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energies Article Analytical and Experimental Study of Thermoelectric Generator (TEG) System for Automotive Exhaust Waste Heat Recovery Faisal Albatati * and Alaa Attar Citation: Albatati,F.;Attar,A. Analytical and Experimental Study of Thermoelectric Generator (TEG) System for Automotive Exhaust Waste Heat Recovery. Energies 2021, 14, 204. https://doi.org/10.3390/ en14010204 Received: 27 November 2020 Accepted: 27 December 2020 Published: 2 January 2021 Publisher’s Note: MDPI stays neu- tral with regard to jurisdictional clai- ms in published maps and institutio- nal affiliations. Copyright: © 2021 by the authors. Li- censee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and con- ditions of the Creative Commons At- tribution (CC BY) license (https:// creativecommons.org/licenses/by/ 4.0/). Department of Mechanical Engineering, Faculty of Engineering at Rabigh, King Abdulaziz University, Jeddah 21589, Saudi Arabia; Loattar@kau.edu.sa * Correspondence: alalbatati@kau.edu.sa Abstract: Nearly 70% of the energy produced from automotive engines is released to the atmosphere in the form of waste energy. The recovery of this energy represents a vital challenge to engine designers primarily when a thermoelectric generator (TEG) is used, where the availability of a continuous, steady-state temperature and heat flow is essential. The potential of semi-truck engines presents an attractive application as many coaches and trucks are roaming motorways at steady-state conditions most of the time. This study presents an analytical thermal design and an experimental validation of the TEG system for waste heat recovery from the exhaust of semi-truck engines. The TEG system parameters were optimized to achieve the maximum power output. Experimental work was conducted on a specially constructed setup to validate the analytically obtained results. Both analytical and experimental results were found to be in good agreement with a marginal deviation, indicating the excellent accuracy of the effective material properties applied to the system since they take into account the discrepancy associated with the neglection of the contact resistances and Thomson effect. Keywords: thermal design of thermoelectric system; energy balance of thermoelectric generator; waste heat recovery system 1. Introduction Generally, it is estimated that about one third of total energy is usefully used while the remaining two thirds are rejected as waste heat. In the automotive industry, particularly, the internal combustion engine has a maximum efficiency of nearly 25%, while the remaining 75% of energy is lost in the form of waste heat from exhaust gases and engine coolant [1]. Many studies have investigated the recovery of waste heat from internal combustion engines using different technologies. Thermoelectric technology is seen as one of the most promising technologies to exploit this waste heat. This is mainly due to the continuous advancement of the materials used in manufacturing thermoelectric modules and, therefore, their overall efficiency [2]. The technology itself is based on a unique solid-state power device that can be easily used in vehicle exhaust pipes to recover a portion of the waste heat and convert it into useful electricity. The earliest experimental attempt on a thermoelectric exhaust generator system for an automotive was conducted by Neild in 1963, as reported by Fagehi et al. [3]. The study’s main target was to produce 500 W of power at 28 V with a minimum efficiency of 3%. The results showed that the maximum power output and efficiency achieved were 156.6 W and 2.2%, respectively. In 1988, Porsche developed a prototype to test a thermoelectric generator (TEG) using the exhaust gas and water circulation systems. The thermoelectric material used was iron silicide (FeSi2), which was connected to the Porsche 944 engine. The temperature difference between the cold and the hot sides of thermoelements was 490 K, and the achieved power output was 58 W for 90 thermoelements [4]. In 1994, Bass, Elsner, and Leavitt [5] developed a thermoelectric power generator system for diesel truck engines with a target power output of 1 kW. The system used 72 thermoelectric modules Energies 2021, 14, 204. https://doi.org/10.3390/en14010204 https://www.mdpi.com/journal/energiesPDF Image | Thermoelectric Generator (TEG) System for Automotive Exhaust
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