Recovering waste energy from engine exhaust

ADAMA SCIENCE AND TECHNOLOGY UNIVERSITY

SCHOOL OF MECHANICAL CHEMICAL AND MATERIALS ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING

RESEARCH PROPOSAL
ON
RECOVERING WASTE ENERGY FROM ENGINE EXHAUST

Prepared by: Mustefa Seyida and

Abubakar Muzayin

Submitted To Esmail Adem (Ph.D.)

February, 2023
Adama. Ethiopia
 Recovering waste energy from engine exhaust

Table of Contents
Abstract.................................................................................................................................................................3
Chapter One..........................................................................................................................................................4
Background of the study...................................................................................................................................4
1.1.2. Previous energy consumption profile of Transportation sector......................................................4
1.1.3. Recovering exhaust heat from internal combustion engines..........................................................5
1.1.4. TEG units and applications............................................................................................................5
1.2. Statement of the Problem......................................................................................................................5
1.3. General Objective..................................................................................................................................5
1.3.1 Specific Objective.........................................................................................................................6
1.4. Research Question.................................................................................................................................6
1.5. Scope.....................................................................................................................................................6
1.6 Significance of the study.......................................................................................................................6
Chapter Two.........................................................................................................................................................7
2. Literature Review..............................................................................................................................................7
2.1 Introduction to recovering waste energy from engine exhaust..................................................................7
2.2 experimental setups under taken on recovering waste energy from engine exhaust.................................8
Chapter Three......................................................................................................................................................12
3.1. Methodology.......................................................................................................................................12
3.2 research gap..................................................................................................................................................13
Chapter four........................................................................................................................................................14
1.1. Work Plan............................................................................................................................................14
1.2. Research Team composition................................................................................................................15
1.3. Beneficiaries........................................................................................................................................15
1.4. Risk and Mitigation.............................................................................................................................15
1.5. Alternative strategies...........................................................................................................................15
1.6. Participating Institution/Industries.......................................................................................................15
1.7. Budget Estimation...............................................................................................................................16
Reference............................................................................................................................................................16

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 Recovering waste energy from engine exhaust

Abstract
The Ethiopian transportation sector accounts three percent of the total energy consumed in Ethiopia
and responsible for two third of fossil fuel related greenhouse gas emissions. It is estimated that
somewhere between 20 to 50% of automotive energy input is lost as waste heat in the form of hot
exhaust gases, heat lost from hot equipment surfaces and heated products. As the automotive sector
continues efforts to improve its energy efficiency, recovering waste heat losses provides an attractive
opportunity for an emission free and less costly energy resource. .in the near future the automotive
industries will upgrade or improving their energy productivity by installing these technologies. This
study was initiated in order to alarming on new waste heat recovery technologies. A bottom up
approach is used to evaluate waste heat quantity, quality, recovery practices, and technology barriers
in some of the largest energy consuming units in Ethiopia automotive industry. The results from this
investigation serve as a basis for understanding the state of waste heat recovery and providing
recommendations for RD&D to design advance waste heat recovery.

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 Recovering waste energy from engine exhaust

Chapter One
Background of the study

The demand of vehicle assembly industry for the transportation purpose in Ethiopia inexorably
increases (TB MITIKU - 2018 - scholar.archive.org ). Vehicle assembly industries are coming under
growing pressure from governments, environmental groups and society, to reduce environmental
impact which automobiles and engines in general have on the community and planet. This is based on
the various gases emissions and particularly high carbon dioxide levels released into the atmosphere.
In addition to that, fossil fuels burning releases excessive heat into the environment. most rapidly in
developing countries with growing economies, one environmental consequence of transportation takes
on increasing potential importance and paves the way for looking at new waste heat recovery
technologies. That consequence is the emission of greenhouse gases (GHG), mostly CO2, in huge
amounts; for example, the transportation sector now accounts for about two third of all CO2 emissions
in the Ethiopia. At some future date, public policy or market forces may result in the transportation
sector having to reduce GHG emissions by introducing new technologies. Automobile assembly
industry in Ethiopia will committed themselves to increase average fuel efficiency to reduce CO2
emissions from the car exhaust at the same time society still places demands on automobile assembly
industries to retain the current attributes of performance, speed and durability, which engines and
vehicles currently display. Following that, among other research streams, manufacturers and designers
are conducting research and development programs, in the area of Automotive energy recovery
systems. Thermal electric generators (TEG) are used to recover the thermal waste energy from the
engine exhaust system, cooling system, gearbox, clutch and differential to produce electrical power.

1.1.2. Previous energy consumption profile of Transportation sector

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Diesel and gasoline are the main fuels consumed in the transport sector. Alternative fuels like
compressed natural gas (CNG) and LPG are not used for transportation in Ethiopia. The economy
meets its entire energy demand through imports. The transport sector consumes 2.9% of the total
energy.

1.1.3. Recovering exhaust heat from internal combustion engines

Research was carried out looking at the thermal efficiency and heat extraction from the exhaust gases
and engine coolant system. The project objective was to give an understanding on how to recover heat
from the exhaust gases after they leave catalytic converter. TEG mounted on the exhaust heat
exchanger, converted the heat to electrical power, which was used to power an electrical motor, as a
proof of concept.

1.1.4. TEG units and applications

TEG units are used in a variety of applications, ranging from low, medium and high temperature
energy sources. In automotive industry we have TEG and collecting energy from exhausted gasses.
TEGs are also found in solar panels, solar hot water systems, energy power stations, biomass powered
stoves 15 and solar pond 16 systems with air turbine incorporated into a solar chimney. Many of these
systems are combined together to enhance their efficiencies and power output.

1.2. Statement of the Problem

Most of the automotive manufacturing industries available in our country are the cause for those
carbon dioxide emission to the atmosphere due to their poor heat to work conversion capability this
may cause severe calamity on the physical environment and the life which is exist on the earth this
research title is proposed to solve this problem and to sustain the use of waste heat for the production
of electricity. The extraction of electricity from waste heat is very challenges due to lack of the
availability of advanced waste heat recovery technology and knowledge which is required to develop
it. This studies require to improve and solve the problem appear on their waste heat recovery technique
by designing and implementing new waste recovery technology

1.3. General Objective

The general objective of this research is to deliver better understanding about waste heat recovery
technology (thermos-electric generator) from automobile exhaust to the automotive manufacturing
industry which is available in Ethiopia.

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1.3.1 Specific Objective

 To reduce carbon dioxide emission by 50%
 To promote green technology
 Minimize the heat exhaust wastage

1.4. Research Question

1. How to reduce carbon dioxide emission by 50%?
2. How to promote green technology?
3. How to minimize the heat exhaust wastage?
4. What Knowledge and Technical Skill is required to implement this Research?

1.5. Scope
This research asses most automotive assembling industry which is available in the area of the study
across the country, Ethiopia. But for the success of the research and availability of the material also for
manageability of the study it is better to limit the study to Adama town.

1.6 Significance of the study

In Ethiopia as developing country, energy trends have showed that the energy consumption rate
would increase in line with the population growth and development of the country. Although the
increase was ongoing, the country was already experiencing a crisis, which meant that quick
solutions were required.

On the other hand, the Ethiopia automotive industry contributes a significant share towards the
country’s GDP; furthermore, the industry is experiencing a shift from Petro/diesel powered vehicles
to electric and hybrid vehicles powered by green energy. Another shift is that the market 15 is
showing a preference for light commercial vehicles like SUVs as opposed to passenger vehicles, as
they are more conventional. They also consume less energy when being produced. Some industries
have already made a shift to become suppliers of electricity to support their industry; this brings
about cost benefits and grows the renewable resource energy generation sector and by so doing
aligns industries with global green energy standards.

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Chapter Two

2. Literature Review
2.1 Introduction to recovering waste energy from engine exhaust
The ability to utilize the exhaust gas heat strictly depends on the engine load and the exchanger design,
which can reach a value of approximately 33% at the full load condition the simulation results prove
that the converter can be effectively implemented for practical purposes. Accuracy of measurements
and impacts on power improvement have also been taken into consideration. Future work will consist
of including a MPPT control for the TEG to deduce maximum power for the converter to operate more
efficiently. Moreover, introduction of a flying battery to avoid any power interruption and more.
(Alladeen et al., 2017)

Waste heat recovery entails capturing and reusing the waste heat from machineries in industries and
using it for generating electrical work. It would also help to recognize the improvement in
performance and emissions of the machineries if these technologies were adopted by the production
industries. If this concept of thermoelectric system is taken to the practical level then there will be
large amount of electricity can be generated, which will be used to run industrial load itself. Also large
amount of wastage heat for pollution is also uses in this system in continue manner. And such
industries also somehow help to protect the environmental pollution.(Factor et al., 2022)

All components operating on a real vehicle need to be completely safe and reliable before they are
allowed to be connected to the vehicle. It is very important that the electrical power management
system of the TEG is thoroughly tested in the laboratory before it can operate on-board since in case of
failure it may affect the entire electronic system of the vehicle. After an internal evaluation from
Scania the entire system was mounted on-board and tested.(Risseh et al., 2018)

In this work, however, the nanosized structure of the bulk sample indicates that the grain growth of the
synthesized powders was insufficient during hot pressing, which should be related to the hollow-like
morphology of the nano powder. The curved flakes should tend to break into smaller pieces during the
hot pressing and this contributed to the formation of the nanostructured bulk material. The presence of
a number of various sizes of nanocrystals in the bulk material may enhance the phonon scattering at
boundaries and reduce the lattice thermal conductivity.(Zhu et al., 2007)

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2.2 experimental setups under taken on recovering waste energy from engine
exhaust
Main path toward reduction of overall TEG system cost is reduction of component cost and in
particular cost of TE elements. At the device level, cost of TE elements can be as high as 30% of
overall device cost. In this program we have demonstrated possibility of manufacturing net shaped TE
elements for power generation applications. Applying methods described here, it is possible to reduce
cost of manufacturing 90 TE elements by the factor of 3. Further reduction by similar factor is
necessary. This cost saving can be achieved by further industrialization and automation of process.
That investigation was beyond the scope of this program.(Report & Vehicles, 2016)

to solve the convex optimization problem of Section III, the problem is expressed in CVX within the
format of disciplined convex programming [25] and then SDPT3 solver [29] is employed to solve the
numerical problem. For all convex problems, we use discretization with a time step of ∆t = 1s. The
validity of the optimal solution is then assessed by the result of dynamic programming (DP)
implementation over the convex model. Convex solver guarantees to converge to the globally optimal
solution within a pre-defined numerical error which any numerical solver has. All of the following
numerical processes have been done using a personal computer with 3.40 GHz Intel Core i7 processor.
(Amirfarhangi Bonab & Emadi, 2020)

Many innovative ideas are not able to be translated into new products. Also, many projects cannot
become technically feasible products. And even if they are technically feasible, they may not
necessarily get market recognition. The success rate of innovation in some industries is very low.
Taking new drug development as an example, commonly, only 1 of 3,000 initial innovative ideas is
able to be commercially successful.(Chen et al., 2019)

Apart from developments in thermoelectric materials, the thermal management of waste heat recovery
thermoelectric generators is essential: energy from the heat source must be managed properly to
maximize net recovered energy. This leads to a change of paradigm in the heat exchanger design:
typical designs of heat exchangers targeting an outlet temperature or a global heat transfer are not
valid, since in waste heat applications the target is to improve the overall energy consumption of a
system and parasitic losses must not exceed the relatively low electrical energy harvested. The
strategies tested to improve heat exchange are based on increasing the heat transfer area or in
disturbing the boundary layer to decrease convective thermal resistance, but both cause an increase in

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pressure drop. In the design process, enhances in heat transfer should be done assuring that the
minimum pressure drop is incurred.(Fernández-Yáñez et al., 2021)

The waste heat recovery performance of a thermoelectric generator (TEG) was experimentally
investigated. Forty customized thermoelectric modules (TEMs) were installed on the upper and lower
sides of a rectangular exhaust gas channel in a 4 5 arrangement. Water at an ambient temperature of
293 K was supplied from a cooling tower and was used to create a temperature difference across each
TEM. The water flow rate was fixed at 8 SLPM. A turbocharged six-cylinder diesel engine was used
as the heat source; the engine was operated under various conditions. Three engine rotation speeds—
1000, 1500, and 2000 rpm—were employed to determine the effect of the exhaust gas flow rate on the
TEG power output. The temperature of the exhaust gas was varied by changing the engine load, i.e.,
the brake mean effective pressure (BMEP), at an interval of 0.2 MPa. From the experimental results, a
contour map showing the power output of the TEG as a function of the engine load and speed was
obtained. From the contour map, we observed that the power output of the TEG increases with the
engine load or speed.(Choi et al., 2019)

This review pointed out the major driving forces that pose a pressure on the air quality Addis Ababa
and potentially recorded adverse impacts of air pollution that commonly observed in the health
centers, clinics and hospitals of the city. Experiences of other developing and developed country cities
are also reviewed. Accordingly, the major driving forces from ambient air pollution in Addis Ababa
are transport and urbanization with its increasing regular and irregular economic activities The
population is increasing alertly. Related to this, motorized transportation s system is correspondingly
increased.(Tarekegn & Gulilat, 2018)

The development of renewable energy has become a key issue in transforming countries’ economy in
the context of climate change mitigation at national and regional levels. Drivers of renewable energy
production are largely gleaned from public discourses with little empirical backing. The empirical
evidence on drivers of renewable energy production would promote small-scale enterprises in the
development of renewable energy technology and respond to the current energy demand.(Bayale et al.,
2021)

By combining semiconductor nanowire FET and high frequency nanowire NEMS resonators, the
NEMFET is an exciting new device design that transcends previous NEMS switches and traditional

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FETs with finite subthreshold slope. The 3-terminal NEMFET eliminates the need for the gate
electrode to contact the moving channel, 74 meaning both can be covered with protective oxide layers,
greatly increasing the reliability and stability of NEMS devices. We already demonstrated less than 2
V Vpi-Vpo operational voltage window with the potential to use fixed surface charges or work
function differences to shift the Vpi values further towards zero.(Utami, 2013)

in conclusion, the design proposed in this project recover waste heat from the engine exhaust gasses.
The heat from the room surface that is attached to engine exhaust is converted to electrical output via
thermoelectric generators connected in series on top and back surface of the room surface. That output
power can serve various purpose such as charging a battery, lightening of lamp or in any low wattage
appliances. Out unique contribution to previous work is that our work can be utilized by everyone
domestically and commercially due to its simple design.(Al-abdulhadi & Al-radhi, 2016)

A complete computational model has been developed capable to simulate the thermoelectric
generation of the Peltier module. It solves the equations of thermoelectricity and the heat transfer
phenomenon. The thermoelectric parameters are defined as a function of the temperature, what allow
us to keep in mind the Thomson effect.The computational model has been validated using
experimental data of a test bench for different room temperatures and different heat fluxes. The errors
are lower than the 5%. Our computational model has important advantages with other calculation
methods from the literature.(Ariana, 2016)

From the results obtained, it was observed that the temperature distribution was impacted greatly by
the variable leg geometry along the leg height. For instance, the conventional Rectangular shape
experienced a smoother temperature distribution compared to the Cone and Diamond shapes. In terms
of the electric potential, the newly introduced Diamond shape showed the highest voltage potential in
comparison to the Rectangular shape, which had the lowest voltage potential. Furthermore, at the
second stage of the research, the whole module consisting of 128 pairs p and n for the two most
different results was analysed. It is worth noting that the voltage for a TEG module was 5.67 V and
5.68 V for Rectangular and Diamond shapes, respectively, and the results were found to be
comparable to the theoretical analysis.(Doraghi et al., 2021)

Experiments confirm textural field and microscopic evidence that a miscibility gap exists between
sulfide and arsenide melts. The miscibility gap is large, with up to 2 wt% As in sulfide and 1–2 wt% S

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in arsenide melt. In the experiments reported here, the width of the two-liquid field in T-X space is
controlled by Pt–Pd abundances bulk ratios. In natural melts where Pt and Pd are mere traces, the
parameter controlling the exsolution of arsenide from sulfide will be the activities of the NiAsS and/or
Ni As components, abundant as phases in natural arsenide mineralization.(Helmy, Ballhaus, Fonseca,
& Nagel, 2013)

Phase relations and compositions. Run products of the equilibration experiments are quenched Fe–
(Cu) sulfide melt, mono-sulfide (Fe1 xS) crystals, and in Pt–arsenide-saturated melt compositions the
magmatic Pt–arsenide mineral sperrylite (PtAs2). Phase relations and phase compositions with respect
to Pt contents are shown in Fig. 1. All phases are analyzed for major and trace elements with electron
microprobe and Laser-ablation mass spectrometry.(Helmy, Ballhaus, Fonseca, Wirth, et al., 2013)

In general, the magnitudes of axial conduction fluxes are found to be higher near the inlet region as
compared to exit region due to presence of steeper temperature gradients near inlet region. This is in
turn lowers the effective ΔTTEM at the entry region and increases ΔTTEM near the TEG exit.(Kumar,
2014)

The analysis results show that energy-intensive subsectors such as “Oil refineries,” “Non metallic
minerals,” and “Oil and gas extraction” use more energy per value added, and, although they account
for a large share of California industry’s final energy use (71 percent in 2008), they together produced
only 25 percent of total industry value added in 2008. In contrast, the “Electric and electronic
manufacturing” subsector accounted for 30 percent of the industry value added alone while just
consuming 2 percent of the total final industry energy use in 2008. These four subsectors have a major
influence on the results of the decomposition analysis.(Hasanbeigi et al., 2012)

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Chapter Three
3.1. Methodology
Below is Figure illustrating the research method, which is the path, followed in order to fulfill the
requirement of answering the research question this research consists of interconnected phases which
support each other; however, each phase or stage can be developed independently. Figure 1.8 begins
with “defining the problem”, which paves the foundation of the thesis; it is then followed by
“gathering literature for review”, which paves the way for the literature review and selecting a suitable
methodology to use in the thesis, and this makes up chapter 1 and 2. Chapter 3 begins by gathering
information from various sources including “Manufacturer A” that will be 16 used as a case study.
This information is the process used through the IDA techniques to validate its usefulness.

Information gathering:-
Defining the problem
lit. review

Methodology selectin
internet

Manufacturer A
Data analysis Data collection
Govnmt. Data basis

Data validation

Result and
interpretation

Conclusion.

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Data collection

Primary
Secondary
Observation
.books
Questionaries
.journal
interview

3.2 research gap.

As we understand a lot of research’s are under taken on this title previously. And tried to solve the
problem as much as they can, such as the way to reduce carbon dioxide emission by some amount of
present, promoting green legacy and how to minimize the heat exhaust wastage. So gap we aimed to
fill in our research is the technical skill and knowledge required to implement the research. Because
this part should be the main point of every research and there is a gap of skill and knowledge as we
understand from the most literature reviews we read.

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Chapter four
1.1. Work Plan

Year: 2015 E.C

Activities Responsibility Q1 Q2 Q3 Q4
Prepare proposal and present for Research of Researchers 
the Center
Preparation of study tools The Researchers 
Pre-testing the assessment/survey instrument The Researchers 
Prepare field work(identification of sites) The Researchers 
data collectors The Researchers 
Preparation for data collecting The Researcher 

Travel to data collection(potential The Researcher 

assessment) sites

Data encoding and analysis The Researchers 

Preparation of the report The Researchers 

Presenting the result of assessment. The Researcher 

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1.2. Research Team composition

Sr. Name Position
No
1 Mustefa Seyida Assistant Researcher

2 Abubakar Aliy Assistant Researcher

For successful completion of this research a team comprising of two members are required. The team
composition is shown below.

1.3. Beneficiaries

From the outcome of this research the benefited one will be government policy and decision makers,
and also anyone who can make a decision to implement recommended solutions of this research. This
is mainly used to minimize the risks of implementing any project prior to proper investigations.

1.4. Risk and Mitigation

The risk that we may face in the future to deliver suitable information while collecting data about
waste heat recovery technology is the amount and the quality of heat which is emitted from engine
exhaust is major problem to collect and analyze it. This can be easily solved by awareness of the
organization aimed to to be included in this research.

1.5. Alternative strategies

There is no doubt in our side regarding to the process of developing this prototype because there is
enough readiness to develop it.in case the intended things fail we will obliged to look for other
alternative like increase the amount of heat required and improve the quality of heat to drive TGR
(thermo electric generator).

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1.6. Participating Institution/Industries

No List of Stakeholders Task will perform Location Expected

1 Ministry of Transport Annual Energy consumption data of AA Technical and data

vehicle

2 Ministry of Industry Facilitation and any other support AA Facilitation

from them which is required to
conduct this research

1.7. Budget Estimation

-perdiem: researcher, data collector, labor, driver, and guider

- Transportation: fuel
-Materials: stationery, recording devices, memory devices, computers
-Software license:
-communication: wireless telephone, mobile card

Perdiem
1 Researchers 1 person 2 weeks per site 1*500*15 =7500
(15 days) 500 hundred birr for one day

2 Data collector 1 person 1 week per site 3500

(7 days)

Subtotal 11000ETB

1. Transportation

1 Fuel Number of sites 100 km per site 12100

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TOTAL 23100 ETB

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