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1. A
Project Report
On
ENERGY GENRATION USING EXAUST THEN COOLING
Submitted to
Raj Kumar Goel Institute of Technology, Ghaziabad
In partial fulfilment of the requirement for the degree of
B. Tech.
In
Mechanical Engineering
Submitted By
ITNESH KUMAR DEVANSH SINGH
(1403340095) (1403340067)
DIPENDRA KUMAR VERMA ANURAG SINGH
(1403340073) (1403340045)
Guided By
Mr. Vivek Gupta
Department of Mechanical Engineering
Raj Kumar Goel Institute of Technology Ghaziabad - 201003(U.P.) India
Dr. A.P.J. Abdul Kalam Technical Univrsity, Lucknow
(2017-2018)

2. i
DECLARATION
I hereby declare that this submission is my own work and that, to the best of my knowledge
and belief, it contains no material previously published or written by another person nor
material which to a substantial extent has been accepted for the award of any other degree or
diploma of the university or other institute of higher learning, except where due
acknowledgment has been made in the text.
Approved By: Guided By:
Dr. Durgesh Sharma Mr. Vivek Gupta
Professor & Head Assistant Professor
Department of Mechanical Engineering Department of Mechanical Engineering
RKGIT, Ghaziabad RKGIT, Ghaziabad
ITNESH KUMAR
ROLL NO: 1403340095
Dept of Mech Engineering,
RKGIT,AKTU
DEVANSH SINGH
ROLL NO: 1403340067
Dept of Mech Engineering,
RKGIT, AKTU
DIPENDRA KUMAR VERMA
ROLL NO: 1403340073
Dept of Mech Engineering,
RKGIT,AKTU
ANURAG SINGH
ROLL NO: 1403340045
Dept of Mech Engineering,
RKGIT,AKTU

3. ii
CERTIFICATE
This is to certify that Project Report entitled “Energy Generation using Exhaust of Gases”
which is submitted by Devansh Singh, Itnesh Kumar, Dipenrdra Kumar Verma and Anurag
Singh in partial fulfilment of the requirement for the award of degree B. Tech. in Department
of Mechanical Engineering of Abdul Kalam Technical University, is a record of the candidate
own work carried out by them under my supervision. The matter embodied in this thesis is
original and has not been submitted for the award of any other degree.
Supervisor Date
External Examiner
Dr. Durgesh Sharma
Professor & Head
Department of mechanical Engineering
Raj kumar Goel Institute of Technology
Ghaziabad
MR. VIVEK GUPTA
Project Guide
Assistant Professor
Department of mechanical Engineering
Raj kumar Goel Institute of Technology
Ghaziabad

4. iii
ABSTRACT
A number of irreversible processes in the engine limit its capability to achieve a highly
balanced efficiency. The rapid expansion of gases inside the cylinder produces high
temperature differences, turbulent fluid motions and large heat transfers from the fluid to the
piston crown and cylinder walls. These rapid successions of events happening in the cylinder
create expanding exhaust gases with pressures that exceed the atmospheric level, and they
must be released while the gases are still expanding to prepare the cylinder for the following
processes. By doing so, the heated gases produced from the combustion process can be easily
channelled through the exhaust valve and manifold. The large amount of energy from the
stream of exhausted gases could potentially be used for waste heat energy recovery to generate
power. Various methods to harness the waste heat to produce power effectively had ended up
in vain. This project proposes and implements a thermoelectric waste heat energy recovery
system for internal combustion engine automobiles, including gasoline vehicles and hybrid
electric vehicles. The key is to directly convert the surface heat energy from automotive waste
heat to electrical energy using a thermoelectric generator (TEG), which is then regulated by a
DC–DC Cuk converter to charge a battery using maximum power point tracking. Hence, the
electrical power stored in the battery can be maximized. The experimental results demonstrate
that the proposed system can work well under different working conditions, and is promising
for automotive industry
KEYWORDS: air gun, thermoelectric module fan, battery, electrical generator

5. iv
ACKNOWLEDGEMENT
It gives us a great sense of pleasure to present the report of the B. Tech Project undertaken
during B. Tech. Final Year. We owe special debt of gratitude to Mr. Vivek Gupta, Assistant
Professor Department of Mechanical Engineering, Raj Kumar Goel Institute of Technology,
Ghaziabad for his constant support and guidance throughout the course of our work. His
sincerity, thoroughness and perseverance have been a constant source of inspiration for us. It
is only his cognizant efforts that our endeavours have seen light of the day.
We also do not like to miss the opportunity to acknowledge the contribution of all faculty
members of the department for their kind assistance and cooperation during the development
of our project. Last but not the least, we acknowledge our friends for their contribution in the
completion of the project.

6. v
INDEX
Contents Page no.
Chapter-1. Introduction 1-5
1.1 Introduction 1
1.2 Recent developments 3
1.3 Potential solutions 4
1.4 Various factors affecting engine performance 4
Chapter-2. Theory 6-12
2.1 History 6
2.2 What is a thermoelectric generator? 6
2.3 Seebeck effect 7
2.4 Thermoelectric principle of operation 8
2.5 Technology used in automobile waste heat recovery systems using tegs 9
2.6 Energy generation 11
Chapter-3. Components 13-19
3.1 Peltier Module 13
3.2 TE- Generator 13
3.3 Thermal Grease 14
3.3.1 Heat sink 14
3.4 CPU cooling fan 15
3.5 Hot air gun 16
3.6 Heat chamber 17
3.7 Multimeter 18
3.8 Battery 19
3.9 Printed circuit board 20
Chapter-4. Processes Used 21-25
4.1 Carpentry work 21

7. vi
4.2 Sheet metal work 22
4.3 Gluing 23
4.4 Soldering process 24
Chapter-5. Construction 26-32
5.1 Base 25
5..2 Heat chamber 27
5.3 Wooden Base For the Thermoelectric Generator 28
5.4 Thermoelectric generator 29
5.5 The controlling switches 31
Chapter-6. Identification of Hot Spot in the Silencer 30-31
Chapter-7. Working Procedure 32-34
7.1 Working principle 34
Chapter-8. Calculations 35-36
8.1 Calculation for Voltage generated 35
Chapter-9. Expenses 37
Chapter-10. Conclusion 38-39
References & Image Source 40-41

8. vii
LIST OF FIGURES
S.no. Figure Page No.
1 Percentage of fuel energy distribution 2
2 A real life thermoelectric generator 6
3 Pairs of N and P-type elements 7
4 Seebeck Effect 7
5 Seebeck effect terminals 8
6 Thermionic Principle of Operation 9
7 Rectangular exhaust heat exchanger. 11
8 Honda prototype TEG exhaust heat recovery system. 11
9 Representation of depletion zone in junctions 11
10 Peltier Module 13
11 TE-Generator 14
12 Heatsink 15
13 CPU cooling fan 16
14 Commercial heat gun kit 17
15 Heat Chamber 17
16 Multimeter 18
17 Battery 19
18 PCB 20
19 Carpentry Work 21
20 carpentry work 2 22
21 Metal sheet work 22
22 Glue process 23
23 Soldering process 24
24 Base 25
25 Heat Chamber Contruction 26
26 Base for Thermoelectric Generator 27
27 Thermoelectric generator for heat to electrical conversion 28
28 Modified Thermoelectric generator for cooling 28
29 Picture of switch control system 29

9. viii
30 Silencer Model 30
31 Contours of Temperature 30
32 After finalising picture of project 34

10. ix
LIST OF SYMBOLS
[x] : Integer value of x.
≠ : Not Equal
: Belongs to
€ : Euro- A Currency
_ : Optical distance
_o : Optical thickness or optical half thickness

11. x
LIST OF ABBREVIATIONS
AAM : Active Appearance Model
ICA : Independent Component Analysis
ISC : Increment Sign Correlation
PCA : Principal Component Analysis
ROC : Receiver Operating Characteristics

12. 1
CHAPTER-1
INTRODUCTION
1.1 Introduction
Even a highly efficient combustion engine converts only about one-third of the energy in the
fuel into mechanical power serving to actually drive the automobile. The rest is lost through
heat discharged into the surroundings or, quite simply, leaves the vehicle as “waste heat”.
Clearly, this offers a great potential for the further reduction of CO2 emissions which the BMW
Group’s engineers are seeking to use through new concepts and solutions.
The current research is focusing on a technology, which is able to convert the thermal energy
contained in the exhaust gas directly into electric power. Taguchi [1] invented an exhaust gas-
based thermoelectric power generator for an automobile application. In this invention, the
exhaust gas gases in the pipe provide the heat source to the thermoelectric power generator,
whereas the heat sink (cold side) is suggested to be provided by circulation of cooling water.
An experimental study was conducted at VIT [2] wherein a heat exchanger with 18
thermoelectric generator modules was designed and tested in the engine test rig. This study
revealed that energy can be tapped efficiently from the engine exhaust and in near future
thermoelectric generators can reduce the size of the alternator or eliminate them in automobiles.
A typical total waste heat recovering technology, using thermoelectric generators (TEGs),
coupled with a gasoline engine was investigated in this study conducted at Ambrose Alli
University, Nigeria [5]. According to the experimental analysis conducted by Suryawanshi et
al. [6] the temperature of pipe surface of exhaust gases flowing through exhaust gas pipe is
very high and it is around 2000C to 3000C so a heat exchanger is made, which conducts heat
from exhaust pipe to thermoelectric modules, one surface of these modules is in contact with
the surface of hot side heat exchanger and other is in contact with the surface of cold side heat
exchanger and thus potential difference is created and power is produced due to Seebeck effect.
Baskar et al. [7] did an experiment to study and analyze the feasibility of retrofitting the waste
heat recovery system to a two stroke petrol engine. The experimental performance testing has
shown that the overall efficiency of two stroke petrol engine installed with and without the

13. 2
waste heat recovery system is 29.67% and 29.2% respectively when the power extraction was
90W. Jadhao et al. [8] in his paper had analyzed the possibility of heat recovery from an IC
engine and the various ways to achieve it. He has compared the various possibilities like the
Thermo electric generation, Thermo Ionic Generation and Piezoelectric Generation. He found
that in Thermo Electric generation, optimal temperature difference is sufficient to produce the
required power.
Birkholz et al. [9] have implemented the same TEG principle to recover the heat and to generate
power, but the material they used was FeSi2. Yu and Chau [10] has proposed and implemented
an automotive thermo-electric waste heat recovery system by adopting a Cuk converter and a
maximum power point tracker (MPPT) controller into its proposed system as tools for power
conditioning and transfer. They reported that the power improvement is recorded from 7.5% to
9.4% when the hot-side temperature of the TEG is heated from1000C to 2500C. Also, when
the hot-side temperature of the TEG is fixed at 2500C, the power improvement as much as
4.8% to 17.9% can be achieved.
According to the research paper published by Narumanchi et al [11] TIMs (Thermal Interface
Materials or Thermal Grease) pose a significant bottleneck to heat removal from a device. In
internal combustion engines a huge amount of energy is lost in the form of heat through the
exhaust gas. Conklin and Szybist investigated that the percentage of fuel energy converted to
useful work only 10.4% and also found the thermal energy lost through exhaust gas about
27.7%. The second law (i.e., energy) analysis of fuel has been shown that fuel energy is
converted to the brake power about 9.7% and the exhaust about 8.4% as shown in Figure 1.
Fig 1. Percentage of fuel energy distribution

14. 3
So, this project proposes and implements a thermoelectric waste heat energy recovery system
from the exhaust heat from the internal combustion engine automobiles, including gasoline
vehicles and hybrid electric vehicles. The key is to directly convert the heat energy from
automotive waste heat to electrical energy using a thermoelectric generator. While the electric
power generation by such a system is able to generate is still relatively small at a maximum of
10 W from a single TEG module, rapid progress in materials research can make the ambitious
objective of generating higher watts by all means of feasible proposition.
1.2 Recent Developments
In recent years the scientific and public awareness on environmental and energy issues has
brought in major interests to the research of advanced technologies particularly in highly
efficient internal combustion engines. Viewing from the socio-economic perspective, as the
level of energy consumption is directly proportional to the economic development and total
number of population in a country, the growing rate of population in the world today indicates
that the energy demand is likely to increase. Substantial thermal energy is available from the
exhaust gas in modern automotive engines. Two-thirds of the energy from combustion in a heat
gun is lost as waste heat, of which 40% is in the form of hot exhaust gas. The latest
developments and technologies on waste heat recovery of exhaust gas from internal
combustion engines (ICE). These include thermoelectric generators (TEG), Organic Rankine
cycle (ORC), six-stroke cycle IC engine and new developments on turbocharger technology.
Being one of the promising new devices for an automotive waste heat recovery, thermoelectric
generators (TEG) will become one of the most important and outstanding devices in the future.
A thermoelectric power generator is a solid state device that provides direct energy conversion
from thermal energy (heat) due to a temperature gradient into electrical energy based on
“Seebeck effect”.
The thermoelectric power cycle, charge carriers (electrons) serving as the working fluid,
follows the fundamental laws of thermodynamics and intimately resembles the power cycle of
a conventional heat engine.

15. 4
1.3 Potential Solutions
One potential solution is the usage of the exhaust waste heat of combustion engines. This is
possible by the waste heat recovery using thermoelectric generator. A thermoelectric generator
converts the temperature gradient into useful voltage that can used for providing power for
auxiliary systems such as air conditioner and minor car electronics. Even it can reduce the size
of the alternator that consumes shaft power. If approximately 6% of exhaust heat could be
converted into electrical power, it will save approximately same quantity of driving energy. It
will be possible to reduce fuel consumption around 10 %; hence AETEG systems can be
profitable in the automobile industry.
The number of vehicles (passenger and commercial vehicles) produced from 2005 to 2010
shows an overall increasing trend from year to year despite major global economic downturn
in the 2008–2010 periods Note that China’s energy
1.4 Various Factors Affecting Engine Performance
A number of irreversible processes in the engine limit its capability to achieve a highly
balanced efficiency. The rapid expansion of gases inside the cylinder produces high
temperature differences, turbulent fluid motions and large heat transfers from the fluid to the
piston crown and cylinder walls. These rapid successions of events happening in the cylinder
create expanding exhaust gases with pressures that exceed the atmospheric level, and they must
be released while the gases are still expanding to prepare the cylinder for the following
processes. By doing so, the heated gases produced from the combustion process can be easily
channeled through the exhaust valve and manifold. The large amount of energy from the stream
of exhausted gases could potentially be used for waste heat energy recovery to increase the
work output of the engine. Consequently, higher efficiency, lower fuel consumption by
improving fuel economy, producing fewer emissions from the exhaust, and reducing noise
pollutions have been imposed as standards in some countries. Hatazawa et al., Stabler, Taylor,
Yu and Chau and Yang stated that the waste heat produced from thermal combustion process
generated by gasoline engine could get as high as 30–40% which is lost to the environment
through an exhaust pipe

16. 5
In internal combustion engines a huge amount of energy is lost in the form of heat through the
exhaust gas. Conklin and Szybist investigated that the percentage of fuel energy converted to
useful work only 10.4% and also found the thermal energy lost through exhaust gas about
27.7%. The second law (i.e., exergy) analysis of fuel has been shown that fuel energy is
converted to the brake power about 9.7% and the exhaust about 8.4% as shown in Fig. 3. In
another research the value of exhaust gases mentioned to be 18.6% of total combustion energy.
It is also found that by installing heat exchanger to recover exhaust energy of the engine could
be saved up to 34% of fuel saving
For example, 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.
A vehicle's exhaust can actually be used to generate electricity. Although these technologies
can be used in any car, truck or SUV with an internal combustion engine, they're particularly
important to hybrid vehicles, which need to produce maximum fuel

17. 6
CHAPTER-2
THEORY
2.1 History
In 1821, Thomas Johann Seebeck discovered that a thermal gradient formed between two
dissimilar conductors can produce electricity.[2]
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 regions in
turn creates a voltage difference. In 1834, Jean Charles Athanase Peltier discovered 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 What Is A Thermoelectric Generator?
Fig 2. A real life thermoelectric generator
Thermoelectric generators are solid state heat engines made od pairs of p-type and n-type
elements. The p-type elements are made of semiconductor materials doped such that the charge
carriers are positive (holes) and seebeck coefficient is positive. The N-type elements are made

18. 7
of semi conductor materials doped such that that the charge carriers are negative (electrons)
and the seebeck coefficient is negative.
Fig 3. Pairs of N and P-type elements
2.2. Seebeck Effect
Fig 4. Seebeck Effect
The Seebeck Effect produces an electric current when dissimilar metals are exposed to a
variance in temperature. Seebeck effect applications are the foundation of thermoelectric
generators (TEGs) or Seebeck generators which convert heat into energy. The voltage produced

19. 8
by TEGs or Seebeck generators is proportional to the temperature distance across between the
two metal junctions.
The Seebeck Effect is the conversion of temperature differences directly into electricity. It is a
classic example of an electromotive force (emf) and leads to measurable currents or voltages
in the same way as any other emf. Electromotive forces modify Ohm’s law by generating
currents even in the absence of voltage differences (or vice versa); the local current density is
given by,
J=σ (-∆V + Eemf)
Where, V the local voltage and σ is is the local conductivity. In general the Seebeck effect is
described locally by the creation of an electromotive field.
Eemf = -S ∆T
Where S is the Seebeck coefficient (also known as thermo-power), a property of the local
material, and ∆T is the gradient in temperature T.
Fig 5. seebeck effect terminals
2.3 Thermoelectric Principle Of Operation
Thermoelectricity means the direct conversion of heat into electric energy, or vice versa.
According to Joule's law, a conductor carrying a current generates heat at a rate proportional
to the product of the resistance (R) of the conductor and the square of the current (I). A circuit

20. 9
of this type is called a thermocouple; a number of thermocouples connected in series are called
a thermopile
Fig 6. Thermionic Principle of Operation
Jean C. A. Peltier discovered an effect inverse to the Seebeck effect: If a current passes through
a thermocouple, the temperature of one junction increases and the temperature of the other
decreases, so that heat is transferred from one junction to the other. The rate of heat transfer is
proportional to the current and the direction of transfer is reversed if the current is reversed.
2.4 Technology used in automobile waste heat recovery systems using TEGs
Fig 7. Rectangular exhaust heat exchanger.

21. 10
Large multinational car companies like BMW, Ford, Renault and Honda have demonstrated
their interest in exhaust heat recovery, developing systems that make use of TEGs. All of their
designs are relatively similar. Typically the TEGs are placed on the exhaust pipe surface
(shaped as a rectangle, hexagon, etc.) and they are cooled with cold blocks using engine
coolant. Examples of a rectangular shaped and hexagonal shaped heat exchanger can be seen
in respectively. This technology has not yet been installed in present production cars and is still
in the concept stages. The BMW system uses a shell and tube heat exchanger. High temperature
TEGs are used and the system is rated to produce 750 W from a number of 20 W rated TEGs.
The Ford system heat exchanger uses many small parallel channels lined with thermoelectric
material for the exhaust gases to pass. Liquid cooling is used in this case. This system is rated
to produce a maximum of approximately 400 W with 4.6 kg of thermoelectric material. The
Renault system is to be used on a diesel truck engine. It has dimensions of
10 cm × 50 cm × 31 cm. This system uses a counter flow heat exchanger arrangement using
liquid cooling. A combination of high temperature TEGs at the high temperature end and low
temperature TEGs at the low temperature end were used. The modelled system is predicted to
produce approximately 1 kW. The Honda system used a simple design of a thin flat rectangular
box with TEGs placed on the top and bottom surfaces. Liquid cooling was used in this design.
The system consisted of 32 30 mm × 30 mm TEGs and produced a maximum of approximately
500 W. The claimed fuel consumption reduction is 3%. An image of the prototype from Honda
can be seen in Fig.8
Alternative heat exchanger designs have been explored such as a design by Dai et al.which
used liquid metal exhaust heat exchanger with a solid state electromagnetic pump. The liquid
metal transfers the heat from the exhaust gases to the hot side of the TEGs. The liquid metal
used was a GaInSn alloy with a melting point of 10.3 °C. A total of 40 50 mm × 50 mm BiTe
TEGs were used and the system managed to power a 120 W LED lighting array. Alternative
heat exchangers on the cold side of the TEGs have been explored such a design by Hsu et
al.which used finned air cooled aluminium heat sinks. This system used 24 BiTe TEGs and
generated a maximum of 12.41 W with an average temperature difference of 30 °C

22. 11
Fig 8.Honda prototype TEG exhaust heat recovery system.
2.5 Energy Generation
When a p-type element electrically connects to the n-type element, the mobile holes in the p-
type element “see” the mobile electrons in the n-type element and migrate just to the other
side of the junction.
Fig 9. Representation of depletion zone in junctions

23. 12
When one electrically connects a p-type element to the n-type element, the mobile holes in
the p-type element “see” the mobile electrons in the n-type element and migrate just to the
other side of the junction. For every hole that migrates into the n-type element, an electron
from the n-type element migrates into the p-type element. Soon, each hole and electron that
“switch sides” will be in equilibrium and act like a barrier, preventing more electrons or holes
from migrating. This is called depletion zone.

24. 13
CHAPTER-3
COMPONENTS
3.1 Peltier Module
A thermoelectric (TE) module, also called a thermoelectric cooler or Peltier cooler, is a
semiconductor-based electronic component that functions as a small heat pump. By applying
a low voltage DC power to a TE module; heat will be moved through the module from one
side to the other. One module face, therefore, will be cooled while the opposite face is
simultaneously heated.
Both N-type and P -type Bismuth Telluride Bi2Te3 thermoelectric materials are used in a
thermoelectric cooler
Fig 10. Peltier Module
3.2 TE- Generator
Based on the Seebeck effect, thermoelectric devices can act as electrical power generators. A
schematic diagram of a simple thermoelectric power generator operating based on Seebeck
effect.

25. 14
Figure 11. TE-Generator
3.3 Thermal Grease
Thermal grease (also called thermal gel, thermal compound, thermal paste, heat paste, heat sink
paste or heat sink compound) is a viscous fluid substance, originally with properties akin to
grease, which increases the thermal conductivity of a thermal interface by filling microscopic
air-gaps present due to the imperfectly flat and smooth surfaces of the components; the
compound has far greater thermal conductivity than air (but far less than metal). In electronics,
it is often used to aid a component's thermal dissipation via a heat sink.
3.3.1 Heat Sink
A fan-cooled heat sink on the processor of a personal computer. To the right is a smaller heat
sink cooling another integrated circuit of the motherboard.
A heat sink (also commonly spelled heatsink) is a passive heat exchanger that transfers the
heat generated by an electronic or a mechanical device to a fluid medium, often air or a liquid
coolant, where it is dissipated away from the device, thereby allowing regulation of the device's
temperature at optimal levels. In computers, heat sinks are used to cool central processing units
or graphics processors. Heat sinks are used with high-power semiconductor devices such as
power transistors and optoelectronics such as lasers and light emitting diodes (LEDs), where
the heat dissipation ability of the component itself is insufficient to moderate its temperature.

26. 15
A heat sink is designed to maximize its surface area in contact with the cooling medium
surrounding it, such as the air. Air velocity, choice of material, protrusion design and surface
treatment are factors that affect the performance of a heat sink.
Fig 12. Heatsink
3.4 CPU Cooling Fan
One of the main components is the CPU fan. It is the most economical and effective way to
cool down the processor and protect it from overheating. The CPU fan is critically necessary
to ventilate the heat generated from the components, and actively cools the processor by
bringing in cooler air before the heat damages the computer components.
Cooling fans for the CPU are available in different sizes and is usually sold with an aluminium
or copper heat sink fan. The CPU cooling fans are attached directly on top of the CPU and
works along with an aluminium heat sink fan to cool down the CPU and dispels any hot air
from circulating around any circuitry boards, video cards, the motherboard, and other
components that work with your computer, thereby ensuring that they are cool and operable.

27. 16
Fig 13. CPU cooling fan
3.5 Hot Air Gun
A heat gun is a device used to emit a stream of hot air, usually at temperatures between 100°C
and 550°C (200-1000°F), with some hotter models running around 760°C (1400°F), which can
be held by hand. Heat guns usually have the form of an elongated body pointing at what is to
be heated, with a handle fixed to it at right angles and a trigger, in the same general layout as a
handgun, hence the name

28. 17
Fig 14. Commercial heat gun kit
3.6 Heat Chamber
Fig 15. Heat Chamber

29. 18
Heat chamber is made of insulated material and its function is to transmit heat from heat gun
to the Peltier module’s hot junction side and also provides us with a pathway for the exhaust
gases to escape. It makes sure that the heat is not wasted.
3.7 Multimeter
A multimeter or a multitester, also known as a VOM (volt-ohm-milliammeter), is an electronic
measuring instrument that combines several measurement functions in one unit. A typical
multimeter can measure voltage, current, and resistance. Analog multimeters use a
microammeter with a moving pointer to display reading
Fig 16. Multimeter

30. 19
3.8 Battery
In our project we are using secondary type battery. It is rechargeable type. A battery is one or
more electrochemical cells, which store chemical energy and make it available as electric
current. There are two types of batteries, primary (disposable) and secondary (rechargeable),
both of which convert chemical energy to electrical energy.
In isolated systems away from the grid, batteries are used for storage of excess thermal energy
converted into electrical energy. In fact, for small units with output less than one kilowatt,
Batteries seem to be the only technically and economically available storage means. Since both
the TEG system and batteries are high in capital costs, it is necessary that the overall system
be optimized with respect to available energy and local demand pattern.
Fig 17. Battery

31. 20
3.9 Printed Circuit Board
A printed circuit board (PCB) mechanically supports and electrically connects electronic
components or electrical components using conductive tracks, pads and other features etched
from one or more sheet layers of copper laminated onto and/or between sheet layers of a non-
conductive substrate. Components are generally soldered onto the PCB to both electrically
connect and mechanically fasten them to it.
Fig 18. PCB

32. 21
CHAPTER-4
PROCESSES USED
4.1 Carpentry Work
Fig 19. Carpentry Work
Here we used wooden beams to make a rectangular base for our project and join them together
with nails and some fevicol.
After this the frame was given a base to provide a base for the equipment to be installed. This
was done by attaching a wooden sheet.

33. 22
Fig 20. carpentry work 2
4.2 Sheet Metal Work
Fig 21. Metal sheet work

34. 23
Here we use the steel metal sheet to make the base for our project. This was done to make the
base stronger. Processes involved were
1.Metal sheet cutting
2.Fabricating it in the shape of our base.
3.Attaching it to the base via nails.
4.3 Gluing
Fig 22. Glue process
Here we used a plastic glue gun to glue most of our components together thus giving us quick
and easily applicable process. Most of our components were attached with screws and nails.

35. 24
4.4 Soldering process
We connected the electrical connections of the project by the soldering process. It was
economical and provided us with a much better and strong circuit connections rest of the
connections were insulated by tape.
Fig 23. Soldering process

36. 25
CHAPTER-5
CONSTRUCTION
5.1 Base
The base is the part which holds our project together. Here we used wooden beams to make a
rectangular base for our project and join them together with nails and some fevicol.
After this the frame was given a base to provide a base for the equipment to be installed. This
was done by attaching a wooden sheet. After this the base was covered with a steel sheet to
further strengthen the base and quality.
Fig 24. Base
5.2 Heat Chamber
The heat chamber was constructed to create a zone where the transfer of heat from the heat
gun or source to the Peltier can take place without loss to the surroundings. Wood was used

37. 26
instead of metal for the construction due to its insulating properties. Here we used multiple
pieces of wood to make the rectangular box. We also made a exhaust port on the side to let the
exhaust heat out else it might damage the Peltier module and could result in failure of the
project.
Fig 25. Heat Chamber Contruction
5.3 Wooden Base for the Thermoelectric Generator
The base of the thermoelectric generator was made of wood to prevent the loss of heat by
conduction and reduce chances of electrical conductivity. The base was made to be a of U-
Shape
And keep the generator elevated.

38. 27
Fig 26. Base for Thermoelectric Generator
5.4 Thermoelectric Generator
The Thermoelectric Generator comprises of a Peltier module, a heatsink and a cooling fan to
increase the air flow in the heat sink.
Firstly, we tested the Peltier module by heating its heat side with the heat gun and obtaining
the reading on the multimeter. It enabled us to determine the hot and cold side of the Peltier
and proceed with the construction process.
Now we connected the cold side of the Peltier with the heat sink and connected the fans with
the heat sink. We left the hot side open for the heat from the heat gun to make surface contact.
Now the entire module was connected on the exit side of the heat Chamber and tested for
operation. This generator was created for the conversion of heat to electricity and installed in
he Heat Chamber.

39. 28
Fig 27. Thermoelectric generator for heat to electrical conversion
The second Thermoelectric generator was created for the purpose of converting the electric
energy to run a modified thermoelectric generator to provide a cooling effect
.
Fig 28. Modified Thermoelectric generator for cooling

40. 29
5.5 The controlling switches
The switched to control the working of the project were made from PCB board and some
toggle switches. Now these switches were attached to the PCB board by the Soldering
process. Then they were connected with the rest of the circuits by the soldering process.
Fig 29. Picture of switch control system

41. 30
Chapter-6
Identification of Hot Spot in the Silencer
Fig 30. Silencer Model
A model of silencer is developed using Ansys and it is subjected to analysis in Fluent to identify
the hot spot zone in the silencer.
The meshed file is subjected to analysis using the Fluent. The physics is set up and the flow of
gas is made to take place in the silencer with an average velocity of 40 m/s and the hot gas inlet
temperature was given to be 1000C. The result obtained is shown in the figure below. It is
observed from the contour that the hot region is concentrated around the elbow region where
the colour variations are shown (Red and Yellow coloured spots).
Fig 31. Contours of Temperature

42. 31
Hence it is in agreement with the practical case. The thermal stress is more concentrated in the
Elbow region and the base region of the silencer because the hot exhaust gas will directly strike
the elbow region and take a diversion and so the velocity of gas will be reduced at those spots
and this leads to the accumulation of more exhaust gas in those regions. Hence more amount
of heat is said to be produced in those regions. So if we place the TEG at this portion of the
silencer then there would be maximum heat transfer leading to steady production of electric
power.

43. 32
CHAPTER-7
WORKING PROCEDURE
Block diagram
Hot
Air
gun
Hot
Air passing
device
Battery
Thermoelectric
Generator
Thermoelectric
Generator
Cooling Air Fan

44. 33
7.1 Working principle
The heat gun is started and the acceleration is to be given, so that the amount of heat leaving
the exhaust will be increased. Due to this heat, the surface of the exhaust pipe and the silencer
will be heated to very high temperatures. These hot surfaces will try to liberate the heat to the
atmosphere, which acts as a Heat Sink. Since the atmospheric temperature is less than that of
the silencer surface, a temperature difference is created and hence the surface tries to attain the
equilibrium state through the heat transformation process. But this will take much longer time.
Hence in order to increase the rate of heat transfer the Thermal Grease is used. The Thermal
Grease is coated on the hot surface of the silencers and also in the inner surface of the fins
which are present in the upper part. The fins are also used to increase the heat transfer rate. As
the heat gun moves, the air flow will take place between the fins and it acts as the sink.
As the surface of the silencer gets more and more heated the heat transfer rate will increase due
to the increase in the temperature difference. The Peltier module is placed between the Heat
Source (Hot Silencer Surface) and the Heat Sink (atmosphere) and the fins are placed above
the module. The module is made of semiconducting materials. Hence by the principle of
Seebeck Effect, the temperature difference can be directly converted into voltage by using
some thermoelectric materials. Based on this effect, when the surface heat of the silencer is
passed on to the atmosphere, the electrons and holes of the thermo electric semiconductors will
try to move towards the junction and make the flow of electric current to be possible.
The voltage developed due to this effect can be increased by using some Booster circuit like
DC-DC Cuk Converter. This will step up the voltage generated to some nominal value. So that
we can get the sufficient amount of voltage. For this converter the general formula used to
measure the approximate voltage for the given temperature is T=V/10mV. Hence this voltage
can be connected to some battery and stored, or else it can be given directly to some electric
appliances which uses DC. If we need AC voltage, it can be converted using the rectifier.
The voltage generated can be increased by placing more number of modules and connecting
them with one another to meet the demand of the required voltage. This voltage can then be
supplied to the suitable electrical appliances

45. 34
Fig 32. After finalising picture of project

46. 35
CHAPTER-8
CALCULATIONS
8.1 Calculation for Voltage generated
From the equation of Seebeck effect,
V=α (Th – Tc)
Where,
V – Voltage Generated in Volts α – Seebeck coefficient in μ V/K
Th-temperature of hot surface (silencer) in Kelvin T c-temperature of cold surface
(atmosphere) in Kelvin α of Bismuth Telluride – 287μV/K
Tc = 303 k
A few temperatures of the hot silencer is taken into consideration and the corresponding
voltages that are expected to be generated according to the Seebeck equation is calculated as
follows,
V = α (Th – Tc)
Case 1:
Th= 403 k
V= (287 ×10-6
) × (403-303)
= (287 ×10-6
) × (100)
=0.0287 V
Case 2:
Th= 453 k
V = (287 ×10-6
) × (453-303) = (287 ×10-6
) ×(150)

47. 36
= 0.04305 V
These voltages are 36 eager in value. This can be boosted up using the booster circuit. The
experimental results obtained are tabulated as follows:
Table 1: Voltage generated and boosted for different temperatures
Temperature Voltage without Voltage after boosting
difference δt (k) boosting (volt) (volt)
80 0.02296 1.44
100 0.02870 2.53
120 0.03444 3.21
140 0.04018 3.85
150 0.04305 4.43
160 0.04592 4.94
180 0.05166 5.37
200 0.05740 6.10

48. 37
CHAPTER 9
EXPENSES
Name Cost (in Rupees)
Peltier Module 180×3 = 540
Heatsink 230×3 = 690
Hot Air Gun 900
Multimeter 200
Battery 600
PCB 120
Metal Sheet 170
Plywood 160
Wood Beams 120×2= 240
Iron Nails 10
Fevicol 20
PCB Switches 10×2 = 20
Wiring 50
Glue Gun 550
Solder 70
TOTAL 4340

49. 38
CHAPTER-10
CONCLUSION
The abundance of waste-heat sources and increasing energy efficiency goals make waste heat
recovery with thermoelectric power generation a promising technology. The realization of
commercial thermoelectric generators hinges on solving the intimately coupled challenges with
materials development and systems engineering. Measuring system performance with
thermoelectric material ZT alone is insufficient for determining generator performance, and
other thermo mechanical/chemical material properties and components strongly impact
product development. Major issues to resolve for TEG commercialization are material
selection based on average (not peak) ZT, material thermal and chemical stability, engineering
of interfaces and interface materials, and optimization of hot and cold side thermal resistances
(e.g. heat exchangers).
Moreover, the manufacturability of thermoelectric devices combined with the total system cost
will influence the technology's time-to-market, readiness of product supply, and cost
competitiveness. Active research and development efforts along with the emergence of new
prototypes and pilot systems indicate solutions to the linked materials and systems challenges
are well underway, and thermoelectric generators can contribute to sustainable development.
Thus the eco-friendly power generation method can be implemented for domestic and
commercial use at an affordable cost. The efficiency of the engine will not be affected because
only the surface heat of the silencer is drawn out. The main objective of this project is to recover
the surface exhaust heat to avoid the accidents (Burn-outs) caused by the overheated silencers,
and to convert the recovered heat to useful electric energy. This objective has been successfully
accomplished in this project. The output could be increased by connecting a number of TEGs
in series, so that the voltage gets added up leading to increased power. The energy produced
from this system could be used to power any auxiliary devices in an automobile directly or it
could be stored in a battery and then used for cooling.

50. 39
Investigations have found that an appropriate way of improving the overall efficiency of the
fuel use in a car is to recover some of the wasted heat.

51. 40
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5. Fig8.www.researchgate.net/publication/284113555/figure/fig8/AS:298916592537603@14
48278677189/Honda-prototype-TEG-exhaust-heat-recovery-system.png
6. Fig 9. https://www.marlow.com/hs-
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