Progress Towards an Optimization Methodology for Combustion-Driven Portable Thermoelectric Power Generation Systems

There is enormous military and commercial interest in developing quiet, lightweight, and compact thermoelectric (TE) power generation systems. This paper investigates design integration and analysis of an advanced TE power generation system implementing JP-8 fueled combustion and thermal recuperation. In the design and development of this portable TE power system using a JP-8 combustor as a high-temperature heat source, optimal process flows depend on efficient heat generation, transfer, and recovery within the system. The combustor performance and TE subsystem performance were coupled directly through combustor exhaust temperatures, fuel and air mass flow rates, heat exchanger performance, subsequent hot-side temperatures, and cold-side cooling techniques and temperatures. Systematic investigation and design optimization of this TE power system relied on accurate thermodynamic modeling of complex, high-temperature combustion processes concomitantly with detailed TE converter thermal/mechanical modeling. To this end, this paper reports integration of system-level process flow simulations using CHEMCAD (TM) commercial software with in-house TE converter and module optimization, and heat exchanger analyses using COMSOL (TM) software. High-performance, high-temperature TE materials and segmented TE element designs are incorporated in coupled design analyses to achieve predicted TE subsystem-level conversion efficiencies exceeding 10%. These TE advances are integrated with a high-performance microtechnology combustion reactor based on recent advances at Pacific Northwest National Laboratory (PNNL). Predictions from this coupled simulation approach lead directly to system efficiency-power maps defining potentially available optimal system operating conditions and regimes. Further, it is shown that, for a given fuel flow rate, there exists a combination of recuperative effectiveness and hot-side heat exchanger effectiveness that provides a higher specific power output from the TE modules. This coupled simulation approach enables pathways for integrated use of high-performance combustor components, high-performance TE devices, and microtechnologies to produce a compact, lightweight, combustion-driven TE power system prototype that operates on common fuels.