Design and optimization of automotive thermoelectric generators for maximum fuel efficiency improvement

• A three-dimensional automotive thermoelectric generator (TEG) model is developed.
• Heat exchanger design and TEG configuration are optimized for maximum fuel efficiency increase.
• Heat exchanger conductivity has a strong influence on maximum fuel efficiency increase.
• TEG aspect ratio and fin height increase with heat exchanger thermal conductivity.
• A 2.5% fuel efficiency increase is attainable with nanostructured half-Heusler modules.

Automotive fuel efficiency can be increased by thermoelectric power generation using exhaust waste heat. A high-temperature thermoelectric generator (TEG) that converts engine exhaust waste heat into electricity is simulated based on a light-duty passenger vehicle with a 4-cylinder gasoline engine. Strategies to optimize TEG configuration and heat exchanger design for maximum fuel efficiency improvement are provided. Through comparison of stainless steel and silicon carbide heat exchangers, it is found that both the optimal TEG design and the maximum fuel efficiency increase are highly dependent on the thermal conductivity of the heat exchanger material. Significantly higher fuel efficiency increase can be obtained using silicon carbide heat exchangers at taller fins and a longer TEG along the exhaust flow direction when compared to stainless steel heat exchangers. Accounting for major parasitic losses, a maximum fuel efficiency increase of 2.5% is achievable using newly developed nanostructured bulk half-Heusler thermoelectric modules.