1. PBJ Xaustors -Exhaust Waste Energy Recovery Peter Jorg James Stewart Robert Wiegers Jeremy Boles – Graduate Mentor Client: Frank Albrecht – Future Truck

2. Presentation Overview Background Concepts Testing Product Realization Recommendations

3. 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.

4. 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)

5. Concept Selection Thermophotovoltaics  Enable usage of high temp (over 1,000ºF) waste heat  Projected high cost  Little availability to date Modified turbo system  Off the shelf parts  Low Cost  High back pressure Adsorption cooling  Potential for elimination of harmful refrigerants  Makes direct use of thermal energy  Cooling unit must be rather large

6. 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

7. Vehicle Testing  Attachment of the thermocouples to the exhaust pipes  Data Acquisition unit in cab of truck

8. Vehicle Testing Results -Future Truck Optimal thermal conditions 450 ° – 500 ° F

9. Solution Concept – Engine->Exhaust->TE chips->Battery IC Engine Exhaust System TE HX Load Matching Circuit Vehicle Battery 41% Mechanical Output 25% Peripheral Systems 34% Power to Exhaust 0.75% Exhaust Power Converted to Electrical Power Power to Vehicle Subsystems Unrecovered Power

10. Thermoelectric Testing -bench Field point modules collecting data Fan emulating airflow from driving Heat sink and air ducting Heat distribution plate Heat source DMM measuring current Computer analyzing data Thermocouples taking measurements

11. Lab View Controls Sampling Number Resistance input Voltage, power readouts File path Temp readings Temperature difference graph Power vs. temp difference graph

12. Generator Testing Results Temperature Difference ºF Power output W

13. Theoretical Output

14. Thermoelectric Testing -engine DMM measuring voltage output Exhaust system Thermal bypass valves James Test engine Exhaust coupler

15. Thermal Bypass

16. Product Realization

17. Exhaust System Comparison 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

18. Budget

19. 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

20. Continuing Work Load Matching Circuit Underestimated aftermarket availability EE recommendations Forced Air Cooling Original implementation scheme Change in plans Parasitic fan

21. 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

22. And now a moment of Zen Any Questions?