The Atlas project aims to develop solid-state semiconductor thermoelectric generator (TEG) units for integration into vehicle exhaust systems, enhancing energy efficiency. 

Deliverables: 

• Commercialising a specialised energy recovery system based on ETL’s thermoelectric technology. 

• Testing and validating TEGs in rugged off-road conditions, potentially leading to intellectual property. 

• Gathering performance data from laboratory and field testing. 

• Improving production processes to secure thermoelectric device supply via UK manufacturing. 

• Establishing a UK supply chain in partnership with companies like Kennametal, South Wales. 

Goals: 

• Achieving high-standard project delivery within the specified timeframe. 

• Enhancing brand awareness for ETL. 

• Establishing ETL as an industry leader in thermoelectric technology. 

ETL’s thermoelectric devices have applications beyond vehicles, including high-temperature cooling. This project serves as a platform to evaluate these devices under extreme conditions, with potential applications in various sectors, such as medical and Oil and Gas, including controlling sensitive instruments in extreme environments and energy harvesting. 

This project marks a pivotal step towards scaling production, potentially expanding into industrial waste heat and energy harvesting applications, with increased production volume expected to fund process enhancements and lower production costs. 

Toyota Motor Manufacturing (UK) Ltd has reached a groundbreaking milestone in its pursuit of zero-carbon emissions, proudly unveiling a prototype hydrogen fuel cell-powered Toyota Hilux pickup. Spearheaded by Toyota and supported by a consortium of esteemed partners, including European Thermodynamics Ltd, Ricardo, D2H, and Thatcham Research, this project marks a significant leap forward in sustainable automotive technology. 

• Toyota Motor Manufacturing (UK) Ltd, in collaboration with European Thermodynamics Limited and industry leaders, has unveiled a pioneering hydrogen fuel cell-powered prototype of the iconic Toyota Hilux pickup. 

• Supported by partners like Ricardo, D2H, and Thatcham Research, this project represents a significant leap towards achieving zero-carbon emissions and advancing sustainable automotive technology. 

• European Thermodynamics Limited, known for its expertise in thermal management solutions, contributes to the project by enhancing thermal management efficiency using reversible fan and multi-fan solutions for the hydrogen fuel cell system. 

• Funded by the UK Government’s Advanced Propulsion Centre (APC), this initiative aligns with the global shift towards sustainable transportation and underscores Toyota’s commitment to shaping the future of mobility. 

• The project highlights the power of collaboration among industry leaders, showcasing what can be achieved when innovation, sustainability, and shared goals converge. 

Rapid development of the hydrogen fuel cell-powered Hilux prototype exemplifies the potential of collective expertise and investment in zero-emission vehicles and technologies in the UK automotive supply chain.ss 

European Thermodynamics Limited a renowned name in thermal management solutions, stands as a key consortium member, contributing its expertise in thermal management development and support to the initiative. This collaboration is poised to play an important role in the support of the advancement of zero-emission transportation solutions.

The project has been brought about by the requirement for a reliable dual fuel, diesel and natural gas (NG), engine system that meets and exceeds future EU IV+ and US 2010 legislation. 

HGV operators, NG providers and EU governments have already invested many £millions to date in NG infrastructure and refueling sites. However, there has been limited uptake in the conversion of entire fleets of vehicles to natural gas. 

The DUET dual-fuel system will offer customers the unique assurance that the vehicle will continue to operate normally on 100% diesel should the natural gas infrastructure fail in any way. 

The avoidance of such opportunity cost (or cost-of-failure) makes dual-fuel the only option for most long-distance heavy-haulage operators. Without such operators adopting natural gas, it is doubtful that the use of natural gas as a road-fuel will grow as much as the UK and EU Governments expect in order to contribute to committed reductions in transportation carbon. 

The project will also be looking at the after-treatment of exhaust gases together with the development of a heavy-duty thermoelectric generator (TEG) to reach future emissions targets and seek to deliver high quality tier 1 prototype products that meet UN safety and ISO quality standards. 

Aims 

The aim is to develop new heavy duty dual-fuel (DF) combustion and after-treatment technologies to meet future international legislation including future Euro VI+ emissions compliance with reduced carbon footprint at acceptable cost. 

The main deliverables will be a demonstration of 23% source to wheel carbon reduction relative to Euro VI HD diesel operation and development of heavy-duty thermoelectric generator (TEG) to reach future emissions targets. 

Research shows that a major barrier to the purchase of electric vehicles (EVs) is the limited operating range compared to the majority of the available car models on the market. The main ways to increase the operating range of an electric car are: to increase the engine efficiency, to improve the battery efficiency, to reduce the mass of the car and/or, to improve the energy use in the car. 

The project will target the energy consumption challenge by focusing on improving energy consumption of the vehicle and battery efficiency; to get more available energy for mobility and consume less energy from the grid. EV motors and batteries do not create heat in the same way as internal combustion engines and therefore require specific thermal management solutions. Current HVAC (heating, ventilation, and air conditioning) technologies reduce the EVs potential operating range by up to 25%. 

Aims 

The primary aim is the development of a novel energy-efficient climate system for the optimisation of interior temperature control management. This integrated approach combines the application of the thermoelectric Joule and Peltier effects, the development of efficient insulation of the vehicle interior and energy recovery from heat zones. Battery life will increase in duration due to enhancement as a side effect of thermal management. Battery energy consumption will reduce by Peltier cooling integration, innovative automated and eco-driving strategies and the electronic control of power flows. 

The main objectives are the reduction of at least 50% of energy used for passenger comfort (<1,250 W) and at least 30% for component cooling in extreme conditions with reference to electric vehicles currently on the market. 

The project has received funding from the European Union‘s Horizon 2020 research and innovation programme under Grant Agreement n° 653851. 

VIPER 2 builds on the success of the VIPER project. Using conventional concepts of engine management in thermal energy, the engine will be re-examined using state-of-the-art simulation tools and a novel test engine which will allow the heat available to be directed to the most import components such as the cylinder liner walls. 

Some of the heat that will inevitably escape down the exhaust will be converted into electricity using a thermoelectric generator. In the longer term, if all the project targets are met, it is believed that a 5% improvement in fuel economy is possible through the conversion and management of heat energy. The challenge is to achieve a dramatic cost reduction of the TEG components along with an improvement in function while increasing technology readiness level (TRL) from 2-3 and manufacturing readiness level (MRL) 3 to 6-7 and 5 respectively. This research programme, scheduled to start in early 2014, is enabled by a £2 million grant from the UK government’s Technology Strategy Board (TSB), and builds on an earlier programme which was also co-funded by the TSB. 

Project end date: May 2017 

Aims 

To achieve a dramatic cost reduction of the components along with a functional improvement 

Success of the project will secure an entirely new, high-tech opportunity for UK manufacturing. 

Innovative coolant and lubricant systems in the engine allowing more precise management of the engine warm up thereby reducing friction loss. 

The Powerdriver project aimed to develop an innovative, environmentally friendly thermoelectric power generation system for automotive and marine applications that is powered by exhaust waste thermal energy to reduce fuel consumption. 

The project further aimed to advance thermoelectric chemistry and structural understanding by creating highly innovative nano-structured, functionally graded and multi-layer TEG structured compounds targeting commercial competitiveness in waste heat energy recovery applications. The WASTE heat being used to produce electricity to power on-board applications in automotive and marine sectors. 

Project end date: Finished January 2014 

Aims 

Overcome the limitations relating to the production of an automotive and marine power generation system by integrating cutting-edge nano-structured silicide and functionally graded telluride thermo-electric materials into a heat exchanger assembly that will enable electrical power to be generated from the exhaust system without affecting back-pressure or engine balance. 

Improve fuel efficiency for automotive and marine applications. 

Reduce emissions (CO2, nitrogen oxides, hydrocarbons, carbon monoxide and particulates). 

Partners: (image in folder) 

Results 

Silicide thermoelectric materials development produced p- and n-type materials via mechanical alloying, however, they demonstrated significant handling and processing difficulties. An alternate method produced an n-type material with a ZTmax of up to 1.4. Telluride thermoelectric materials development generated p-type GeTe with a ZTmax of 1.7 and two n-type compositions based on PbI2 doped PbTe with ZTmax values of 0.9 & 1.2. 

Two small device prototype thermoelectric modules were produced; one silicide based and the other lead telluride based. A third module based on bismuth telluride was also evaluated. Separate joining methods were developed for each module based on their calculated working temperatures. 

A hot side air exhaust heat exchanger was designed and optimised so that the heat transfer was maximised without causing excessive exhaust back pressure, in order that the net fuel economy was positive. The predicted pressure drop was 21 mbar compared with 85 – 86 mbar for the final prototype and the predicted efficiency was 60% compared to the test efficiency of 48 – 50%. Complimentary cold side cooling plates were designed, built and tested. At a flow rate of 10 l/min, the predicted pressure drop was 115 mbar compared with 140 mbar for the actual full prototype. 

The associated thermoelectric generator was built using solely commercially sourced bismuth telluride thermoelectric modules rather than the silicide/telluride hybrid originally designed because of joining problems experienced in the assembly of the silicide modules. An integrated automotive system based on parallel plate design was mounted onto a fully instrumented hot air test-rig to simulate the exhaust of a 2-litre gasoline car. 

For the Rolls-Royce and Halyard marine application a multi-layer parallel plate design concept based on the passenger car application was used. For the Rolls–Royce application the predicted power output was 14.0 – 27.7 kW (silicide only) and 14.6 – 31.5 kW (hybrid). For the Halyard application the corresponding figures were 2.7 – 4.9 kW and 2.9 – 5.7 kW. 

A single patent application has resulted in relation to an approach to overcome the stress-related issues and to provide potential for simplifying the number of components.