DESIGN AND FABRICATION OF

COOLING SYSTEM USING

WASTE HEAT

PROJECT REPORT
Submitted by

SURESH PANDI. S 71381311409

6
VIGNESH. P 71381311410
4
YUHENDRA VARMA. S 71381311411
1
NANDHA KUMAR. E 71381311431
4

In the partial fulfillment for the award of the degree

BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING

SRI RAMAKRISHNA INSTITUTE OF TECHNOLOGY

COIMBATORE-641010
ANNA UNIVERSITY: CHENNAI- 600025
APRIL 2017
 BONAFIDE CERTIFICATE

Certified that this project report “DESIGN AND FABRICATION OF

COOLING SYSTEM USING WASTE HEAT” is the
Bonafide work of

SURESH PANDI. S 713813114096

VIGNESH. P 713813114104
YUHENDRA VARMA. S 713813114111
NANDHA KUMAR. E 713813114314

Who carried out the project work under my supervision.

SIGNATURE SIGNATURE
Dr. P. VIJIAN Mr. R. IMMANUAL

PROFESSOR& HEAD SUPERVISOR

Department of Mechanical Engineering ASSOCIATE PROFESSOR
Department of Mechanical Engineering
Sri Ramakrishna Institute of Technology
Sri Ramakrishna Institute of Technology
Coimbatore-641010.
Coimbatore-641010.

Submitted for the project work – ME6811 for the Anna University Examination
April /May 2017 conducted on -----------------

INTERNAL EXAMINER EXTERNAL EXAMINER

 ACKNOWLEDGEMENT

With immense pleasure and gratitude, we wish to thank our management and
Dr. M. Paulraj, M.E., Ph.D., Principal, Sri Ramakrishna Institute of Technology, for
having us this opportunity to undergo this course and to undertake this project.

We are extremely grateful to Dr. P. Vijian, M.E., Ph.D., Head of the Department,
Department of Mechanical Engineering, Sri Ramakrishna Institute of Technology, for his
stained interest and advice right from day one which has contributed great to the
completion of this project.

We are sincerely thankful to our project guide Mr. R. IMMANUAL, M.E.,

Associate professor, Department of Mechanical Engineering, Sri Ramakrishna Institute
of Technology, for his valuable support and guidance throughout this project.

We would like to expand our sincere thanks to our project coordinator

Mr. K. Augustine Babu, B.E., M. Tech., for his constant source of inspiring
encouragement and guidance.

We are also responsible to submit our sincere thanks to all the staffs of the
Mechanical Department for their constant encouragement throughout.
 ABSTRACT

In most of the thermal applications heat dissipated as waste. By using

thermoelectric module, the waste heat converted into useful electricity and then
the electricity is used to produce cooling effect using thermoelectric modules,
which have the capability to produce cooling effect. In this project first study
about the parameters which affects the electricity generation as well as cooling
effects by making an experimental setup. Then optimization for maximum
electric power as well as maximum cooling effect will occur. Based on the
optimization results, choose one of application in which maximum cooling
generation occurs. For that application developing the product of thermoelectric
cooling system using waste heat. Develop a software based on the experimental
results which gives the efficiency of the system based on input parameters.
 iii
TABLE OF CONTENTS

S.NO TITLE PAGE

ABSTRACT ⅲ
LIST OF FIGURES ⅳ
LIST OF TABLES ⅴ

1 INTRODUCTION
2 LITERATURE REVIEW
3 MATERIAL SELECTION
3.1 TEC1-12706 & PROPERTIES
3.2 3V INPUT-12V OUTPUT DC STEP UP
CONVERTER
3.3 HEAT SINK AND ITS PROPERTIES
3.4 THERMAL PASTE
3.5 ANEMOMETER
3.6 MULTIMETER
4 MATERIALS SPECIFICATIONS
5 SOURCE OF ENERGY
5.1 HEATING
5.1.1 MODES OF HEAT TRANSFER
5.2 HEAT TRANSFER
6 THERMOELECTRIC EFFECT
6.1 INTRODUCTION TO
THERMOELECTRIC EFFECT
6.2 ENERGY CONVERSION PROCESS
6.2.1 SEEBECK EFFECT

7 POWER GENERATION
7.1 INTRODUCTION TO
POWER GENERATION
7.2 VOLTAGE STEP UP PROCESS
7.3 VOLTAGE STEP DOWN PROCESS
8 COOLING PROCESS
8.1 THERMOELECTRIC COOLING
8.2 PELTIER EFFECT
9 DESIGN AND EXPERIMENTAL SETUP
9.1 DESIGN OF AIR FLOW BOX
9.2 DESIGN OF COOLING BOX
9.3 EXPERIMENTAL SETUP
10 WORKING
11 RESULTS AND OBSERVATIONS
12 COST ESTIMATION
13 CONCLUSION
14 REFERENCES
 iv

LIST OF FIGURES

FIG NO. TITLE PAGE

3.1 TEC1-12706
INTRODUCTION
 CHAPTER 1

INTRODUCTION

In Automobiles, due to the lot of moving parts and burning of fuels, heat
is generated. This generated heat is wasted in the atmosphere. In account to use
that heat in effiecient manner, we have come up with an idea to create a cooling
system by using heat generated from automobiles. In air conditioners, during
cooling process the Chlorofluro carbon (CFC) is emerged out. This Chloro fluro
carbon is harmful to the atmosphere and may also lead to the global warming.
The power input to the airconditioner is given by the battery in vehicles. It may
reduce the lifetime of the battery and also cause starting problem. In order to
overcome this problems and also to use the waste heat in efficient manner, the
cooling is done by Seebeck and Peltier effects.

A Thermoelectric generator, or TEG (also called a see beck generator) is

a solid-state device that converts heat (temperature differences) directly into
electrical energy through a phenomenon called the seebeck effect (a form of
thermoelectric effect).

The thermoelectric effect is the fact that a temperature gradient in a

conducting materials results in heat flow. This results in the diffusion of charge
carriers between the hot and cold regions in turn creates a voltage differences.

The major component to produce electricity is thermoelectric module

(TEC module). A Thermoelectric module is a circuit containing thermoelectric
materials that generate electricity from heat directly. Thus, the major aim of our
project is to convert the waste heat energy into a useful electrical energy for
generating cooling effect in cars by using a thermoelectric module.
LITERATURE REVIEW
 CHAPTER 2

LITERATURE REVIEW

The total power input is directly proportional to flow rate of exhaust gas
not by the gas temperature. Based on the result, the optimal design areas were
0,22m2 for the co-flow and 0.33m2 for the counter flow [1].

The counter flow arrangement is recommended because it maintains a

smaller division from the peak power output than a co-flow arrangement at their
respective optimal design area if there is sufficient system space. Finally result
that power of TEG is mainly depends upon the flow of exhaust gas [2].

Optimal module area that is appropriate to the mass flow rate of fluids,
but this is not affected by the intake temperature of fluids. Co-flow and counter
flow of fluid is done on thermoelectric generator. Finally result that is counter
flow produces a small higher maximum power output when compared to Co-
flow but it needed a large module area [3].

The power output of the thermoelectric generator is mainly depending upon the
engine performance that is load and speed. So, the variation of engine load and
speed creates a variation in the power output of the thermoelectric generator.

The heat source for the thermoelectric generator is obtained by engine.

The cooling source for thermoelectric generator is obtained by cooling tower.
Finally result that is obtained is power output of the TEG is mainly depends
upon the exhaust gas of the engine [4].

Thermoelectric generator is mainly work on the principle of seebeck

effect that is temperature difference is created on the TEG voltage is created.
Heat energy is supplied to one side of the TEG and cooling energy is supplied
to the TEG thus temperature difference create voltage.

Heat source for the TEG is obtained from exhaust of the automobile.
Cooling source for the TEG is obtained from cooling tower [5].

The maximum power output of thermoelectric generator is obtained by regular

flow of exhaust gas or fluid. The counter flow arrangement is recommended
because it maintain a smaller division from the peak power output than a co-
flow arrangement at their respective optimal design [6].
 The waste heat recovery chamber harvests energy from exhaust heat that
the TEGs convert into electricity. The estimation of generated power is an
important part of the system design. Methods of Computational Fluid Dynamics
(CFD) assist the analysis and improve the performance with great accuracy but
great computational duration [7]

The use of this method saves much time relative to such CFD methods. In
3D, thermal resistance analysis, a node of unknown temperature is located at the
centroid of each cell into which the system is divided. The relations of unknown
temperatures at the cells are based on the energy conservation and the definition
of thermal resistance [8].

The temperatures of inlet waste hot gas and ambient fluid are known.
With these boundary conditions, the unknown temperatures in the system are
solved, enabling estimation of the power generated with TEGs. A 3D model of
the system was simulated with FLOTHERM. its numerical solution matched the
solution of the 3D thermal resistance analysis within 6%.

The power generated with the same system with TEGs (TMH400302055,
Wise Life Technology, Taiwan) was measured; the experimental result is
consistent with the result obtained from the 3D thermal resistance analysis; the
relative deviation is approximately 10%.

The power generated is affected by many variables; the positions of the

TEGs, the uniformity of the internal flow of the velocity profile and the internal
and external flow velocities are considered in our 3D thermal resistance analysis
[9].

According to the results, both the positions of the TEGs and the
uniformity of the internal flow of the velocity profile should be considered to
maximize the power generation. Under varied operational conditions, the power
generated from the system might be more sensitive to the velocity of either the
internal or external flow [10].

Choosing an appropriate method makes increasing the power generation

efficient. The relations between variables and power generation are readily
revealed, even with varied parameters, yielding an optimal design of a waste
heat recovery system [11].
MATERIAL SELECTION
 CHAPTER 3

MATERIAL SELECTION

3.1 TEC1-12706 & PROPERTIES

FIG 3.1 TEC1-12706

 TEC1-12706 is a high performance thermoelectric module.

 A thermoelectric module is a circuit containing thermoelectric materials that
generate electricity from heat directly.
 A direct electric current will flow in the circuit when there is a temperature
difference between two materials.
 Generally, the current magnitude has a proportional relationship with the
temperature difference.
 The performance specifications of tec1-12706 are
 The hot side temperature range is 250 c to 500 c.
 The heat transfer (Qmax)value ranges from 50 watts to 57 watts.
 The maximum current produced by the tec1-12706 will be 6.4 Amps.
 The maximum voltage generated by the tec1-12706 will be 14.4 amps to 16.4
volts.
3.2 3V INPUT-12V OUTPUT DC STEPUP CONVERTER

FIG 3.2 3V INPUT-12V OUTPUT DC STEPUP CONVERTER

 This converter that can use 3.3V to 5V power supply source into 12V-13.8V
output max current 100mA.
 It can increase low voltage battery to high voltage load as need with high
efficiency.
 It is used for a power supply, 3.3-5volts 750 mA up.
 If use the power supply of 5 Volts DC current 300mA, can apply the output
voltage is 12 Volts DC at 100mA maximum.
 Maximum current output 100mA.Normal switching frequency about 43KHz.
 It can adjust the output voltage. There is power on LED display.
 If use the power supply of 3.3 Volts DC current 660mA, can apply the output
voltage to 12 Volts DC at current maximum to 50mA.
 IN point for connect power supply 3.3-5 Volts DC.
 OUT point is used as DC power supply to any loads which this voltage is
changed by the input voltage and adjust at VR10K

3.3 HEAT SINK AND ITS PROPERTIES

 FIG 3.3 HEAT SINK

 A Heat sink is a passive heat exchanger that transfers the heat generated by an
electronic or a mechanical device into a coolant fluid in motion
 Then-transferred heat leaves the device with the fluid in motion, therefore
allowing the regulations of the device temperature at physically feasible levels
 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 basic device is insufficient to moderate
its temperature
 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 materials, protrusion design and surface treatment are
factors that affect the performance of a heat sink
 The heat sink is usually made of copper and aluminum
 Copper is used because it has many desirable properties for thermally efficient
and durable heat exchangers
 First and foremost, copper is an excellent conductor of heat .this means that
copper ‘s high thermal conductivity allows heat to pass through it quickly

3.4 THERMAL PASTE

 FIG 3.4 THERMAL PASTE

 Thermal paste is a very high heat conductive paste that is used between two
objects to get better heat conduction.
 It fills in all those microscopic imperfections on the heat sink and CPU/GPU
that can trap air in them and cause a loss in the heat sink’s performance.
 Thermal paste is a kind of thermally conductive compound, which is commonly
used as an interface between heat sinks and heat.
 Thermal paste ensures that there is proper conduction of heat from the CPU to
the cooling system, which an air gap cannot fulfill.
 It is very important that the thermal resistance between the CPU and heat sink is
as low as possible.
 The need of physical contact to move heat efficiently from the cold side of the
TEC module.
3.5 ANEMOMETER

An anemometer is a device used for measuring the velocity of the wind.

The word anemometer is derivative e from the Greek word anemos, which
means wind, and is used to describe any wind speed measurement instrument
used in meteorology. This is also called as Air flow meters or Air velocity
meters. There are various types of anemometers used globally.

They are

 Cup Anemometer

 Vane Anemometer

 Digital Anemometer

For our purpose, we are using HAND HELD DIGITAL

ANEMOMETER. Due to varying speed of the automobile we cannot get
accurate flow of air in other analog air flow meters, in order to get the correct
flow and exhaust temperature, we are using this instrument.

Fig 3.5 hand held digital anemometer

3.6 MULTIMETER

Multimeter is a device used for measuring different electronic functions such as

voltage, current and resistance. It combines several measurement functions into
one unit. It is also known as Multi tester or volt-Ohm-Millimeter (VOM).

A multimeter can be a hand-held device useful for finding basic fault and field
service work, or a bench instrument which can measure to a very high degree of
accuracy. They can be used to troubleshoot electrical problems in a wide array
of industrial and household devices such as electronic equipment’s motor
controls, domestic appliances, power supplies, and wiring systems.

The kind of Multimeter that we are using for our purpose is Digital
Multimeter.

Fig 3.6 Multimeter

MATERIALS SPECIFICATIONS

CHAPTER 4
 MATERIAL SPECIFICATIONS

TABLE 4

S.NO ELEMENTS MATERIAL/ NO OF ELEMENTS

MODEL NO.

1 TEC1-12706 CERAMIC 6

BISMUTH TELLURIDE

2 CONVERTER CN6009 1

3 HEAT SINK ALUMINIUM 2

4 THERMAL 4

COMPOUND PASTE

5 THERMACOAL REQUIRED

AMOUNT

6 BATTERY 12V

(RECHARGEABLE)
SOURCE OF ENERGY

CHAPTER 5
 SOURCE OF ENERGY

5.1 HEATING

FIG 5.1 HEAT DISSIPATING FROM CAR

 The source of heat energy is car exhaust energy.

 The waste heat from exhaust is fed into the Tec module
 In car engine, heat is produced due to spark produced by the moving parts
 This heat is wasted into the atmosphere conveniently
 But, now we have come up with an idea to effectively use this heat energy to
create a cooling system

5.1.1 MODES OF HEAT TRANSFER

 Heat energy can be transferred by means of various wastes such as

 Conduction
 Convection
 Radiation

Thermal conduction is the transfer of heat by microscopic collisions of particles

and movement of electrons within a body. The microscopically colliding objects, that
include molecules, atoms and electrons, transfer disorganized microscopic kinetic and
potential energy jointly known as internal energy.

Conduction takes place in all phases of matter such as solids, liquids, gases and
plasmas. The rate at which energy is conducted as het between two bodies is the
function of temperature difference between two bodies and properties of conductive
medium through which heat is transferred. Thermal conduction was originally called
diffusion.

Heat spontaneously flows from hotter to a colder body. For example, heat is
conducted from hot plate of an electric stove to the bottom of saucepan in contact
within it. In the absence of an external driving energy source to the contrary, within a
body or between bodies, temperature difference decay over time and thermal
equilibrium is approached, temperature becoming more uniform.

In conduction, the heat flow is within and through the body itself. In contrast, in
heat transfer by thermal radiation, the transfer is often between bodies, which may be
separated spatially. Also possible is transfer of heat by a combination of conduction
and thermal radiation. In convection, internal energy is carried between bodies by a
moving material carrier. In solid, conduction is mediated by the combination of
vibrations and collisions of molecules, of propagation and collisions of phonons, and
of diffusion and collisions of free electrons.
 In gases and liquids, conduction is due to the collisions and diffusion of
molecules during their random motion. Photons in this context do not collide with one
another, and so heat transport by electromagnetic radiation is conceptually distinct
from heat conduction by microscopic diffusion and collisions of material particles and
phonons. But the distinction is often not easily observed, unless the material is semi-
transparent.

In the engineering sciences, heat transfer includes the processes of thermal

radiation, convection, and sometimes mass transfer. Usually, more than one of these
processes occurs in a given situation. The conventional symbol for the material
property, thermal conductivity, is K.

Thus, in our project there is a heat transfer from engine (solid medium) to TEC
module (solid medium) i.e., from one solid medium of higher temperature to another
solid medium of lower temperature with direct contact.

So we can conclude that for the energy generation purpose in vehicles, the mode
of heat transfer will be conduction between engine and tec1-12706.

Convective heat transfer often referred to simply as convection, is the transfer

of heat from one place to another by the movements of fluids. Convection is usually
the dominant form of heat transfer (convection) in liquids and gases. Although often
discussed as a distinct method of heat transfer, convective heat transfer involves the
combined processes of conduction (n heat diffusion) and advection (heat transfer by
bulk fluid flow)

The term convection can sometimes refer to transfer of heat with any fluid
movement, but advection is the more precise term for the transfer due only to bulk
fluid flow. The process of transfer of heat from a solid to fluid, or the reverse, is not
only transfer of heat by bulk motion of the fluid, but diffusion and conduction of heat
through the still boundary layer next to the solid.
 Thus, this process without a moving fluid requires both diffusion and advection
of heat, a process that is usually referred to as convection. Convection that occurs in
the earth’s mantle causes tectonic plates to move.

Convection can be forced by movement of fluid by means other than buoyancy

forces (for example, a water pump in an automobile engine). Thermal expansion of
fluids may also force convection. In other cases, natural buoyancy forces alone are
entirely responsible for fluid motion when the fluid is heated, and this process is called
“natural convection”.an example is the draft in a chimney or around any fire.

In natural convection, an increase in temperature produces a reduction in

density, which in turn causes fluid motion due to pressures and forces when fluids of
different densities are affected by gravity (or any force). For example, when water is
heated on stove hot water from bottom of the pan rises, displacing the colder denser
liquid which falls. After heating has stopped, mixing and conduction from this natural
convection eventually result in a nearly homogenous density, and even temperature.

Without the presence of gravity (or conditions that cause a g-force of any type),
natural convection does not occur, and only forced-convection modes operate.

The convection heat transfer mode comprises one mechanism. In addition to

energy transfer due to specific molecular motion (diffusion), energy is transferred by
bulk, or macroscopic, motion of the fluid. This motion is associated with fact that, at
any instant, large numbers of molecules are moving collectively or as aggregates.

Such motion, in the presence of a temperature gradient, contributes to heat

transfer. Because the molecules in aggregate retain their random motion, total heat
transfer is then due to the superposition of energy transport by random motion of the
molecules and by the bulk motion of the fluid.
5.2 HEAT TRANSFER

 The source of cooling energy from atmospheric air.

 The heat sink is attached to the TEC module using thermal compound.
 With the help of heatsink one side of the TEC module has been cooled in the
atmospheric air while moving the vehicles.

FIG 5.2 HEAT TRANSFER

THERMOELECTRIC EFFECT
 CHAPTER 6

THERMOELECTRIC EFFECT

6.1 INTROUCTION TO THERMOELECTRIC EFFECT

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.

A thermoelectric module is a circuit containing thermoelectric materials that

generate electricity from heat directly. A thermoelectric module consists of two
dissimilar thermoelectric materials joining in their ends: an n-type (negatively
charged); and a p-type (positively charged) semiconductors. A direct electric current
will flow in the circuit when there is a temperature differences between the two
materials. Generally, the magnitude has a proportional relationship with the
temperature differences.

In application, thermoelectric modules in power generation work in very tough

mechanical and thermal conditions. Because they operate in very high temperature
gradient, the modules are subject to large thermally induced stresses and strains for
long period of time. they also are subjected to mechanical fatigue caused by large
number of thermal cycles.

Thus, the junctions and materials must be selected so that the two
thermoelectric materials are thermally in parallel, but electrically in series. the
efficiency of thermoelectric module is greatly affected by its geometrical design.

Using thermoelectric modules, a thermoelectric system generates power by taking in

heat from a source such as hot exhaust flue. In order to do that, the system needs a
large temperature gradient, which is not easy in real world applications.
 The cold side must be cooled by air or water. Heat exchanger are used on both
sides of the modules to supply this heating and cooling.

There are many challenges in designing a reliable TEG system that operates at
high temperatures. Achieving high efficiency in the system requires extensive
engineering design in order to balance between the heat flow through the modules and
maximizing the temperature gradient across them.

To do this, designing heat exchangers technologies in the system is one of the

most important aspects of TEG engineering.in addition , the system requires to
minimize the thermal losses due to the interfaces between materials at several places.
Another challenging constraint is avoiding large pressure drops between the heating
and cooling sources.

FIG 6.1 THERMOELECTRIC EFFECT

6.2 ENERGY CONVERSION PROCESS

Thermoelectric effect is basically based on the energy conversion process i.e.,

may be the conversion of heat energy into electrical energy. In this project, we
covered the heat energy dissipated from the bike engine into an electrical energy by
using the thermoelectric module.

Initially, one side of the thermoelectric module is pasted in an aluminium metal.

Then the aluminium metal is mounted in the engine outer surface for effective heat
transfer purpose.

The heat dissipated from engine is absorbed by the aluminium metal, then the
heat from the aluminium metal is transferred to the one faces of the TEC module for
energy generation process, there should be a maintenance of temperature difference
between two faces of the thermoelectric module.

For producing the temperature difference between the two faces of the
thermoelectric modules, heat sink has been used. The main purpose of heat sink is to
cool the metal by placing it on the hot material. It consists of fins, with the help of
fins, the heat from the TEC module is expanded through the fins and also the air with
high velocity is also acting as a cooling medium for cooling the one side of the TEC
module.

When the vehicle is in motion, the air with velocity will cool the one side of the
Tec module. The heat from engine will transferred to another side. It will make an
effective temperature difference between the two faces of the thermoelectric module.
Thus, the temperature difference will tend to produce the electric current which has
been used to charge the mobile. But, due to the variation of magnitude heat energy
there should not be the constant current. For obtaining the constant output voltage, the
converter has been used.
6.2.1 SEEBECK EFFECT

Thomas Johann Seebeck [ 1770 – 1831]

FIG 6.2.1 (a) THOMAS SEEBECK

 The simplest thermoelectric generator consists of thermocouple of n type and p
type elements connected electrically in series and thermally in parallel.
 Heat is input from one side and rejected from other side.
 A voltage will be generated across Thermocouple.
 The magnitude of the voltage is proportional to the temperature gradient.

FIG 6.2.1 (b) SEEBECK EFFECT

POWER GENERATION

CHAPTER 7
 POWER GENERATION

7.1 INTRODUCTION TO POWER GENERATION PROCESS

Power generation from heat is called as the thermoelectric effect. Thermo

means heat and the electric stands for the current. Thus, the thermoelectric effect
means that the production of electric current from the heat dissipated from the engine.

Inside the thermoelectric module there is an array of consecutive p type and n

type semiconductors. While heating the one side of the Tec module by using the
engine heat cooling another side by atmospheric air with high velocity, the electrons in
the semiconductor device will get loosed and tends to move from its location to other.

It will tend to produce the electric current. This type of producing the electric
current by variation of temperature is called as the seebeck effect. This Tec module is
also called as the seebeck module or Peltier module, because it also obeys the law of
Peltier effect. Peltier effect is defined as the production of temperature difference
across the material by giving the input voltage.

7.2 VOLTAGE STEP UP PROCESS:

 The current generated from the thermoelectric module series connection may be
higher than the required amount (5volts) or sometimes lower than the required
amount. If the output current from TEC module is lower than required voltage, then
the obtained current should be stepped up to give constant 12 volts

This process of increasing the voltage is called as the voltage step up process.
The voltage step up process is very much is essential for obtaining the current of
12volts. Conveniently, for voltage step up and step down process, transformers have
been used. There are basically two types of transformers which are,

 Step up transformers

And

 Step down transformers

Step up transformers are used to increase the voltage according to our

requirement. Step down transformers are used to decrease the voltage according to our
requirement. But for reducing the cost estimation, we have to use a new component
called converter.

The main purpose of converter is to boost up the output voltage. If it is used in

our power generation, even when there is a minimum amount of output voltage from
the Tec module. There will be a power generation with efficient voltage. Thus, in
normal temperature difference conditions instead of using the transformer the
converter has been used.

7.3 VOLTAGE STEP DOWN PROCESS

 If the output voltage is higher than the required level(5volts), then we have to
decrease the voltage into required voltage. This process of decreasing the voltage up to
the required amount is called voltage step down process.

For producing the stepdown process, we have to use transformers. Instead of

using the step-up transformers for decreasing the output voltage, we can use LM7805
integrated circuit. This IC consist of three terminals. The main purpose of LM7805 is
to give the constant current of 5 volts output.

For charging the normal mobile phones, the voltage required is 5v to 10 volts .
if the output voltage produced from the TEC module is greater than this range, we
have to use this IC LM7805 will tends to reduce the output voltage and give the
constant output voltage of 5 volts.

LM7805 is used for step down purpose instead of using the transformers,
because the cost of transformer is very much greater than the integrated circuit LM
7805. This electronic circuit give the constant 5volts output for charging the mobile
phones.
COOLING PROCESS

CHAPTER 8
 COOLING

8.1 THERMOELECTRIC COOLING

Thermoelectric cooling uses the Peltier effect to create a heat flux between the

junction of two different types of materials. A Peltier cooler, heater, or
thermoelectric heat pump is a solid-state active heat pump which transfers heat
from one side of the device to the other, with consumption of electrical energy
depending on the direction of the current.

Such an instrument is also called a Peltier device, Peltier heat pump, solid

state refrigerator, or thermoelectric cooler (TEC). It can be used either for
heating or for cooling, although in practice the main application is cooling. It
can also be used as a temperature controller that either heats or cools.

This technology is far less commonly applied to refrigeration than

vapour-compression refrigeration. The primary advantages of a Peltier cooler
compared to a vapor-compression refrigerator are its lack of moving parts or
circulating liquid, very long life, invulnerability to leaks, small size, and flexible
shape. Its main disadvantages are high cost and poor power efficiency. Many
researchers and companies are trying to develop Peltier coolers that are cheap
and efficient.
A Peltier cooler can also be used as a thermoelectric generator. When
operated as a cooler, a voltage is applied across the device and thus, a difference
in temperature will build up between the two sides. When operated as a
generator, one side of the device is heated to a temperature greater than the
other side, and thus, a difference in voltage will build up between the two sides.
However, a well-designed Peltier cooler will be a mediocre thermoelectric
generator and vice versa, due to different design and packaging requirements.
8.2 PELTIER EFFECT

The thermoelectric effect is the direct conversion of temperature differences to

electric voltage and vice versa. A thermoelectric device creates voltage when
there is a different temperature on each side.
Conversely, when a voltage is applied to it, it creates a temperature
difference. At the atomic scale, an applied temperature gradient causes charge
carriers in the material to diffuse from the hot side to the cold side.
This effect can be used to generate electricity, measure temperature or
change the temperature of objects. Because the direction of heating and cooling
is determined by the polarity of the applied voltage, thermoelectric devices can
be used as temperature controllers.

FIG 8.2 PELTIER EFFECT

 DESIGN AND EXPERIMENTAL SETUP

CHAPTER 9

DESIGN AND EXPERIMENTAL SETUP

9.1 DESIGN OF AIR FLOW BOX

 AIR EXIT

TEC MODULE

AIR INLET

FIG 9.1 AIR FLOW BOX

 Air flow box is the major component to apply heat in one side of the TEC
module.
 The exhaust gas from the vehicle could pass through the air flow box.
 The heat of exhaust gas is absorbed by the aluminium air flow box.
 The heat from the aluminium box is transferred to one side of the thermoelectric
module.
 By using the anemometer, the air flow velocity and the temperature of the
exhaust gas is being measured.
 Air flow box is assembled in the exhaust pipe of the automobile.

9.2 DESIGN OF COOLING BOX

 Sheet metal

Thermacol

Wooden box

FIG 9.2 COOLING BOX

 Cooling box is designed with three layers.

They are,
 Wooden box (outer layer)
 Thermacol (middle layer)
 Sheet metal (inner layer)
 Cooling effect from the thermoelectric module is transferred to the sheet metal.
Thermacoal and wooden box arrangement is used to sustain the cooling effect
inside the cooling box.
 Cooling fin with fan is mounted in the back side of the thermoelectric module,
which removes the generated heat from the Thermoelectric module.

9.3 EXPERIMENTAL SETUP

FIG 9.3.a FIG 9.3.b

FIG 9.3.c
WORKING
 CHAPTER 10

 Initially, heat from the air flow box has been absorbed by the one side of the
thermoelectric module.
 Another side of the thermoelectric module is subjected to the atmospheric air.
Due to the heat variation on both side of the thermoelectric module, voltage is
developed (seebeck effect).
 The developed voltage is very low (3V to 5V). It is not efficient to create a
cooling effect.
 Thus, DC step up converter is used to step up the low voltage to high voltage of
range 20V to 30V.
 The developed voltage has been again fed into another thermoelectric cooler
module. Due to the applied voltage, temperature difference is created across the
thermoelectric module.
 The cooling effect is transferred to the cooling box. To sustain cooling effect
inside the cooling box, the wooden and thermacol arrangements are made.
 The heat may be transferred to the cold side of the thermoelectric module, thus
the cooling fin with fan is placed on the hot side of the thermoelectric module.
 The heat is expanded to the fins and the heat has been cooled with the help of
fan.
RESULTS AND OBSERVATIONS
 CHAPTER 11

RESULTS AND OBSERVATIONS

 The different parameters such as velocity of exhaust gas, temperature of exhaust

∆gas, temperature of heat applied, temperature difference on thermoelectric
module and generated voltage and the temperature on cooling box has been
measured with the help of anemometer, thermocouple and the multimeter.
 The following table has been plotted based on the observation of temperature
difference and voltage produced.

TABLE 11.1

HOT SIDE COLD SIDE TEMPERATURE VOLTAGE

TEMPERATURE TEMPERATURE DIFFERENCE PRODUCED
(℃) TH (℃) TC (∆T = TH – TC) ℃ V (Volts)

60 16 44 1.5

70 14 56 2.6

80 12 68 3.0

90 10 80 4.2

95 8 87 5.3
TABLE 11.2

VOLTAGE PRODUCED V (VOLTS) STEPPED UP VOLTAGE VS (VOLTS)

1.5 1.5

2.6 2.6

3.0 15

4.2 27

5.3 27
GRAPH 11.1: TEMPERATURE DIFF vs VOLTAGE PRODUCED

V
6

3
∆T
2

0
40 45 50 55 60 65 70 75 80 85 90

GRAPH 11.3: STEPPED UP VOLTAGE Vs TEMPERATURE

 TC
35

30

25

20

15

10

0
0 5 10 15 20 25 30

STEPPED UP VOLTAGE VS IN VOLTS

Thus, the cooling effect has been successfully created with the help of
thermoelectric module.
COST ESTIMATION

CHAPTER 12
 COST ESTIMATION

TABLE 12:

S.NO ELEMENTS COST (RS)

1 TEC1-12706 (6) 1000

2 THERMAL PASTE (4) 120

3 3V DC TO 12V DC STEP UP 250

CONVERTER

4 HEAT SINK WITH FAN 200

5 ALUMINIUM SHEET 700

6 THERMACOL 100

7 WOOD 200

TOTAL 2,570
CONCLUSION
 CHAPTER 13
CONCLUSION

Project has been completed successfully with the help of TEC Module, step up
converters and cooling fins. The important facts to create this thermoelectric
cooling are,
 Waste heat from engine is preserved and used as electrical energy for
cooling purpose
 There is no running cost
 Installation is simple, quiet and easy.
 It does not affect the engine efficiency and battery performance.
 The cost is economically low.
 It is an Eco-friendly process.
 It occupies small space.
REFERENCES
 CHAPTER 15

REFERENCES

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recovery.
5. Design method of thermoelectric generator based on performance for waste heat
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