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Executive Summary Thermoelectric (TE) generators convert heat directly into electricity when a temperature gradient is applied across the junctions of two dissimilar metals. These devices have the potential to increase the fuel economy of conventional vehicles by recapturing a portion of the waste heat from the engine exhaust and generating electricity to power a vehicle’s accessory loads. At present, device efficiencies are low (~5%); however, thin-film and quantum well technologies offer the possibility of higher efficiency in the future (~10 % to 15%). Four vehicle platforms are considered: a midsize car, a midsize sport utility vehicle, a Class 4 truck, and a Class 8 truck. A simple vehicle and engine waste heat model shows that the Class 8 truck presents the least challenging requirements for TE system efficiency, mass, and cost. This is because Class 8 trucks have a relatively large amount of exhaust waste heat, have low mass sensitivity, and travel a high number of miles per year, all of which help to maximize fuel savings and economic benefits. A driving and duty cycle analysis for the Class 8 truck elucidates trade-offs in system sizing and shows the strong sensitivity of waste heat, and thus TE system electrical output, to vehicle speed and driving cycle. It is not feasible for a TE system to replace the alternator, as too little waste heat is available during city driving and/or idling. Together with a typical alternator, a TE system could enable the electrification of 8% to 15% of a Class 8 truck’s accessories, providing 2% to 3% fuel savings. Additional electrification would require a larger alternator and battery to augment the TE system so that adequate electrical power is available during low-speed driving and idling. Achieving an economic payback in three years dictates that the TE system cost less than roughly $450/kW, requiring an almost tenfold reduction from today’s costs. Such a cost reduction might be enabled in the future by thin-film devices that use expensive TE junction materials more efficiently. ivPDF Image | Feasibility of Thermoelectrics for Waste Heat Recovery in Conventional Vehicles
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