WASTE HEAT RECOVERY FROM SILENCER BY

USING THERMOELECTRIC GENERATOR

A
REPORT
SUBMITTED IN PARTIAL FULLFILLMENT OF THE
MINOR PROJECT COURCE
For the award of
Bachelor of Technology
(Mechanical Engineering)

Submitted by
NAME ID. NO.
GAUTAM POSHIYA 17ME098
BUDHALAL KHODIFAD 17ME099
HARDIK VAGHELA 17ME431
PANKAJ BHOLA 17ME435
Under the guidance of
Prof. B. S. Patel

Birla Vishvakarma Mahavidyalaya

Engineering College (An Autonomous Institution)
Vallabh Vidyanagar – 388 120
Affiliated to Gujarat Technological University
May-2021
 CERTIFICATE

Date: 28/04/2021

This is to certify that the Project entitled “WASTE HEAT RECOVERY FROM
SILENCER BY USING THERMOELECTRIC GENERATOR” has been carried out by
GAUTAM POSHIYA (17ME098), BUDHALAL KHODIFAD (17ME099), HARDIK
VAGHELA (17ME431), PANKAJ BHOLA (17ME435) in the 8th semester under my
guidance in partial fulfilment of the degree of Bachelor of Technology in Mechanical
Engineering, Birla Vishvakarma Mahavidylaya, Vallabh Vidyanagar, during the academic
year 2020-21.

Guide: Prof. B. S. Patel (Mechanical Engineering Dept., BVM Engineering College,

Vallabh Vidhyanagar, India.)

Head of the Department

 Originality Report Certificate

It is certified that Project Report titled “WASTE HEAT RECOVERY FROM

SILENCER BY USING THERMOELECTRIC GENERATOR” by GAUTAM
POSHIYA (17ME098), BUDHALAL KHODIFAD (17ME099), HARDIK VAGHELA
(17ME431), PANKAJ BHOLA (17ME435)

has been examined by us. We undertake the following:

(1) Project has significant new work / knowledge as compared already published or
are under consideration to be published elsewhere. No sentence, equation,
diagram, table, paragraph or section has been copied verbatim from previous
work unless it is placed under quotation marks and duly referenced.
(2) The work presented is original and own work of the author (i.e. there is no
plagiarism). No ideas, processes, results or words of others have been presented
as Author own work.
(3) There is no fabrication of data or results which have been compiled / analyzed.
(4) There is no falsification by manipulating research materials, equipment or
processes, or changing or omitting data or results such that the research is not
accurately represented in the research record.
(5) The report has been checked using DUPLI CHECKER (copy of originality
report attached) and found within limits, (i.e., permitted similarity index <= 20
%)

Name and signature of Students:

GAUTAM POSHIYA (17ME098)

BUDHALAL KHODIFAD (17ME099)

HARDIK VAGHELA (17ME431)

PANKAJ BHOLA (17ME435)

III
 PLAGIARISM REPORT

Software: Duplichecker (https://www.duplichecker.com/)

Abstract

Chapter 1

Chapter 2
Chapter 3

Chapter 4

Chapter 5

Average Plagiarism = 11.5 %

V
 ACKNOWLEDGEMENT

In performing our project, we would like to express our deep and sincere gratitude to
the Prof. B.S. PATEL, Birla Vishvakarma Mahavidyalaya who deserve the most for his
patience, motivation, and immense knowledge. His guidance helped us in doing a lot of
research and came to know about so many new things about project, we are really thankful to
them.

Many people, especially our classmates and team members itself, have made valuable
comment suggestions on this proposal which gave us the inspiration to improve our
assignment. We thank all the people for their help directly and indirectly to complete our
assignment. We thank the BVM Mechanical department for giving us the opportunity to work
in this project.
 ABSTRACT

Our aim is to identify the hot spot at different section among the length of silencer a new design
(concept) for design & fabrication of silencer is adopted thermo electric module will be provided at
different section of silencer which generate electricity. We are using the concept of conduction heat
transfer through solid wall so we transfer the energy by diathermic wall of silence and utilize it.The
system converts the waste heat from the exhaust manifold into electrical energy using a TEG. The
output is then boosted by a Joule Thief converter to run the required load or to charge a battery. The
experimental results demonstrate that the proposed system recovers considerable amount of waste heat
which can be used to power some auxiliary automobile devices. The converting of heat energy into
electric energy is working on the principle of p-n junction from hot body to cold body. So, from this
how we can utilize waste energy of engine which is passing through silencer is used for generating
power, in other way also we will utilize this energy for charging the battery so we can quickly charge
the battery, we can perform both the operation simultaneously.

vii
CHAPTER 1: INTRODUCTION

CONTENTS
CHAPTER 1: INTRODUCTION ........................................................................................... 1

1.1 TYPES OF HEAT RECOVERY SYSTEM ...............................................................................2

1.1.1 THERMAL WHEEL HEAT RECOVERY ...........................................................................2

1.1.2 PLATE HEAT OR RECUPERATOR TECHNOLOGY .....................................................3

1.1.3 HEAT PUMPS .........................................................................................................................3

1.1.4 RUN AROUND COIL OR CLOSED LOOP TECHNOLOGY ...........................................3

1.1.6 BOILER FLUE ECONOMIZERS .............................................................................................5

1.2 THERMOELECTRIC SYSTEMS .............................................................................................5

1.3 HEAT EXCHANGERS FOR TEG ............................................................................................5

1.4 OBJECTIVE.................................................................................................................................6

1.5 METHODOLOGY .......................................................................................................................7

CHAPTER 2: LITERATURE REVIEW .............................................................................. 8

2.1 HISTORY ............................................................................................................................................8

2.2 RESEARCH PAPER ..........................................................................................................................8

2.3 RESEARCH PAPER CONCLUSION ............................................................................................11

2.4 SUMMARY OF LITRATURE REVIEW ......................................................................................16

CHAPTER 3: MATERIAL SELECTION & ITS ANALYSIS ......................................... 18

3.1 BLOCK DIAGRAM OF SETUP .....................................................................................................18

3.2 INTERNAL COMBUSTION ENGINE (EXHAUST) ...................................................................18

3.3 SELECTION OF SILENCER .........................................................................................................19

3.4 THERMO-ELECTRIC GENERATOR (TEG) .............................................................................19

3.4.1 THERMOELECTRIC POWER ..............................................................................................20

3.4.2 HEAT TO ELECTRICITY ......................................................................................................21

3.4.3 POWER FROM WASTE HEAT..............................................................................................22

3.4.4 PORTABLE POWER ...............................................................................................................23

CHAPTER 4: POWER CALCULATION........................................................................... 25

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4.1 THEORETICAL POWER CALCULATION ................................................................................25

4.1.1 VOLTAGE(V) ............................................................................................................................25

4.1.2 CURRENT(I) .............................................................................................................................26

4.1.3 POWER(P) .................................................................................................................................26

4.1.4 HEAT INPUT TO THE THERMOCOUPLE(Qh) ..................................................................26

4.1.5 EFFICIENCY OF TEG .............................................................................................................26

4.2 THEORETICAL SAMPLE CALCUTION ....................................................................................27

4.2.1 SAMPLE CALCULATION FOR FIRST READING ............................................................28

4.3 GRAPHICAL PRESENTATION BASED ON THEORETICAL CALCULATION .................30

4.3.1 ∆T VS POWER .........................................................................................................................30

4.3.2 TIME VS HEAT ........................................................................................................................30

4.3.3 TIME VS EFFICIENCY ...........................................................................................................31

4.3.4 ∆T VS EFFICIENCY ...............................................................................................................31

4.4 CONCLUSION FROM THEORETICAL CALCULATION .......................................................32

CHAPTER 5: COMPONENTS & COST ESTIMATION ................................................. 33

5.1 READY COMPONENTS .................................................................................................................33

5.2 FUNCTION OF PARTS...................................................................................................................35

5.3 COST ESTIMATION.......................................................................................................................36

5.3.1 READY MATERIAL COST.....................................................................................................36

5.3.2 OTHER COST ...........................................................................................................................36

5.3.3 TOTAL COST............................................................................................................................37

5.4 FINAL MODEL OF PROJECT ......................................................................................................37

CHAPTER 6: REFERENCES .............................................................................................. 38

6.1 REFERENCES..................................................................................................................................38

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WASTE HEAT RECOVERY FROM SILENCER BY USING THERMOELECTRIC
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CHAPTER 1: INTRODUCTION

The automobile industry is one of the world’s most significant financial sectors.
Automobiles use IC engines, which have huge measure of energy misfortune up to 70% as
warmth. In the new occasions, researchers have attempted and refined the vehicle innovation
apparently, but they could not control the loss in IC engine in the form of waste heat.

Thermoelectric generator (TEG) is a device which converts thermal energy

straightforwardly into electrical energy by using see beck effect. The utilization of TEG in
automobile IC engine is a progressive thought, which reduce load on alternator which changes
the battery, subsequently thus contributing to decreases in fuel consumption.

FIGURE 1.1 AUTOMOTIVE ENERGY FLOW DIAGRAM

The temperature of the ‘exhaust bend pipe surface’ through which exhaust gases are
flowing, ranges between 150°C to 200°C, by attaching a aluminum plate to this bend pipe hot
junction of the thermoelectric module is create, other side cold junction is created by aluminum
heat sink. As this potential difference is created, voltage is produced by using see-beck effect.
If we want to further increase output voltage, we have to use booster circuit.

Thermoelectric generation is now being explored for its power recovery potential in
automobiles. Out of the energy that comes from a combustion process in an engine, 40% is lost
through exhaust gases. Thermoelectric generators are intended to capture some of this
otherwise lost energy.it is a solid-state device that provide direct energy conversation from
thermal energy into electrical energy due to temperature gradient. This study focuses on the
design and testing of an experimental model that aims to improve the temperature distribution

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 CHAPTER 1: INTRODUCTION

and lower the overall temperature for the cold side and measures temperature change across
the TEG for two cold side geometries. The test stand is intended for a secluded format,
permitting the test segment to be effortlessly exchanged between the baseline and impingement
geometries.

1.1 TYPES OF HEAT RECOVERY SYSTEM

Heat recovery systems can arrive in a variety of structures; however, all include some
form of heat exchanger. This sits in the structure, generally in the loft or on the roof, and pipes
feed down from it into each room, drawing out the stale air and replacing it with warmed, clean
air.

1.1.1 THERMAL WHEEL HEAT RECOVERY

With the biggest air recuperation effectiveness of all the ventilation systems, thermal wheel
units additionally will in general be a lot greater in size. They are comprised of two huge wheels
with a honeycomb array. It's one portion of which is attracting exhaust air and the other half
natural air from outside. The wheels rotate in opposite directions to each other and the energy
from the exhaust air is transferred to the incoming air and heating it up.

FIGURE 1.2 THERMAL WHEEL HEAT RECOVERY DIAGRAM [20]

The heat exchanger wheels are ordinarily made of aluminum but can really be built from a
wide range of materials including plastic and even paper. The advantage of the thermal wheel

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WASTE HEAT RECOVERY FROM SILENCER BY USING THERMOELECTRIC
GENERATOR

is that it is highly productive compared to other systems and is likely to provide a speedier
return on investment if set up appropriately. As a heat recovery system, the speed of rotation
of the wheels, and the measure of energy transferred, can be controlled to raise or lower the
temperature of the air that is taken care of once more into the structure.

1.1.2 PLATE HEAT OR RECUPERATOR TECHNOLOGY

More normal than thermal wheel heat recovery since it tends to be utilized on a smaller scale
is plate heat or recuperator technology. It involves a box with a series of parallel plates made
from metal or plastic which permits the extracted air to pass over the incoming air, transferring
the energy and heating it up. The air streams are isolated by the plates and never contact so one
of the critical elements in the productivity of any system is how thin and conductive each plate
are Plate heat recovery systems generally have an efficiency of around 70% at their best.

FIGURE 1.3 PLATE HEAT TECHNOLOGY [21]

1.1.3 HEAT PUMPS

Heat pumps take the heat from one region and transfer it to another location. They work
likewise to a refrigeration unit and it very well may be utilized for both cooling and warming
the air. There are a various different variety and they can draw heat from the external air as
well as from the ground through the utilization of an organization of pipes.

1.1.4 RUN AROUND COIL OR CLOSED LOOP TECHNOLOGY

A run around coil can be introduced to an existing air handing system and typically comprises
of two coils that are associated with one another by a pumped circuit of pipes.

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CHAPTER 1: INTRODUCTION

Water is normally used to charge the circuit, getting the heat from the exhaust pipe and
transferring it to the supply air coil. Heat recovery systems, for example, these are utilized
where the two air streams are not close enough for more effective systems such as the thermal
wheel or recuperator technology. It by and large conveys a most extreme effectiveness of
around 50%.

FIGURE 1.4 RUN AROUND COIL TECHNOLOGY [22]

1.1.5 HEAT PIPE TECHNOLOGY

Of all the heat recovery systems, heat pipes are the least maintenance. They can, however, only
be utilized where the air dealing is done in one system. It utilizes a tube system with a
refrigerant to extract the heat from the exhaust air and pass it to the supply air. Vertical pipes
utilize the dissipation of the refrigerant to transfer the heat whilst horizontal ones incorporate
wicks inside the pipework that additionally permit the exchange of refrigerant. Vertical arrays
(max 75%) are more effective than horizontal (max 50%).

FIGURE 1.5 HEAT PIPE TECHNOLOGY [23]

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 WASTE HEAT RECOVERY FROM SILENCER BY USING THERMOELECTRIC
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1.1.6 BOILER FLUE ECONOMIZERS

As heat recovery systems, boiler flue economizers would now be able to be fitted as a matter
of course on new boilers. They can likewise be retro fitted to older models and catch the heated
vapor which can then be utilized in a variety of ways to improve the boiler efficiency. In most
cases efficiencies of 5 to 15% can be obtained by condensing or non-condensing gas-to-water
systems.

FIGURE 1.6 BOILER FLUE ECONOMISERS [24]

1.2 THERMOELECTRIC SYSTEMS

The driving technology behind thermoelectric generation is the known as the Seebeck
effect. When a temperature gradient is applied to a thermoelectric material, specifically metals
or semiconductors, the heat passing through is carried by the same particles that carry charge.
Once the heat is removed through the cold side or a heat sink, free electrons are deposited on
the cold side. The movement of charge produces a voltage that can be harnessed and used for
[1]
other purposes, such as providing power for minor car electronics. Equation V=S∆T
demonstrates how a temperature gradient affects the voltage, with S as the Seebeck coefficient.

1.3 HEAT EXCHANGERS FOR TEG

In order to increase the efficiency of the TEG, two methods can be used. The
thermoelectric material can be made with a higher ZT value, although this is difficult to do and
generally the process in improving the material is costly and time consuming. Another method
would be to improve the temperature gradient across the thermoelectric material. This method
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 CHAPTER 1: INTRODUCTION

is much simpler and can produce effective results. For each degree Kelvin, the efficiency of
[2]
the TEG system can improve up to 0.04% . A type of heat exchanger made to fit around the
TEG may make the necessary improvements in the temperature gradient. This type of heat
exchanger needs to interact with the thermoelectric material for both heat transfer and stability
purposes. The solution includes three main pieces of the system: the thermoelectric material
itself, the hot side loop, and the cold side loop. The hot side loop is an open loop that represents
the exhaust pipe. The thermoelectric element lies on a flattened section of the pipe. Around the
hot side and the thermoelectric element, the cold side loop will run, containing coolant from
the car’s existing coolant loop. This study focuses on the improving the heat transfer from the
TE element to the coolant loop, which decreases the temperature of the cold side of the TEG.

1.4 OBJECTIVE

➢ Analysis of waste heat of exhaust gas for producing power with concept of conduction
heat transfer.

➢ Find the hot spot in the silencer for getting maximum heat.

➢ Power producing by thermoelectric generator is use for electrical equipment as well as

recharge the battery.

➢ Testing the performance of this setup on exhaust emission.

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 WASTE HEAT RECOVERY FROM SILENCER BY USING THERMOELECTRIC
GENERATOR

1.5 METHODOLOGY

Review of research paper

Study of heat recovery systems

Study of thermoelectric system

Make a model of project

Theoretical and experimental

power calculation

BLOCK DIAGRAME

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 CHAPTER 2: LITERATURE REVIEW

CHAPTER 2: LITERATURE REVIEW

2.1 HISTORY
In 1821, Thomas Johann Seebeck rediscovered that a thermal gradient created
between two dissimilar conductors can produce electricity. At the heart of the thermoelectric
effect is the fact that a temperature gradient in a conducting material results in heat flow; this
results in the diffusion of charge carriers. The flow of charge carriers between the hot and cold
areas in turn creates a voltage difference. In 1834, Jean Charles Athanasy Peltier found the
reverse effect, that running an electric current through the junction of two dissimilar conductors
could, depending on the direction of the current, cause it to act as a heater or cooler.

2.2 RESEARCH PAPER

AMIT TIWARI, HIMANSHU VASNANI, DR. NEERAJ KUMAR, MAHENDRA
LABANA “A Review on Waste Heat Recovery and Reused of Exhaust Gases from Diesel
Engines” This work centres around the Rankine cycle as the most promising existing
innovation for engine waste heat recovery in terms of recuperation efficiency. While it is a
relatively developed technology and is broadly used in power generation, its utilization in
vehicles presents new challenges in system design. These come from environmental and
packaging issues, as well as difficulties relating to the quality and quantity of the accessible
heat and its transient availability. It is not yet clear which working fluid and expansion device
are ideal for use in a Rankine cycle-based system for vehicular applications. However, past
investigations have demonstrated that these parts are among the most important factors for the
system’s performance. Waste heat is heat, which is produced in a process by way of fuel
combustion or chemical reaction, and then dumped into the environment even though it could
still be reused for some helpful and financial purpose. This heat depends partially on the
temperature of the waste heat gases and mass flow rate of exhaust gas. Waste heat losses arise
both from equipment inefficiencies and from thermodynamic restrictions on equipment and
processes.[3]

LEGROS ARNAUD, GUILLAUME LUDOVIC, DINY MOUAD, ZAÏDI HAMID AND

LEMORT VINCENT “Comparison and Impact of Waste Heat Recovery Technologies
on Passenger Car Fuel Consumption in a Normalized Driving Cycle” The reason of this
article was to analyse different waste heat recovery system technologies designed for
automotive applications. A total writing survey is done and results in two comparative graphs.
In the subsequent part, simulation models are constructed and calibrated in order to assess the
fuel consumption reduction that can be accomplished on a real driving cycle. The strength of
this article is that the models are calibrated utilizing actual data. At long last, those simulations
results are analysed and the Rankine cycle and turbo compound are the two most beneficial
solutions. However, the simulations of the turbo compound show its restrictions because the
impact on the exhaust pressure drop is not taken into account in the assessment of the vehicle

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WASTE HEAT RECOVERY FROM SILENCER BY USING THERMOELECTRIC
GENERATOR

fuel utilization. Fuel decrease of up to 6% could be accomplished, depending on the driving

cycle and the waste heat recovery technology.[4]

BALESHWAR KUMAR SINGH, DR. NITIN SHRIVASTAVA “Exhaust Gas Heat

Recovery for C.I Engine-A Review” The focus of the study is to survey the modern changes
and technologies on waste heat recovery of exhaust gas from internal combustion engine. These
include the thermoelectric generator, turbocharger, exhaust gas through I.C engine. Because of
the total heat supplied to the engine in the form of fuel around 30-40%, heat is converting in to
the utilization full mechanical work and residual parts of the wastage heat 60-70% as friction,
exhaust gas and engine cooling system. Waste heat release in the form of fumes in climate
through I.C engine, which also includes the exhaust gases. The results are global warming,
greenhouse effects and entropy increases etc. Hence, it is needed to use the waste heat in to
useful work. The recovery of waste heat not only conserves fossil fuel but also control the
climate contamination. Therefore, main objective of this paper is to assess (waste heat recovery
system) technology dependent on the total waste heat converted into the useful mechanical
work and potential methods to recovery of the waste heat from I.C engine. As a result, waste
heat recovery from the I.C engines and utilization shall be remaining best method in future
automobile application save the fuel and protect the environment.[5]

J. S. JADHAO, D. G. THOMBARE “Review on Exhaust Gas Heat Recovery for I.C.

Engine” The increasingly worldwide problem regarding quick economy development and a
relative lack of energy, the internal combustion engine exhaust waste heat and environmental
pollution has been more emphasized heavily recently. Out of the total heat supplied to the
engine in the form of fuel, around, 30 to 40% is converted into useful mechanical work; the
remaining heat is expelled to the climate through exhaust gases and engine cooling systems,
resulting in to entropy rise and serious environmental pollution, so it is needed to utilized waste
heat into useful work. The recovery and utilization of waste heat not only conserves fuel (fossil
fuel) but also reduces the amount of waste heat and greenhouse gases damped to climate. The
study shows the accessibility and possibility of waste heat from internal combustion engine,
additionally describe loss of exhaust gas energy of an internal combustion engine. Potential
methods to recover the waste heat from internal combustion engine and performance and
emissions of the internal combustion engine. Waste heat recovery system is the most ideal
approach to recover waste heat and saving the fuel.[6]

BIBIN P VARGHESE, V HARIGANESH, AJISH SOMAN “Design and CFD

Investigation of Exhaust Gas Recovery System for 4SSC Diesel Engine” With worldwide
reserves of fossil fuels slowly decreasing and air pollution increasing, automotive engineers
are constantly on the lookout for approaches to make vehicles more fuel efficient and to reduce

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CHAPTER 2: LITERATURE REVIEW

their carbon emissions. One of the most surprising places they've discovered wasted energy is
in the car's exhaust. Actually, automotive designers have been tapping the hidden power of
automobile exhaust since the early 1970s. Because this technology reuses the exhaust before it
can exit the vehicle, it also helps reduce the emissions produced by a car and assists battle with
air pollution. Advancements made to maximize the efficiency of a vehicle's exhaust are known
collectively as exhaust heat recovery and recirculation. There are few different ways to use a
vehicle's exhaust to increase its fuel efficiency and make it run with fewer emissions. For
instance, the heat of the car's exhaust can be used to warm the engine coolant to keep the engine
running warm, even when the motor has been turned off for a significant length of time. Out
of the total heat supplied to the engine in the form of fuel, roughly, 30 to 40% is converted into
useful mechanical work; the remaining heat is removed to the climate through exhaust gases
and engine cooling systems, resulting in to entropy rise and serious environmental pollution,
so it is required to utilized waste heat into useful work. This paper work presents design and
CFD investigation of exhaust gas recovery for a 4SSC Diesel engine.[7]

MR. RUPESH SURYAVANSHI, PROF.A.D. PITALE “A Review on Waste Heat

Recovery in Industries” This research article presents a review of various works focused on
waste heat in industry for improving energy efficiency. The different reviews based on the
aspects of heat recovery and the methodologies and technologies being employed for its
optimization in industries also study through literature. This work also concentrated on the
different parameters governing the waste heat recovery in the industries. [8]

M. DUBEYA, A. ARORAA, H. CHANDRAB “Review on Recovery and Utilization of

Waste Heat in Internal Combustion Engine” Today the demand of energy is increasingly
worldwide problem regarding rapid economy development and lacks in supply of energy.
Recently exhaust waste heat and environmental pollution has been more emphasized of internal
combustion engine. About 75% of the fuel energy loses through the engine coolant, exhaust
and surface radiation, result the entropy will rise and serious environmental pollution occur, so
it is required to utilize waste heat into useful work. The energy released during combustion
power produced by the burning fuel is used for work output is around 20% only. Major part of
the heat supplied is not used as work output in an internal combustion engine but dumped into
the atmosphere as waste heat. The recovery and utilization of waste heat not only conserves
fuel but also reduces the amount of waste heat and greenhouse gases damped to environment.
Depending on engine load approximately 30-40% of the energy is recovered that rejected to
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 WASTE HEAT RECOVERY FROM SILENCER BY USING THERMOELECTRIC
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the environment through exhaust gas. The overall efficiency of an engine can be improved
when waste heat energy is tapped and converted into usable energy. The study shows the loss
of exhaust gas energy and also describes the availability and possibility of waste heat from
internal combustion engine. The best way to recover the waste heat and saving the fuel is waste
heat recovery system.[9]

X. LIU, Y.D. DENG, S. CHEN, W.S. WANG, Y. XU, C.Q. SU “A case study on
compatibility of automotive exhaust thermoelectric generation system, catalytic
converter and muffler” The power generation of an exhaust TEG (thermoelectric generator)
depends on heat energy and thermoelectric conversion efficiency. However, there are
compatibility problems among TEG, CC (catalytic converter) and muffler. The present work
tried to vary the installation position of TEG and propose three different cases. Case 1: TEG is
located at the end of the exhaust system; case 2: TEG is located between CC and muffler; case
3: TEG is located upstream of CC and muffler. Simulation and experiment were developed to
compare thermal uniformity and pressure drop characteristics over the three operation cases.
From the simulation and experiment, heat exchanger in case 2 obtained more uniform flow
distribution, higher surface temperature and lower back pressure than in
other cases. At the same time, the CC and muffler could keep normal working in case 2,
providing a theoretical and experimental basis for the exhaust gas waste heat recovery
system.[10]

2.3 RESEARCH PAPER CONCLUSION

TABLE 2.1 RESEARCH PAPER ANALYSIS

NAME OF PAPER VOLUME CONCLUSION

NO
A Review on Waste Volume 06 There is a pressing need to improve the efficiency
Heat Recovery and Issue 09 of IC engines because of the danger of climate
Reused of Exhaust September change and the earth’s diminishing fossil fuel
Gases from Diesel 2017 reserves, making the use of waste heat recovery
Engines systems for IC engines increasingly attractive.

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CHAPTER 2: LITERATURE REVIEW

Systems based on the Rankine cycle are

considered to be among the most promising
technologies for this purpose because of their heat
recovery efficiency.
It has been observed that there is a large amount
heat is waste from the engine. Approximately heat
lost by exhaust as is same to useful work produced
by engine.
It is identified that there is large potential of
energy saving through the use of waste heat
recovery technologies.
The recovery and utilization of waste heat not
only conserves fuel but also reduces the
greenhouse gases and waste heat by increasing
efficiency of engine.
This study shows the Benefits of waste heat
recovery, Heat carried away by the exhaust gas,
various possible methods for heat recovery.
Comparison and ISSN 1996- A complete state of the art review of the main
Impact of Waste Heat 1073 technologies to recover waste heat energy in the
Recovery 14TH exhaust gases of a light duty vehicle engine has
Technologies on AUGUST been provided.
Passenger Car Fuel 2014 As a conclusion to that state of the art, major
Consumption in a drawbacks of those technologies have been
Normalized Driving pointed out and several relevant performance
Cycle indicators have been compared: efficiency, cost,
technical maturity, packaging and weight to
power ratio. The second part of this article focuses
on the evaluation of the performance of three of
those technologies on two different gasoline
engines considering two different driving cycles.
This evaluation is based on simulation. The
models of three waste heat recovery systems have

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WASTE HEAT RECOVERY FROM SILENCER BY USING THERMOELECTRIC
GENERATOR

been built and calibrated based on measurement

data. The results presented in this article only rely
on quasi-steady state models.
Thus, the results presented here are not totally
representative of the reality.
Exhaust Gas Heat IJESRT ISSN By using waste heat recovery concept, we can
Recovery for C.I 2277-9655 save the fuel and utilized the waste heat also.
Engine-A Review NOVEMBER There is the large amount of energy- saving
2014 through waste heat.
Through above paper waste heat recovery are
utilized in the form of heat generating, mechanical
and electrical and refrigeration system in I.C
engine.
Mainly waste heat recovery from exhaust gas and
converted in to mechanical work and then convert
into electrical power through thermoelectric
generator. Thermoelectric generator is very low
efficiency. But It is helped by waste heat
increasing the thermal efficiency and reduction in
emission.
The biggest advantage is to improve cabin warm
up performance. Thermo-Electric and Rankin
cycle system “only” deliver minor fuel economy
benefit over the NEDC (New European Drive
Cycle) test.
Review on Exhaust IJEIT Volume It has been identified that there are large potentials
Gas Heat Recovery 2, Issue 12, of energy savings through the use of waste heat
for I.C. Engine June 2013 recovery technologies.
Waste heat recovery defines capturing and
reusing the waste heat from internal combustion
engine for heating, generating mechanical or
electrical work and refrigeration system.

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CHAPTER 2: LITERATURE REVIEW

It would also help to recognize the improvement

in performance and emissions of the engine. If
these technologies were adopted by the
automotive manufacturers then it will be result in
efficient engine performance and Low emission.
The waste heat recovery from exhaust gas and
conversion in to mechanical power is possible
with the help of Rankine, Stirling and Brayton
thermodynamic cycles, vapour absorption.
For waste heat recovery thermoelectric generator
is use low heat, which has low efficiency. It is
helpful for the same amount
Design and CFD IJSETR, The initial phase of the project work delivers the
Investigation of Volume 4, following, the objective formulation done
Exhaust Gas Issue 5, May successfully which is followed by the literature
Recovery System for 2015 review which provided details of exhaust gas
4SSC Diesel Engine” recovery system design, methods, type of heat
recovery system, practical problems in heat
recovery system, CFD simulation techniques for
heat recovery system, engines used in the heat
recovery system, this details provides the research
gap in the literature review, where low powered
diesel engines plays important role in exhaust gas
recovery system which can be used for
multipurpose operation in rural and urban areas.
Based on this a proposed system is developed
with research methodology which shows the
systematic work involved in this project work.
Design of heat recovery system is successfully
done with CFD simulation to evaluate the heat
recovery and the results are encouraging to go
ahead with experimental results.

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Mechanical Engineering Department, Birla Vishvakarma Mahavidyalaya
WASTE HEAT RECOVERY FROM SILENCER BY USING THERMOELECTRIC
GENERATOR

A Review on Waste Vol.5, No.4, Recovering Waste heat is the need of the day for
Heat Recovery in April 2017 E- the industries of developing countries.
Industries ISSN: 2321- Extent of literature available shows a
9637 continuously increasing interest of researchers,
managements and engineers in recovering the
heat.
Many big industrial plants have already realized
the importance of heat recovery and they are
effectively utilizing it in one or other way.
Efforts are being done to improve the recovery
efficiencies by using the latest technological
advancements and optimization methods.
Review on Recovery BITCON 2015 It has been identified that there are large potentials
and Utilization of E-ISSN 2249– of energy savings through the use of waste heat
Waste Heat in Internal 8974 recovery technologies.
Combustion Engine It would also help to recognize the improvement
in performance and emissions of the engine. If
these technologies were adopted by the
automotive manufacturers then it will be result in
efficient engine performance and Low emission.
The waste heat recovery from exhaust gas and
conversion in to mechanical power is possible
with the help of Rankine, Stirling and Brayton
thermodynamic cycles, vapour absorption.
For waste heat recovery thermoelectric generator
is use low heat, which has low efficiency. It is
helpful for the same amount of increases in
thermal efficiency and reduction in emission.
A case study on January 2014 A research was carried out to test three cases
compatibility of about the installation position of the
automotive exhaust thermoelectric generator.
thermoelectric
generation system,

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Mechanical Engineering Department, Birla Vishvakarma Mahavidyalaya
 CHAPTER 2: LITERATURE REVIEW

catalytic converter In case 2, the heat exchanger obtained a relatively

and muffler high surface temperature and an ideal temperature
uniformity to improve the efficiency of the TEG.
The pressure drop of CC, muffler and heat
exchanger was relatively low, which met the
requirement of the exhaust gas system. At the
same time, the CC and muffler in case 2 can keep
normal working. So case 2 is the best.
In future study, the method of simulation
modeling with infrared experimental verification
introduced here in needs to be combined with heat
transfer theory and materiality to serve for further
structural design and optimization of
thermoelectric modules and TEG,
so as to improve the overall exhaust heat
utilization and enhance the power generation.

2.4 SUMMARY OF LITRATURE REVIEW

➢ The recovery and utilization of waste heat not only conserves fuel but also reduces the
greenhouse gases and waste heat by increasing efficiency of engine.

➢ Mainly waste heat recovery from exhaust gas and converted in to mechanical work and
then convert into electrical power through thermoelectric generator.

➢ It has been identified that there are large potentials of energy savings through the use of
waste heat recovery technologies.

➢ The waste heat recovery from exhaust gas and conversion in to mechanical power is
possible with the help of Rankine, Stirling and Brayton thermodynamic cycles, vapour
absorption.

➢ A research was carried out to test three cases about the installation position of the
thermoelectric generator.

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 CHAPTER 3: MATERIAL SELECTION & ITS ANALYSIS

CHAPTER 3: MATERIAL SELECTION & ITS ANALYSIS

3.1 BLOCK DIAGRAM OF SETUP

This is the normal block diagram of arrangement in which exhaust coming from the engine is going
through silencer than with the help of thermoelectric generator heat is converted in to a electric power,
that power we can use in different places.

FIGURE 3.1 BLOCK DIAGRAM [11]

Now we discuss all the components used in this setup in detail.

3.2 INTERNAL COMBUSTION ENGINE (EXHAUST)

At a stoichiometric air-fuel ratio, the exhaust gas temperature is different from that in a lean or rich
air-fuel proportion. At rich air-fuel ratio, the exhaust gas temperature either increases or decreases
relying upon the fuel. For a normal 4-stroke engine, exhaust temperature ranges from 40 to 200 °C.

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 WASTE HEAT RECOVERY FROM SILENCER BY USING THERMOELECTRIC
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High temperatures (regularly above 900 °C) can be an indicator of perilous conditions that can lead
to catastrophic engine failure.

Fossil fuels supply nearly 80% of world energy demand. Burning of fossil fuel consistently has
related with its emissions in the forms of nitrogen oxides (NOX), sulphur oxides (SOX), carbon
monoxide (CO), unburned hydrocarbons (UHC). These emissions have environmental impacts that
are both local and global. Besides, in recent years, air quality has become a serious issue in many
countries, and the interest to replace fossil fuels with renewable and sustainable energy sources has
expanded for reducing CO2 and methane emissions. [12]

3.3 SELECTION OF SILENCER

Selecting the appropriate Silencer will ensure adequate and economical sound attenuation for
your application. The initial step is to investigate your system and determine the amount of noise
reduction required. This is communicated as insertion loss in decibels when referring to silencer
acoustical performance data. You will also need to know the maximum amount of resistance you can
add to the air flow that your system can deal with. This is expressed as static pressure drop in inches
of water and is the extra resistance the fan or air moving equipment in the system will have to be able
to overcome to maintain the same air flow and proficiency.

You should have the following information available when select your silencer:

• Insertion Loss in db. required at each octave.

• Total air flow in CFM

• Maximum static pressure drops in inches per water column (WG)

• Duct, exhaust or fan size dimensions

• Maximum allowable length of silencer

Once you have this data you will be able to simply select the silencer size and model that matches
your criteria. You will see that we have two fundamental silencer designs, one resulting in Standard
Pressure Drops (our Model SP) and one resulting in Lower Pressure Drops (our Model LP). Typically,
low pressure drops silencers bring about lower insertion loss as well, especially in the lower frequency
ranges. [13]

3.4 THERMO-ELECTRIC GENERATOR (TEG)

Thermoelectric generators are largely solid-state devices that convert heat into electricity. Unlike
traditional dynamic heat engines, thermoelectric generators contain no moving parts and are totally

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CHAPTER 3: MATERIAL SELECTION & ITS ANALYSIS
quiet. Such generators have been used reliably for over 30 years of maintenance-free operation in deep
space probes for example the Voyager missions of NASA.1 Compared to large, traditional heat
engines; thermoelectric generators have lower efficiency. But for little applications, thermo electrics
can become competitive because they are compact, simple (inexpensive) and scalable. Thermoelectric
systems can be effectively designed to operate with small heat sources and small temperature
differences. Such small generators could be mass delivered for use in automotive waste heat recovery
or home co-generation of heat and electricity. Thermo electrics have even been scaled down to harvest
body heat for powering a wristwatch.

FIGURE 3.3 SCHEMATIC DIAGRAM OF TEG [14]

3.4.1 THERMOELECTRIC POWER

A thermoelectric produces electrical power from heat flow across a temperature gradient. As
the heat flows from hot to cold, free charge carriers (electrons or holes) in the material are
furthermore driven to the cold end. The subsequent voltage (V) is proportional to the temperature
difference (ΔT) via the Seebeck coefficient, S, (V = SΔT). By connecting an electron conducting (n-

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WASTE HEAT RECOVERY FROM SILENCER BY USING THERMOELECTRIC
GENERATOR

type) and hole conducting (p-type) material in series, a net voltage is produced that can be passed
through a load. A decent thermoelectric material has a Seebeck coefficient between 100 μV/K and
300 μV/K; thus, consequently achieve a few volts at the load, many thermoelectric couples need to
be connected in series to make the thermoelectric device. A thermoelectric generator changes over
heat (Q) into electrical power (P) with efficiency η. The measure of heat, Q, that can be coordinated
however the thermoelectric materials frequently depends on the size of the heat exchangers used to
collect the heat on the hot side and reject it on the cold side. As the heat exchangers are regularly
much larger than the thermoelectric generators themselves, when size is a requirement (or high P/V
is desired) the design for maximum power

P = ηQ [15]

The efficiency of a thermoelectric converter depends heavily on the temperature difference ΔT = Th –

Tc across the device. This is because the thermoelectric generator, like all heat engines, cannot have
an efficiency greater than that of a Carnot cycle (ΔT/ Th). The efficiency of a thermoelectric generator
is regularly defined as

η= (ΔT/Th) * ((1 + ZT)1/2 – 1) / ((1-ZT) 1/2 + Tc/Th) [15]

3.4.2 HEAT TO ELECTRICITY

For huge electrical power generation applications traditional dynamic thermal to electric
generators (e.g., Rankine, Brayton, or Stirling engine) have several times the productivity of a
thermoelectric system. However, such dynamic systems are costly and do not scale easily for small
applications.
When high quality combustible fuel is available, internal combustion engines are cost effective and
reasonably efficient in the 100 W to 100 kW range but tend to be loud. For applications requiring less
than 100W, the adaptability of thermo electrics gives them a clear benefit.

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CHAPTER 3: MATERIAL SELECTION & ITS ANALYSIS

FIGURE 3.4 ACTUAL TEG IN BMW CAR [15]

3.4.3 POWER FROM WASTE HEAT

Efforts are already underway to demonstrate waste heat recovery in automobiles even relatively
inefficient thermo electrics can be competitive for use with such waste heat sources (e.g., automobile
exhaust) when design, fabrication, and maintenance cost are considered in. The thermoelectric
generator will extract waste heat from the exhaust that will deliver DC electrical power to recharge the
battery. By reducing or even eliminating the need for the alternator, the load on the engine is reduced
thereby improving fuel efficiency by as much as 10%. Instead of recovering waste heat, Co-generation
recovers some of the useful work wasted on heat. Often a high energy content fuel with a high flame
temperature (such as natural gas) is used for low ΔT heating (e.g., home heating or hot water). In
electricity–heat cogeneration, electricity is produced with nearly 100% efficiency (as opposed to 40%
for power plants) because the remaining energy is used for heating instead of being wasted. In
applications such as home co-generation, the desire for silent, vibration, and maintenance free
operation will favour thermo electrics. Residential co-generation and automotive waste heat recovery
are two examples where “small” systems could have an impact on the global energy consumption if
implemented on a large scale.

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WASTE HEAT RECOVERY FROM SILENCER BY USING THERMOELECTRIC
GENERATOR

FIGURE 3.5 TEG SETUP DIAGRAM [15]

3.4.4 PORTABLE POWER

For small portable applications, power sources that are smaller and lighter than conventional
batteries are of great commercial interest. The energy density of a combustible fuel is 10 to 100 times
that of a battery. Thus, in principle, even for low thermal-to-electric conversion efficiencies (e.g., a
few percent), a small combustor supplying heat to a thermoelectric generator could provide greater
energy density than a battery. However, a 10% efficient generator can require at least 500°C. In
addition, to ensure that the heat is directed through the thermoelectric and not lost in the exhaust, the
heat exchangers must be carefully designed. One such design is that of a “Swiss roll” combustor where
catalytic combustion is localized to a small region to maintain a high source temperature while the
exhaust is directed through a counter flow heat exchanger to preheat the incoming gasses. The thermal
efficiency of such combustors can be 80-95%. Perhaps the best way to achieve high efficiency with
such a device is to include a fuel cell just before the catalytic combustion. A single chamber fuel cell7
produces electricity when placed in a hot fuel-air mixture. The unreacted fuel could then be combusted
by the catalyst for use by the thermoelectric. of the thermoelectric elements such that 5V can be
produced with a 10K temperature drop (Thermo Life). At the same time, manufacturers of bulk
thermoelectric devices, which typically have thermoelectric elements of 1-2 mm in length, can now
reduce the size of the thermoelectric elements13 even to 100μm.14 A good example of thermoelectric
energy harvesting is the thermoelectric wristwatch, which utilizes thin bulk thermoelectric devices.
The watch is driven by body heat converted into the electrical power by the thermoelectric. At least
two models have been built, one by Seiko and another by Citizen. The Seiko watch14. under normal
operation produces 22 μW of electrical power. With only a 1.5K temperature drop across the intricately
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CHAPTER 3: MATERIAL SELECTION & ITS ANALYSIS
machined thermoelectric modules, the open circuit voltage is 300 mV, and thermal to electric
efficiency is about 0.1%. Although no longer in production, the thermoelectric wristwatch
demonstrates the viability of utilizing thermoelectric in small power sources. As the cost of producing
these devices drops with mass production and the increasing need for remote power sources, viable
applications will undoubtedly arise. In addition, with the ever increasing economic and social cost of
energy production, small thermal to electric power sources for cogeneration and waste heat recovery
may someday play a significant role, however small.

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 CHAPTER 4: POWER CALCULATION

CHAPTER 4: POWER CALCULATION

4.1 THEORETICAL POWER CALCULATION

Bismuth Telluride-based thermoelectric modules are planned essentially for cooling or
consolidated cooling and warming applications where electrical force makes a temperature
distinction across the module. By utilizing the modules "in turn around," notwithstanding,
whereby a temperature differential is applied across the essences of the module, it is feasible
to produce electrical force. In spite of the fact that force yield and age proficiency are extremely
low, valuable force frequently might be gotten where a wellspring of warmth is accessible.

A thermoelectric module utilized for power age has certain similitudes to a regular
thermocouple. Allow us to view at a solitary thermoelectric couple with an applied temperature
distinction as demonstrated in Figure.

FIGURE 5.1 SIGNAL THERMOELECTRIC COUPLE [16]

4.1.1 VOLTAGE(V)
With no load (RL not connected), the open circuit voltage as measured between points a and b
is:
V = S x ΔT [1] …[1]

Where:
V = the output voltage from the module (generator) in volts
S = the average Seebeck coefficient in volts/°K
ΔT = the temperature difference across the module in K where ΔT = Th-Tc

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WASTE HEAT RECOVERY FROM SILENCER BY USING THERMOELECTRIC
GENERATOR

4.1.2 CURRENT(I)
When a load is connected to the thermoelectric couple the output voltage (V) drops as a result
of internal generator resistance. The current through the load is:
S x ΔT [17]
____________________
I=
RC + R L
Where:
I = the generator’s output current in amperes
Rc = the average internal resistance of the thermoelectric module in ohms
RL = the load resistance in ohms

4.1.3 POWER(P)
By the multiplication of equation [1] and [2] we get the power
P=V x I

4.1.4 HEAT INPUT TO THE THERMOCOUPLE(QH)

The total heat input to the couple (Qh) is:
Qh = (S x Th x I) – (0.5 x I2 x Rc) + (Kc x ΔT) [17]
Where:
Qh = the total heat input in watts
Kc = the thermal conductance of the module in watts/°K
Th = the temperature at hot side of the couple in °K

4.1.5 EFFICIENCY OF TEG

The efficiency of the generator (Eg) is:
VxI
____________________
Eg =
Qh

We have thus far talked about an individual thermoelectric couple, however since a complete
module comprises of a number of couples, it is important to rewrite our equation for an actual
module, as follows:
VO = SM x ΔT = I x (RM + RL) [17]
Where:
VO = the generator’s output voltage in volts
SM = the module’s average Seebeck coefficient in volts/°K
RM = the module’s average resistance in ohms

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 CHAPTER 4: POWER CALCULATION

It should be remembered that module Seebeck coefficient, resistance and thermal

conductance properties are temperature dependent and their values should be calculated as
described in Section 11. The values of SM, RM, and KM should be selected at the average
module temperature Tavg
Where:
Th + Tc
____________________
Tavg =
2
The power output (Po) from the module in watts is:
P o = RL x

It is conceivable, however unlikely, that the exact conditions will exist within a given
generator application whereby one module will give the specific output power desired. Thus,
most thermoelectric generators contain a number of individual modules which might be
electrically connected in either series, parallel, or series/parallel arrangement. A common
generator configuration is illustrated in Figure. This generator has a NT total number of
modules with NS number of modules associated in series and NP number of modules
associated in parallel. The total number of modules in the system is:
NT = NS x NP

4.2 THEORETICAL SAMPLE CALCUTION

How much heat will be recovering from exhaust and how much heat is utilize for it?

All the calculation are theoretical and assuming we are doing on cooper diesel engine. So, by
getting reading from college datasheet we get

Mass flow rate of cooling water:

⍴xV [18]
Mw = Time

1000 𝑥 0.25 𝑥 0.25 𝑥 0.29

= 202.2

= 0.089 Kg/s

Where:

⍴ = Density of water in Kg/m3

V = Volume of box in m3

Time in Second

Mw Cpw (Two-Twi) = Mg Cpg (Tgi-Tgo) [18]

0.0896 x 4.186 x (34-31) = Mg x 1.005 x (132-39)

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 WASTE HEAT RECOVERY FROM SILENCER BY USING THERMOELECTRIC
GENERATOR

Mg = 0.01204 Kg/s

Mass flow rate of gas (without loading condition):

Mg = 0.01204 kg/s

Cpg = 1.005 kj

❖ We have taken reading of exhaust gas at outlet with gap of 2 minutes.

4.2.1 SAMPLE CALCULATION FOR FIRST READING

Ta = 27֯ C Tgi = 120 ֯ C
Qg = Mg x Cp x (Tgi -Ta) [18]
= 1.125 KW
Heat lost from exhaust of cooper diesel engine is 1.125 KW.
How much heat we are using from this?
From datasheet of TEG-12706 at ΔT = 93֯ C
we get, Seebeck coefficient S = 65 mV/k [19]
electrical resistance = 2.1 Ω [19]
With no load (RL not connected), the open circuit voltage as measured between points a and
b is:

V = S x ΔT

= 65 x 93
= 6.045 V

For TEG-12706 couple

Rq/Ro = 0.95 … [19]
Rq = Thermal resistance
Ro = Electrical resistance
Rq = 2.1 x 0.95 = 1.9 k/W.
Current through the load is calculating from equation [2]

S x ΔT
____________________
I=
RC + R L

here Rc = 2.1 Ω
Rl = 0 Ω

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 CHAPTER 4: POWER CALCULATION

I = 2.88 A
Power
P=VxI
= 6.045 x 2.88
= 17.4096 W
How much heat used by TEG?
Qh = (S x Th x I) – (0.5 x I2 x Rc) + (Kc x ΔT) [17]
here Kc = 1/Rq = 0.52 W/k [18]
Qh = 113.82 W
• % of heat utilized = (Qh/Qg) x 100
= 10.11 %
• Efficiency of TEG
VxI
_____________
x100
Eg =
Qh

= 15.28 %
TABLE 5.1 THEORETICAL CALCULATION

Sr.no T(Min.) Tf(°C) ∆T I(A) V(v) P(W) Qg(kW) Qh(W) ղq(%) ղg(%)

1. 0 27 0 0 0 0 0 0 0 0

2. 2 120 93 2.88 6.045 17.4096 1.125 113.82 10.117 15.288

3. 4 136 109 3.373 7.085 23.8977 1.3189 134.40 10.190 17.785

4. 6 146 119 3.6833 7.735 28.4903 1.440 147.95 10.274 19.256

5. 8 152 125 3.87 8.125 31.4437 1.5125 156.18 10.326 20.128

6. 10 154 127 3.931 8.255 32.4504 1.5367 158.92 10.341 20.419

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 WASTE HEAT RECOVERY FROM SILENCER BY USING THERMOELECTRIC
GENERATOR

4.3 GRAPHICAL PRESENTATION BASED ON THEORETICAL CALCULATION

4.3.1 ∆T VS POWER

∆T VS POWER
35 32.4504
31.4437

30 28.4903

23.8977
25

20
POWER

17.4096

15

10
P(W)

5
0
0
0 20 40 60 80 100 120 140
∆T

FIGURE 5.2 GRAPH OF ∆T VS POWER

4.3.2 TIME VS HEAT

TIME VS HEAT
1800

1512.5 1536.7
1600
1440
1400 1318.9

1200 1125
Qg(W)
HEAT

1000
Qh(W)
800

600

400
134.4 147.95 156.18 158.92
200 113.82
0
0
0 2 4 6 8 10 12
TIME(MINUTE)

FIGURE 5.3 GRAPH OF TIME VS HEAT

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CHAPTER 4: POWER CALCULATION

4.3.3 TIME VS EFFICIENCY

TIME VS EFFICIENCY
25

20.128 20.419
19.256
20
17.785

15.288
EFFICIENCY

15

10.117 10.19 10.274 10.326 10.341

10

ղq(%)
5
ղg(%)
0
0
0 2 4 6 8 10 12
TIME

FIGURE 5.4 GRAPH OF TIME VS EFFICIENCY

4.3.4 ∆T VS EFFICIENCY

∆T VS EFFICIENCY
25

ղq(%) 20.419
20.128
19.256
20
ղg(%) 17.785

15.288
EFFICIENCY

15

10.117 10.19 10.27410.341

10.326
10

0
0
0 20 40 60 80 100 120 140
∆T

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 WASTE HEAT RECOVERY FROM SILENCER BY USING THERMOELECTRIC
GENERATOR

FIGURE 5.5 GRAPH OF ∆T VS EFFICIENCY

4.4 CONCLUSION FROM THEORETICAL CALCULATION

Result show that voltage,current,power developed and efficiency of the system increase
with the increasing in exhaust temperature, flow rate of exhaust gas. If the temperature
differncr between hot side and cold side of thermoelectric generator is increase then output
voltage also increase as a result of theoretical calculation we can see that the production of the
power is depending upon two parameter one is the temperature difference and second one is
engine running time.

NOTE : We want to take Readings but due to COVID-19 unable to go college So here we
had concluded our project if we get opportunity to take readings then we will definatly take
opportunity and take readings and learn something new and specify our project brifly.

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 WASTE HEAT RECOVERY FROM SILENCER BY USING THERMOELECTRIC
GENERATOR

CHAPTER 5: COMPONENTS & COST ESTIMATION

5.1 READY COMPONENTS

List of components which we have taken from market and direct to use.

TABLE 5.1 READY COMPONENTS

NAME OF
DESCRIPTION FIGURE
COMPONENT

2 x TEG-12706
40x40mm
THERMO
Thermoelectric
ELECTRIC
Power Generator
GENERATOR
TEG 200°C Peltier
Module

FIGURE 5.1 TEG

Numbers of the fins

11
ALUMINUM FINS 100 x 69 x 36mm
Weight 223gm
(Approx.)

FIGURE 5.2 ALUMINUM FINS

Aluminium U shape
ANGLE PLATE Plate
200 x 70 x 25 mm

FIGURE 5.3 ANGLE PLATE

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CHAPTER 5: COMPONENTS & COST ESTIMATION

Length 150mm
BOLT AND NUTS
(8 NOS)

FIGURE 5.4 BOLTS AND NUTS

MS RACTANGLE 4 x (100 x 30 x 12
ROD mm)

FIGURE 5.5 RACTANGLE BAR

Vin: 3V
LED
Imax:25mAh

FIGURE 5.6 LED

WIRE 1 METERS

FIGURE 5.7 WIRE

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 WASTE HEAT RECOVERY FROM SILENCER BY USING THERMOELECTRIC
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HEAT PASTE 30gm

FIGURE 5.8 HEAT PASTE

5.2 FUNCTION OF PARTS

1) Thermoelectric Generator (TEG)
It is a solid-state device that convert temperature difference into electric energy. It consists
of thermo couple N & P type elements connected electrically in series and thermally in
parallel. It is a main component of our project. That convert Thermal energy into electrical
energy without any mechanical device.
2) Aluminum Fins (Heat sink)

It is an object that absorbs and dissipates heat from another object. It contains no. Of fins
cooled by air cooling system. It has high thermal conductivity.

3) U plate

A heat source is a system from which heat is radiate or produces to a heat sink.

4) Bolt and Nuts

Purpose of Bolt and Nut is to join the Silencer and all the parts together.

5) MS rectangle rod

To support the assembly.

6) LED

It emits the light when current flow through it.

7) Wire

It allows the electricity flow from thermoelectric generator to the LED lamps

8) Heat paste

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Heat paste is similar to grease. It fills the micro air gap between TEG and Aluminium fins
and to increase the thermal conductivity.

5.3 COST ESTIMATION

It is divided in to three different categories

1. Ready material cost

2. Other cost

5.3.1 READY MATERIAL COST

TABLE 5.2 MATERIAL COST

Sr. No Description Price Per Nos. Qty Total Cost

(Rs) (Rs)
1. TEG 500 3 1500
2. ALUMINUM FINS 750 2 1500
2. ANGLE PLATE 180 RS / KG 1 180
3. RACTANGLE ROD 60 4 240
4. FASTNER 20 4 80
6. WIRE 15 RS/METER 1 15
7. LED 10 3 30
8. HEAT PASTE 50 1 50
Total 3595

5.3.2 OTHER COST

Other cost like Transportation and fabrication are below

TABLE 5.3 OTHER COST

Sr. DESCRIPTION QTY. COST

No (RS)
1 TRANSPORTATION - 500
2 FABRICATION LABOUR - 100
TOTAL 700

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 WASTE HEAT RECOVERY FROM SILENCER BY USING THERMOELECTRIC
GENERATOR

5.3.3 TOTAL COST

TABLE 5.4 TOTAL COST

S.N. DESCRIPTION COST

(RS)
1 MATERIAL COST 3595
2 OTHER EXPANSES 700
TOTAL 4295

TOTAL COSTING OF PROJECT = Rs. 4295.

5.4 FINAL MODEL OF PROJECT

FIGURE 5.8 FINAL MODEL OF THE PROJECT

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 WASTE HEAT RECOVERY FROM SILENCER BY USING THERMOELECTRIC
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CHAPTER 6: REFERENCES

6.1 REFERENCES

[1] P. Mohamed Shameer, D. Christopher, (2013) “Design of Exhaust Heat Recovery Power
Generation System Using Thermo-Electric Generator”, pp 5.

[2]

[3] Amit Tiwari, Himanshu Vasnani, Dr. Neeraj Kumar, Mahendra Labana,2017, “A Review
on Waste Heat Recovery and Reused of Exhaust Gases from Diesel Engines” Vol.006,
Issue 006.

[4] Legros Arnaud, Guillaume Ludovic, Diny Mouad, Zaïdi Hamid And Lemort Vincent,2014
“Comparison and Impact of Waste Heat Recovery Technologies on Passenger Car Fuel
Consumption in a Normalized Driving Cycle”

[5] Baleshwar Kumar Singh, Dr. Nitin Shrivastava ,2014, “Exhaust Gas Heat Recovery for
C.I Engine-A Review”

[6] J. S. Jadhao, D. G. Thombare,2013, “Review on Exhaust Gas Heat Recovery for I.C.
Engine”, Vol.2, Issue 12.

[7] Bibin P Varghese, V Hariganesh, Ajish Soman, 2015, “Design and CFD Investigation of
Exhaust Gas Recovery System for 4SSC Diesel Engine”, Vol.4, Issue5.

[8] Mr. Rupesh Suryavanshi, Prof.A.D. Pitale, 2017, “A Review on Waste Heat Recovery in
Industries” International Journal of Research in Advent Technology, Vol.5, No.4.

[9] M. Dubeya, A. Aroraa, H. Chandrab, 2015, “Review on Recovery and Utilization of

Waste Heat in Internal Combustion Engine” BITCON 2015 E-ISSN2249–8974.

[10] X. Liu, Y.D. Deng, S. Chen, W.S. Wang, Y. Xu, C.Q. Su, 2014, “A case study on
compatibility of automotive exhaust thermoelectric generation system, catalytic
converter and muffler”.

[11] J. S. Jadhao, D. G. Thombare, 2013, “Review on Exhaust Gas Heat Recovery for I.C.
Engine”, Volume 2, Issue 12, page no.6.

[12] A thesis by Jechan Lee Dr. Marco J. Castaldi, 2010, “A Study on Performance and
Emissions of a 4-stroke IC Engine Operating on Landfill Gas with the Addition of H2, CO
and Syngas.

[13] INC Panl-Flow HVAC and Industrial Silencers HVAC and Industrial Silencers selection
manual.

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 CHAPTER 6: REFERENCES

[14] P. Mohamed Shameer, D. Christopher, 2013, “Design of Exhaust Heat Recovery Power
Generation System Using Thermo-Electric Generator”, page no.3.

[15] G. Jeffrey Snyder, “Small thermoelectric Generator”, page no.1

[16] https://thermal.ferrotec.com/technology/thermoelectric-reference-guide/thermalref13/

[17] C. Ramesh Kumar, Ankit Sonthalia And Rahul Goel, 2011, “Experimental study on waste
heat recovery from an internal combustion engine using Thermoelectric technology”, Vol.
15, No. 4, pp. 1011-1022

[18] Er. R.K. Rajput, 2015, “Heat and Mass Transfer” 5th Edition,

[19] Kubov V.I., Dymytrov Y.Y. Simple, 2017 “Method of thermoelectric cooler (Peltier
device) parameters determination based on datasheet and modelling results”,

[20] https://images.app.goo.gl/oawiBUEinb3sU51e6

[21] https://images.app.goo.gl/ymCR35LYDjSs621L9

[22] https://images.app.goo.gl/NaLPr5rn7aqB9mdQ8

[23] https://pin.it/2RwHdHE

[24] https://images.app.goo.gl/egLi2GrtF8YecfRr6

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