pbj xaustors -exhaust waste energy recovery
DESCRIPTION
Client: Frank Albrecht – Future Truck. PBJ Xaustors -Exhaust Waste Energy Recovery. Peter Jorg James Stewart Robert Wiegers Jeremy Boles – Graduate Mentor. Presentation Overview. Background Concepts Testing Product Realization Recommendations. Background. - PowerPoint PPT PresentationTRANSCRIPT
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?