Brand Management – Communication Interne Renault Trucks SAS
Joint Company Volvo Group
RENOTER ProjectLuc Aixala
2nd Thermoelectric Applications Workshop: 3-6 January 2011 in San Diego
Mack TrucksMack Trucks
Introduction - Volvo Group
Mack Trucks Renault Trucks UD Trucks Volvo Trucks
Construction Buses Volvo Penta Equipment Volvo Aero Financial Services
Renault Trucks Joint Company - Volvo Group RENOTER project presentation
Luc Aixala (4-1-2011) 2
1) Introduction
RENOTER acronym for:
“Récupération d’ENergie à l’échappement d’un mOteur par ThERmoélectricité”
8 partners including 3 laboratories
Started Q4/2008 – duration 3 yyearsQ
Budget 4.2M€
Partially funded by French Government
Supported by French Automotive Clusters
Renault Trucks Joint Company - Volvo Group RENOTER project presentation 3 Luc Aixala (4-1-2011)3
1) Project Goals
Passenger Car – Diesel : 100W NEDC - 300W on customer cycle – Gasoline : 500W on customer
Heavy-Duty Truck 1kW on cruise point – 1kW on cruise point
Focus on cheap, available, efficient, and sustainable TE materials. Work on efficient material integration and production process Target cost of 0.3 – 1.3 $/We all included
Renault Trucks Joint Company - Volvo Group RENOTER project presentation
Luc Aixala (4-1-2011) 4
Heavy-duty truck application
Renault Trucks Premium model
11L engine (460 hp - 1620 lbft)
Avg. FE = 6.8 mpg*
Exhaust Gas Recirculation Cooler selected as heat source
* =32M/100km - for the duty cycle of the project
Renault Trucks Joint Company - Volvo Group RENOTER project presentation
Luc Aixala (4-1-2011) 5
1) EGR specifications 650
600 10
550 8
500
EG
R g
as t
emp
erat
ure
(°C
)
450 6
400
350 4
250
300 2
200 0
EGR gas mass flow rate (kg/s)
0.02 0.04 0.06 0.08 0.1 0
Avg. T° ~400°C – Avg. Q ~45g/s
% oo
f ti
me
Renault Trucks Joint Company - Volvo Group RENOTER project presentation
Luc Aixala (4-1-2011) 6
Passenger car application
Laguna III model
2.0L dCi engine (150hp – 250lbft) Euro5
FE = 45 mpgpg
Exhaust line chosen as heat source
(EGR flow ~0 at full load)
* On Mix NEDC
Renault Trucks Joint Company - Volvo Group RENOTER project presentation
Luc Aixala (4-1-2011) 7
Available exhaust energy
Specifications for diesel engine
Avg. Temperature Avg. flow TEG Power (Target)
NEDC
Constant speed 100 km/h
165 °C
328 °C
12 g/s
25 g/s
100 W
300 W
Constant speed 120 km/h 398 °C 53 g/s 500 W
Renault Trucks Joint Company - Volvo Group RENOTER project presentation
Luc Aixala (4-1-2011) 8
3) Materials
Many TE materials available
Project specification includes performance, cost, working temperature, manufacturing…
Best ZT @ 200 - 400°C
Peak Temperature ~500-600°C
Sustainable and low-cost materials
Renault Trucks Joint Company - Volvo Group RENOTER project presentation
Luc Aixala (4-1-2011) 9
3) Materials TE Material
State-of-art N-
type P-
Type ZT
200°C
ZT
400°C
OK for 600°C
Max Temperature Est. € per dm3
Bi2Te3 1 - NO (250°C) 800-900
PbTe 0.75 1.0
YES (600°C)*
700
LAST (Ag-Pb-Sb-Te) 0.8 1.4 500-800
TAGS (Te-Ag-Ge-Sb) - 0.7 1.2
Z SbZn4Sb3 - 0 70.7 1 21.2 NO (400°C)NO (400°C) 2525
Mg2Si ~ 0.3 0.8 YES (600°C) 80-450
HMS - 0.4 0.6 YES (800°C) 150
Skutterudites (CoSb) 0.5 0.7 YES (700°C) 300-450
SiGenanostructured 0.2 0.4 YES (1200°C) 2900
Clathrates (GaGe) 0.2 0.7 YES (>1000°C) 3000 (*encapsulated)
Renault Trucks Joint Company - Volvo Group RENOTER project presentation 10 Luc Aixala (4-1-2011)
3) Low temperature material: Bi2Te3
Material worked by Nancy University
Doping both types (p-n) for automotive application + up-scaling process
Bi2Te3 after Hot Pressing (Ø30mm)
Renault Trucks Joint Company - Volvo Group RENOTER project presentation 11 Luc Aixala (4-1-2011)
3) High temperature materials
HMS and Mg2Si worked by Montpellier University
Good results so far for HMS p-type
HMS Ø20mm HMS Ø8mm
HMS Ø40mm
Renault Trucks Joint Company - Volvo Group RENOTER project presentation 12 Luc Aixala (4-1-2011)
3) High temperature materials
Consistent n-type samples obtained but up-scaling difficult
Replacement of Germanium dopant by cheaper one ongoing
Work on p-type
Time
Mg2Si after Spark plasma sintering (Ø8mm)
Renault Trucks Joint Company - Volvo Group RENOTER project presentation 13 Luc Aixala (4-1-2011)
4) TEG design
Good thermal efficiency
Low backpressure REQ. Ensure reliability through thermal & mechanical stress control
Ease of manufacturing
Renault Trucks Joint Company - Volvo Group RENOTER project presentation 14 Luc Aixala (4-1-2011)
• Indirect contact TE and cold tube
Hot tube
TE TE
TETE
To reach a good heat transfer between hot gas and TE face:
• Rectangular tubes in stainless steel with turbulator inside
• Direct contact TE & hot tube To minimize heat exchanger
structure and weight
4) Novel TEG design
through a fin
• Cold tubes in aluminum for 2 functions: heat sink and tie rod
Hot tube
Cold tube Cold tube To be reliable vs. Thermal and
Mechanical stress Compressible Cold fin • In- between fin, compressible material to
joint absorb TEG internal constraint • Electrical insulation layer between TE /
Hot Tubes, TE / Cold fins
Renault Trucks Joint Company - Volvo Group RENOTER project presentation 15 Luc Aixala (4-1-2011)
4) TEG description
Compact + light weight
Easy packaging (flexible geometry)
Sub-components technologies validated
Able to support any type of TE material + resists to high T°
Renault Trucks Joint Company - Volvo Group RENOTER project presentation 16 Luc Aixala (4-1-2011)
5) Simulation and testing
7000 legs of Mg2Si and HMS (4mm x 6mm x 6mm)
Brazing propertied of Bi2Te3 modules
Heat exchanger data from bench characterization
1kW
10kg
7L
Sherpa Engineering simulation software
Renault Trucks Joint Company - Volvo Group RENOTER project presentation 17 Luc Aixala (4-1-2011)
ZT values used for simulation coming from LPM Nancy
0,6
0,7
0,8
0,9
1
1,1
0
0,1
0,2
0,3
0,4
0,5
0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750
Temperature (°C)
Mg2Si n‐type
MnSi p‐type
Renault Trucks Joint Company - Volvo Group RENOTER project presentation 18 Luc Aixala (4-1-2011)
Simulation outputs (Truck EGR) T
empee
ratu
re (
°C) Full torque = 400W 1200
500 1000
450 800
400 600
400 Half torque = 100W 350
200 300
0
0.05 0.1 0.15 0.2 0.25 0.3 Gas mass flow rate (kg/s)
Full power = 1200W 1600 600
1400 550
P
(W
) el
ec
Renault Trucks Joint Company - Volvo Group RENOTER project presentation 19 Luc Aixala (4-1-2011)
Module testing
Similar performance as literature and commercial modules
Used to determine thermal and electrical contact resistances
High temperature + small TEG under work
120 plots Bi2Te3 module built at CRISMAT-CNRT
Renault Trucks Joint Company - Volvo Group RENOTER project presentation 20 Luc Aixala (4-1-2011)
Module testing
Thermoelectrical performances under verification
Will validate TEG concept and interfaces (brazings, barriers…)
Heat exchanger portion
Renault Trucks Joint Company - Volvo Group RENOTER project presentation 21 Luc Aixala (4-1-2011)
6) Conclusions
Non-toxic and non-costly materials (Te and Pb alternatives)
Simulation software tuned with real module tests
New efficient TEG design allowing screening of any novel materials
1kW (trucks) and 300W (cars) targets achievable during this year Mass market application in sight but will take time (cost vs. efficiency)
source: Renault Trucks
Renault Trucks Joint Company - Volvo Group RENOTER project presentation 22 Luc Aixala (4-1-2011)
Acknowledgments
RENOTER project team
DGIS (Direction Générale de la Compétitivité, de l'Industrie et des SServiices))
Région Basse-Normandie
Renault Trucks Joint Company - Volvo Group RENOTER project presentation 23 Luc Aixala (4-1-2011)
Top Related