 2010

2 Consortium and main objectives Starting Date: 1 st December 2009 Ending Date: 30 th November 2012 Grant agreement n Consortium Objectives Reduction of fuel consumption and CO 2 emissions of vehicles by massively harvesting electrical energy from the exhaust system Development of innovative TE materials and modules assembly process to overcome the limitations of commercial devices Development of efficient electronics to manage generated power Full integration on-board vehicle: evaluate the interaction and the effects on all other vehicle subsystems 8

3 Innovative TE materials and modules Filled Skutterudites (CoSb 3 based) Advantages respect to PbTe Lighter weight Lower elements toxicity Absence of Tellurium Resistance to higher temperatures Higher ZT values reported in literature N-type Yb 0.2 Co 3 Sb 12 P-type Mm 0.9 Fe 3 CoSb W on 1.6x1.6cm T=480K 9

4 Demonstrator fabrication and on-board integration TE modules employed in the TEG were base on Bi 2 Te 3 with customized design Innovative process assembly to work over 300 C 2.3 l Diesel engine IVECO Daily light duty truck 10

5 Project main results Development and on-board integration of a TEG based on advanced bismuth telluride TE modules. 480W generated power on the test rig 220W peak generated power over the NEDC and over the WLTP cycle (performance limitation due to max allowable temp on Bi 2 Te 3 module) 2.2% fuel consumption reduction and 6.7 g/km CO 2 reduction over NEDC cycle. 3.9% fuel consumption reduction and 9.6 g/km CO 2 reduction over WLTP cycle 11

6 Conclusions and needs Thermoelectric performances obtainable with standard materials (low-medium T, ZT 1) are sufficient for thermoelectricity to become a product on automotive, probably the widest and most outstanding market for a new technology What is crucial is not the efficiency, nor the peak performances but AVAILABILITY AND COST OF RAW MATERIALS COST OF PROCESSES ELEMENTS TOXICITY SCALABILITY OF MATERIALS PRODUCTION AND PROCESSES TO LARGE SCALE Another critical point is the step from new materials to modules HIGH T WORKING CONDITION STABILITY IN THERMAL CYCLING AVOID ELEMENT DIFFUSION, DIFFERENTIAL THERMAL EXPANSION, SUBLIMIZATION 12

7 Conclusions and needs For car manufacturers it is a matter of time and money The automotive industry is in a hurry!!! New CO 2 emission limits for 2020 Thermoelectric modules based on low cost and available materials ready to be a product in 2018 Target price: 1-2 /W at modules level, 2-3 /W at system level The future research need for automotive industry is: Focus on low cost process to synthetize TE materials Focus on modules development Focus on scalability (involvement of large European industries for the production of hundreds of tons or million of pieces per year) 13