Open Access
Prospects of waste-heat recovery from a real industry using thermoelectric generators: economic and power output analysis
(Elsevier, 2020) Araiz Vega, Miguel; Casi Satrústegui, Álvaro; Catalán Ros, Leyre; Martínez Echeverri, Álvaro; Astrain Ulibarrena, David; Ingeniaritza; Institute of Smart Cities - ISC; Ingeniería; Gobierno de Navarra / Nafarroako Gobernua, 0011-1365-2018-000101
One of the options to reduce industrial energy costs and the environmental impact is to recover the waste-heat produce in some processes. This paper proposes the use of thermoelectric generators at a stone wool manufacturing plant to transform waste-heat from a hot gas flow into useful electricity. A combination of two computational models, previously developed and validated, has been used to perform the optimization from a double point of view: power output and economic cost. The proposed thermoelectric generator includes fin dissipaters and biphasic thermosyphons as the hot and cold side heat exchangers respectively. The model takes into account the temperature drop along the duct where the gases flow, the electric consumption of the auxiliary equipment, and the configuration and geometry of the heat exchangers. After the simulations a maximum net power production of 45 838 W is achieved considering an occupancy ratio of 0.40 and a fin spacing of 10 mm. The installation cost is minimized to 10.6 €/W with an occupancy ratio of 0.24. Besides, the Levelised Cost of Electricity, LCOE, is estimated for a thermoelectric generator for the first time. It is necessary to use standar methodologies to compare this technology to others. The LCOE estimated for the proposed design is around 15 c€/kWh within the ranges of current energy sources, proving, in this way, the capabilities of waste-heat recovery from industrial processes at reasonable prices with thermoelectric generators.
Open Access
Experimental development of a novel thermoelectric generator without moving parts to harness shallow hot dry rock fields
(Elsevier, 2022) Alegría Cía, Patricia; Catalán Ros, Leyre; Araiz Vega, Miguel; Rodríguez García, Antonio; Astrain Ulibarrena, David; Ingeniaritza; Institute of Smart Cities - ISC; Ingeniería
Nowadays, geothermal energy in shallow hot dry rock fields is not exploited enough due to the high economic and environmental impact as well as the lack of scalability of the existing technologies. Here, thermoelectricity has a great future potential due to its robustness, absence of moving parts and modularity. However, the efficiency of a thermoelectric generator depends highly on the heat exchangers. In this work, a novel geothermal thermoelectric generator is experimentally developed, characterizing different configurations of biphasic heat exchangers to obtain low thermal resistances that allow the maximum efficiency in the thermoelectric modules. As a result, robust and passive heat exchangers were obtained with thermal resistances of 0.07 K/W and 0.4 K/W in the hot and cold sides, respectively. The geothermal thermoelectric generator was built with the most effective heat exchangers and was experimented under different temperature and convection conditions, generating 36 W (17 W by a prototype with 10 modules and 19 W by a prototype with 6 modules) for a temperature difference of 160 °C between the heat source and the environment. Furthermore, the experimental development showed that it is possible to increase electricity generation with a more compact generator, since a decrease in the number of modules from 10 to 6 increases the efficiency from 3.72% to 4.06%. With this research, the feasibility of a novel and robust geothermal thermoelectric generator whose working principle is phase change has been experimentally demonstrated, as well as the importance of compactness to maximize its efficiency and thus, power generation.
Open Access
New opportunities for electricity generation in shallow hot dry rock fields: a study of thermoelectric generators with different heat exchangers
(Elsevier, 2019) Catalán Ros, Leyre; Aranguren Garacochea, Patricia; Araiz Vega, Miguel; Pérez Artieda, Miren Gurutze; Astrain Ulibarrena, David; Institute of Smart Cities - ISC
Despite being one of the largest renewable sources, geothermal energy is not widely utilized for electricity generation. In order to leverage shallow hot dry rock (HDR) fields, the present paper proposes an alternative to enhanced geothermal systems (EGS): thermoelectric generators. Based on the conditions of Timanfaya National Park, a prototype has been built to experimentally analyze the feasibility of the proposed solution. The prototype is composed by a two phase closed thermosyphon (TPCT) as hot side heat exchanger, two thermoelectric modules, and it considers different cold side heat exchangers: fin dissipators assisted by a fan and loop thermosyphons, both with various geometries. Experiments have demonstrated that loop thermosyphons represent the best alternative due to their low thermal resistance and, especially, due to their lack of auxiliary consumption, leading to a maximum net power generation of 3.29 W per module with a temperature difference of 180 °C (200 °C in the hot side and 20 °C as ambient temperature), 54% more than with fin dissipators. Hence, there exists a new opportunity for electricity generation in shallow hot dry rock fields: thermoelectric generators with biphasic thermosyphons as heat exchangers, a patented and robust solution.
Open Access
Thermoelectric generator with passive biphasic thermosyphon heat exchanger for waste heat recovery: design and experimentation
(MDPI, 2021) Araiz Vega, Miguel; Casi Satrústegui, Álvaro; Catalán Ros, Leyre; Aranguren Garacochea, Patricia; Astrain Ulibarrena, David; Ingeniaritza Elektrikoa, Elektronikoaren eta Telekomunikazio Ingeniaritzaren; Institute of Smart Cities - ISC; Ingeniería Eléctrica, Electrónica y de Comunicación; Gobierno de Navarra / Nafarroako Gobernua
One of the measures to fight against the current energy situation and reduce the energy consumption at an industrial process is to recover waste heat and transform it into electric power. Thermoelectric generators can be used for that purpose but there is a lack of experimental studies that can bring this technology closer to reality. This work presents the design, optimizations and development of two devices that are experimented and compared under the same working conditions. The hot side heat exchanger of both generators has been designed using a computational fluid dynamics software and for the cold side of the generators two technologies have been analysed: a finned dissipater that uses a fan and free convection biphasic thermosyphon. The results obtained show a maximum net generation of 6.9 W in the thermoelectric generator with the finned dissipater; and 10.6 W of power output in the generator with the biphasic thermosyphon. These results remark the importance of a proper design of the heat exchangers, trying to get low thermal resistances at both sides of the thermoelectric modules, as well as, the necessity of considering the auxiliary consumption of the equipment employed.
Open Access
Computational study of geothermal thermoelectric generators with phase change heat exchangers
(Elsevier, 2020) Catalán Ros, Leyre; Araiz Vega, Miguel; Aranguren Garacochea, Patricia; Astrain Ulibarrena, David; Ingeniaritza; Institute of Smart Cities - ISC; Ingeniería
The use of thermoelectric generators with phase change heat exchangers has demonstrated to be an interesting and environmentally friendly alternative to enhanced geothermal systems (EGS) in shallow hot dry rock fields (HDR), since rock fracture is avoided. The present paper studies the possibilities of the former proposal in a real location: Timanfaya National Park (Canary Islands, Spain), one of the greatest shallow HDR fields in the world, with 5000 m2 of characterized geothermal anomalies presenting temperatures up to 500 °C at only 2 m deep. For this purpose, a computational model based on the thermal-electrical analogy has been developed and validated thanks to a real prototype, leading to a relative error of less than 8%. Based on this model, two prototypes have been designed and studied for two different areas within the park, varying the size of the heat exchangers and the number of thermoelectric modules installed. As a result, the potential of the solution is demonstrated, leading to an annual electricity generation of 681.53 MWh thanks to the scalability of thermoelectric generators. This generation is obtained without moving parts nor auxiliary consumption, thus increasing the robustness of the device and removing maintenance requirements.
Open Access
Thermoelectric heat recovery in a real industry: from laboratory optimization to reality
(Elsevier, 2021) Casi Satrústegui, Álvaro; Araiz Vega, Miguel; Catalán Ros, Leyre; Astrain Ulibarrena, David; Ingeniaritza; Institute of Smart Cities - ISC; Ingeniería; Gobierno de Navarra / Nafarroako Gobernua, 0011-1365-2018-000101
Thermoelectricity, in the form of thermoelectric generators, holds a great potential in waste heat recovery, this potential has been studied and proved in several laboratory and theoretical works. By the means of a thermoelectric generator, part of the energy that normally is wasted in a manufacturing process, can be transformed into electricity, however, implementing this technology in real industries still remains a challenge and on-site tests need to be performed in order to prove the real capabilities of this technology. In this work, a computational model to simulate the behaviour of a thermoelectric generator that harvest waste heat from hot fumes is developed. Using the computational model an optimal configuration for a thermoelectric generator is obtained, also an experimental study of the performance of different heat pipes working as cold side heat exchangers is carried out in order to optimize the performance of the whole thermoelectric generator, thermal resistances of under 0,25 K/W are obtained. The optimized configuration of the thermoelectric generator has been built, installed and tested under real conditions at a rockwool manufacturing plant and experimental data has been obtained during the 30 days field test period. Results show that 4.6 W of average electrical power are produced during the testing period with an efficiency of 2.38%. Moreover, the computational model is validated using this experimental data. Furthermore, the full harvesting potential of an optimized designed that takes advantage of the whole pipe is calculated using the validated computational model, resulting in 30.8 MWh of energy harvested during a sample year which could meet the demand of 8.34 Spanish average households.
Open Access
400 W facility of geothermal thermoelectric generators from hot dry rocks on the Canary Islands
(Elsevier, 2025-06-01) Alegría Cía, Patricia; Pascual Lezaun, Nerea; Catalán Ros, Leyre; Araiz Vega, Miguel; Astrain Ulibarrena, David; Institute of Smart Cities - ISC; Universidad Pública de Navarra / Nafarroako Unibertsitate Publikoa
Geothermal energy has a great potential to be harnessed and requires a boost in technologies to enhance its use. The Canary Islands have a great dependence on fossil fuels, and Lanzarote has important geothermal anomalies currently unexploited due to the absence of water in the soil, what hinders the use of vapour turbines. This work presents the development of the first facility of geothermal thermoelectric generators operating in the world. This novel generators are producing 400 W of power in Timanfaya National Park. It has three geothermal thermoelectric generators, each with 4 thermosyphons per borehole and 40 thermoelectric modules that directly transform heat into electricity. This facility, with the advantages of geothermal energy such as continuity and independence on the weather, requires low maintenance because it does not require moving parts nor water consumption. That makes feasible for the first time to harness the geothermal potential in Lanzarote, producing an electric energy of 9.4 kWh per day, which means 3.42 MWh per year. The field installation of this novel technology has enabled to accurately calculate the Levelized Cost of Energy, which is 0.22 €/kWh. Although a 29% decrease in the power generated by thermoelectric module was detected when installing a GTEG with 40 modules with respect to a GTEG with 10 modules, this decrease is compensated by the fact that by installing more modules, the electrical production per borehole is optimized, reducing the LCOE. The developed facility will avoid the emission of 2.3 tons of CO2 and is totally respectful with the environment if compared to conventional geothermal power plants.
Open Access
Experimental development of a novel thermoelectric generator without moving parts to harness shallow hot dry rock fields
(2021) Alegría Cía, Patricia; Rodríguez García, Antonio; Catalán Ros, Leyre; Astrain Ulibarrena, David; Araiz Vega, Miguel; Ingeniería; Institute of Smart Cities - ISC; Ingeniaritza
Nowadays, geothermal energy in shallow hot dry rocks is not exploited enough due to the high economic and environmental impact as well as the lack of scalability of the existing technologies. Here, thermoelectricity has a great future potential due to its robustness, absence of moving parts and modularity. With this research, the feasibility of a novel and robust geothermal thermoelectric generator whose working principle is phase change has been experimentally demonstrated, as well as the importance of compactness to maximize its efficiency and thus, power generation.
Open Access
Corrosion behavior in volcanic soils: in search of candidate materials for thermoelectric devices
(MDPI, 2021-12-21) Berlanga Labari, Carlos; Catalán Ros, Leyre; Palacio, José F.; Pérez Artieda, Miren Gurutze; Astrain Ulibarrena, David; Ingeniaritza; Institute of Smart Cities - ISC; Ingeniería; Institute for Advanced Materials and Mathematics - INAMAT2
Thermoelectric generators have emerged as an excellent solution for the energy supply of volcanic monitoring stations due to their compactness and continuous power generation. Nevertheless, in order to become a completely viable solution, it is necessary to ensure that their materials are able to resist in the acidic environment characteristic of volcanoes. Hence, the main objective of this work is to study the resistance to corrosion of six different metallic materials that are candidates for use in the heat exchangers. For this purpose, the metal probes have been buried for one year in the soil of the Teide volcano (Spain) and their corrosion behavior has been evaluated by using different techniques (OM, SEM, and XRD). The results have shown excessive corrosion damage to the copper, brass, and galvanized steel tubes. After evaluating the corrosion behavior and thermoelectric performance, AISI 304 and AISI 316 stainless steels are proposed for use as heat exchangers in thermoelectric devices in volcanic environments.
Open Access
Design and optimization of thermoelectric generators for harnessing geothermal anomalies: a computational model and validation with experimental field results
(Elsevier, 2024) Alegría Cía, Patricia; Catalán Ros, Leyre; Araiz Vega, Miguel; Erro Iturralde, Irantzu; Astrain Ulibarrena, David; Institute of Smart Cities - ISC; Universidad Pública de Navarra / Nafarroako Unibertsitate Publikoa
Thermoelectric generators have been recently proved to be a feasible alternative to harness hot dry rock fields with very promising results transforming the geothermal heat into electricity. This research deepens in the study of these generators, developing a versatile computational model that serves as a tool to design and optimize this type of thermoelectric generators. This tool is important to develop this thermoelectric technology on a large scale, to produce clean and renewable electrical energy especially in the Timanfaya National Park, in Lanzarote (Spain), where some of the most important shallow geothermal anomalies in the world are located, in order to promote self-consumption in this zone. However, it could be employed in other areas with different boundary conditions. The model, based in the finite difference method applied to the thermal-electrical analogy of a geothermal thermoelectric generator, has been validated with the experimental field results of two thermoelectric generators installed in two different zones of geothermal anomalies. It has achieved a relative error of less than 10% when predicting the power and between 0.5–1.6% in the annual energy generation, what makes it a very reliable and useful computational tool. The developed model has been employed for the first time to estimate the electrical energy that could be generated if harnessing the characterized area of anomalies in Lanzarote. Here, given the continuity of geothermal energy, 7.24 GWh per year could be generated, which means annually 1.03 MWh/m2.