PBJ Xaustors -Exhaust Waste Energy Recovery

PBJ Xaustors-Exhaust Waste Energy Recovery

Peter JorgJames StewartRobert WiegersJeremy Boles – Graduate Mentor

Client: Frank Albrecht – Future Truck

Presentation Overview

BackgroundConceptsTestingProduct RealizationRecommendations

Background

The Future Truck Competition aims to “address important environmental and energy-related issues posed by the growing demand for sport utility vehicles.” In a typical vehicle, the exhaust gas contains one of the largest portions of wasted energy, approximately 34% of available energy from the fuel. The motivation of the project is to capture some of this energy stream.

Problem Formulation

Objectives: Energy recovery will be greater than 180W Compatibility and integration with other Future Truck

subsystems will be realized

Constraints: Additional system weight will be no more than 50 lbf Ground clearance and crush zone competition

requirements will not be violated Effectiveness of catalytic converters will not be

negatively impacted Overall vehicle score will be positively impacted (i.e.

fuel economy points exceed weight penalty)

Concept SelectionThermophotovoltaicsEnable usage of high temp (over 1,000ºF) waste heatProjected high cost Little availability to dateModified turbo systemOff the shelf partsLow CostHigh back pressure

Adsorption coolingPotential for elimination of harmful refrigerantsMakes direct use of thermal energyCooling unit must be rather large

Concept Selection (Cont’d)Thermoelectrics Commercially available Low thermal efficiency, approximately

5% No moving parts, solid state device Compact size and low mass Load matching circuit necessary

Vehicle TestingAttachment of the thermocouples to the exhaust pipes

Data Acquisition unit in cab of truck

Vehicle Testing Results -Future Truck

Optimal thermal conditions

450° –

500°F

Solution Concept – Engine->Exhaust->TE chips->Battery

IC Engine

Exhaust System

TE TE TEHX HX HX

Load Matching Circuit

VehicleBattery

41% Mechanical Output

25% Peripheral Systems

34% Power to Exhaust

0.75% Exhaust Power Converted to Electrical Power

Power to VehicleSubsystems

Unrecovered Power

Thermoelectric Testing -benchField point modules collecting data

Fan emulating airflow from driving

Heat sink and air ducting

Heat distribution plate

Heat sourceDMM measuring current

Computer analyzing data

Thermocouples taking measurements

Lab View ControlsSampling Number

Resistance input

Voltage, power readouts

File path

Temp readings

Temperature difference graph

Power vs. temp difference graph

Generator Testing Results

Temperature Difference ºF

Pow

er

outp

ut

W

Theoretical OutputPower v.s. Delta T

0

5

10

15

20

25

0 50 100 150 200 250

Delta T (ºC)

Po

we

r (W

)

Thermoelectric Testing -engine

DMM measuring voltage output

Exhaust system

Thermal bypass valves

James

Test engine

Exhaust coupler

Thermal Bypass

Product Realization

Exhaust SystemComparison

Last Year Two catalytic converters Split pipe between cats Longer overall distance Many bends Extraneous sources of head loss

This Year One catalytic converter Larger (2.5”) pipe, consolidated after

cat Shorter overall distance Fewer bends Valves

BudgetQty Cost Qty. Cost

Testing Material Experiments & Misc.

Thermocouple Wire 1 $112.00 Initial Money -- $143.00Additional equipment and parts 1 $21.56 Additional Supplies -- $100.00

Chips Phone -- $20.00Peltier Chips and Heat Sinks 1 $880.00 Time Critical Purchases

Chip implemetation hardware 1 $26.97 TEP1-12656-0.6 TE Modules 4 $340.00Copper for Heat sink 1 $85.00 TEP1-12656-0.8 TE Modules 4 $340.00

Exhaust Section Bonded Heat Sinks 8 $480.00Exhaust material 1 $61.49 Phase 1 Implementation

Valves 2 $330.00 Load Circuit & Wiring 1 $225.00Chip Cooling Exhaust Pipe 1 $50.00

AFA ducting 1 $120.00 Attachment Hardware 8 $64.00Air scoop supplies 1 $18.47 Heat Shielding/Conductivity Plate 1 $100.00

Survivability Hardware 1 $150.00Machined Heat Sinks 2 $20.00Air Scoops & Ducting 2 $80.00

$1,655.49 $2,032.00Forcasted Project Cost = Total Project Cost =

Impact to Future Truck

Static Events Design report, innovation Judges’ interest

Dynamic Events Reduced alternator load – improved gas mileage Reduced head loss (?) – better engine

performance Weight issue – added vehicle weight increases

engine load by ~25 W at 60 mph Implementation of phase change material in cat

– leg up in “cold” start emissions run

Continuing Work

Load Matching Circuit Underestimated aftermarket

availability EE recommendations

Forced Air Cooling Original implementation scheme Change in plans Parasitic fan

Recommendations

Thermoelectrics Currently only have 7 operational chips Load circuit implementation necessary Current equipment levels – overall impact

uncertain

Next Step Expansion of generator to two heat sinks Cost = $1200 Roughly doubled output for comparable

weight

And now a moment of Zen

Any Questions?