Portable Power Sources Using Combustion of Butane and Thermoelectrics

John Posthill*, Anil Reddy, Edward Siivola, Gordon Krueger, Mike Mantini, Peter Thomas, Rama Venkatasubramanian
Center for Thermoelectrics Research, RTI International
Research Triangle Park, NC 27709-2194
* jbp@rti.org

Francisco Ochoa and Paul Ronney

Dept. of Aerospace and Mechanical Engineering, Viterbi School of Engineering, University of Southern California
Los Angeles, CA 90089-1453

based TE has been employed in space applications at

Abstract
conditions approaching these temperatures for many years
RTI is currently developing cascade and segmented
and is known to be mechanically robust.
thermoelectric (TE) power modules to achieve a thermal-to-
Figure 1 shows these modules in a flat-plate configuration.
electric efficiency target of 20%. In this context, we have
achieved significant power levels with advanced bulk SiGe At an average ∆T of only 360K, each module produced over
TE modules developed individually. Power levels over 1We 1We. The cold side was near ambient. Electrical output will
per module -- with 11We demonstrated by using 10 modules - increase as the ∆T increases and as the average temperature is
- now make a new thermoelectrics-based man-portable power raised (the ZT of SiGe rises as temperature is increased to ~
supply potentially very attractive. These new modules are 875°C). Based on the performance of this circuit board and
able to operate at high temperatures (>700°C) and are thereby recent power results from SiGe couples (Table 1) we are
able to effectively utilize the temperature from direct confident that we can achieve a design power level.
combustion of any fuel such as butane, propane, natural gas,
diesel or other logistics fuels. Combining: (1) these high-
temperature SiGe TE modules with (2) a combustor with (3) a
lightweight heat exchanger could enable TE to address man-
portable off-grid requirements for fueled power sources.
Portable Power Requirements
There are various requirements for lightweight, refuelable
power sources for different applications [1]. Historically,
batteries have been used to provide power for
communications and other relatively low power requirements
when off the grid. In addition to peak and average power
demands, the first metrics by which a portable power
technology may be assessed is by specific energy (W-h/Kg),
specific power (W/Kg) and power density (W/l). While fuel Figure 1: Ten RTI SiGe TE power modules -- all producing
utilization efficiency plays a key role in determining specific over 1We each, 11We total. Each module footprint = 1.0cm ×
energy, it may not be as critical in defining dry specific power 1.2cm, each module weighs 0.5g.
or dry power density. Thermoelectrics, combined with
direct fuel combustion, represents one potential means of
achieving a rugged, refuelable portable power technology. July 2004 February 2005
The key elements of a fuel-to-electric TE converter are Single
straightforward: (1) TE modules, (2) a combustor that can 35.5 mW 158 mW
couple
deliver heat to the modules, and (3) heat rejection on the cold
Module
side of the TE modules. 1.3 W Est: 5 W
(32 couples)
High-Temperature SiGe TE Modules
Circuit board
RTI has been making flat-plate SiGe modules for several 11.0 W Est: 50 W
months under government contract. They can be attached to (10 Modules)
one or both flat sides of a heat source (combustor) and
operate at a hot side temperature of ~ 700°C. By operating Table 1: Recent SiGe TE device power conversion progress.
our SiGe modules between the temperatures of 700°C to Est. indicates an approximation of what is feasible given
200°C, we can achieve an efficiency of at least 6% with SiGe current single couple results.
materials. A more recent development at RTI has established
Planar Combustor Design
a high temperature braze in fabricating the modules so that
Small butane combustors designed to run at lower
they can withstand the 700°C hot side temperature. SiGe-
temperatures using catalytic Pt mesh and to deliver >100W at

0-7803-9552-2/05/$20.00 ©2005 IEEE 520 2005 International Conference on Thermoelectrics

q ≈ 14W/cm2 were made and operated. Figure 2 shows their
inner construction and visible operation with a special
window installed. The delivery of the specified power was
accomplished and while the air/fuel mixture was not
optimized for combustion efficiency, we did achieve >90%
frequently (Table 2).
To take this further, to a larger design with higher electric
power, a “pancake-style” combustor is suggested where both
sides of the combustor are populated with TE modules and
the accompanying heat rejection on each cold side. All the
key elements of this are shown conceptually in Figure 3.
Air/fuel and exhaust enter/exit from the side while the
majority of the area is available for TE module attachment
and heat delivery. In principle, such a design can be
engineered to operate effectively on any standard fuel.

2A

Figure 3: Conceptual schematic of converter showing: (1) TE

modules, (2) “pancake-style” combustor, and (3) heat
rejection fins.
Lightweight Heat Rejection
This converter design enables a straightforward heat
rejection system to be designed. One of the advantages of
using the high temperature SiGe modules is that the cold side
2B temperature can be ~ 200°C, thereby making a reasonable
heat transfer coefficient to ambient air possible. This also
means that we do not require very high fin area, thereby
Figure 2: (A) a USC butane combustor taken apart to reveal
ensuring that the weight and volume of the heat exchanger
the inner construction and (B) operating with transparent
stays manageable. For these TE modules operating at a ∆T =
window to demonstrate flame control. The materials and
500K, h = 30 - 60 W/m2-K range, which is obtainable with
dimensions were chosen to ensure a uniform delivery of
low to moderate forced air flows. Hence, commercial fans
100W over the 3.5cm × 2cm surface on which the TE
can provide adequate air flow at low power.
modules were subsequently placed.
An additional path to lowering the weight has been
investigated in the context of a smaller, radial heat exchanger.
Estimated Chemical Output Heat Efficiency of Heat The design employed PGS graphite fins, which have the dual
Heat Input Measured Delivered qualities of a very high in-plane thermal conductivity (600-
(W) (W) (%) 800 W/m-K) and low density (1 g/cc) [2]. Figure 4 shows
33 29 91 thermal modeling of a portion of this radial heat exchanger
49 46 94 with PGS graphite fins and an Al alloy base. For fabrication,
65 59 91 a complete frame was designed and made from Al alloy 6061-
118 75 63 T6 in order to hold the fins for use. Attachment between
these dissimilar materials can be accommodated with
130 105 81
appropriate metallization (terminating in Au on both surfaces)
and subsequent soldering or using a high temperature, high-
Table 2: Output heat and efficiency of USC butane thermal conductivity epoxy. In this case, both were used and
combustor. Obtaining efficiency was not a priority in this both proved suitable.
design, nor was the air/fuel mixture optimized for each data Figure 5 shows most of the component parts of this heat
point. exchanger and the final, assembled radial heat rejection
system. Figure 6 shows the performance data and comparison
with the thermal modeling results. While this was an
important step in the development of composite, lightweight
heat exchangers for TE-based portable power applications,
more weight reduction can be achieved if required.

5A

Figure 4: 1/8th thermal model of composite Al/PGS graphite

heat exchanger with estimated air flow from a commercial 5B
fan. At Q = 180/8 = 22.5W, a ∆T from ambient air = 47K
(avg.) was observed at the TE attachment side of the Al base.
Figure 5: (A) all eight sections of radial heat exchanger with
Potential System Considerations lightened commercial fan plus blowup of one section, and (B)
Calculations have been made for the specific energy and entire composite radial heat exchanger assembled as tested,
specific power of an entire system based on certain reasonable total weight = 43.4g.
estimates of system component weights, combustor efficiency
and TE heat-to-electric conversion efficiency.
70
In all cases we assume a combustor chemical-to-heat
efficiency of 70% and a TE efficiency of 6%. We also find 60 Fan =
2.2W
that each module will need to produce only ~ 0.8We; we have
50
already demonstrated over 1We already at lower ∆T. Some
Delta Temp (C)

Fan =
immediate conclusions can be derived from these 40 2.7W
conservative calculations: (1) the specific power will
30
decrease if a larger fuel tank is required for continuous Fan =
operation without refueling. However, for example, if a the 20 3.2W
portable power source can be refueled periodically, say every
3 - 12 hrs., the total dry (and wet) weight can be decreased 10
Modeling
and hence the specific power can be increased considerably, 0
and (2) if we place these systems on a Ragone plot (Figure 7), 0 25 50 75 100 125 150 175 200
we can see how an RTI TE/combustor system compares with
other potential portable power technologies. It appears Test Heater Pow er (W)
competitive with fuel cells, though internal and external
combustion engines still have the edge in terms of specific
power. Additionally, TE-based portable power systems have Figure 6: Performance of the composite radial heat
the potential for simplicity, reliability, minimal moving parts exchanger as referenced to 22°C air ambient and DC fan input
and a quiet alternative to engines. power.
Figure 7: Ragone plot [3] with RTI TE system calculated
numbers from above superimposed. There are many factors
that can affect these values – they are highly system
dependent.
Conclusions
In summary, we have shown the component parts of a TE
converter that can be used for portable power applications.
As higher efficiency TE modules become available
(cascaded/segmented), the use of TE for power conversion
will become even more attractive.
Acknowledgments
The authors are grateful for support of this work through the
Defense Advanced Research Projects Agency (DARPA), the
Army Research Office (ARO), and the Office of Naval
Research (ONR).
References
1. Kailish Shukla, Power Source Requirements, Conference
on Thermal Management for Microscale Power Systems,
21-23 May 2004, Chicago, IL.
2. http://industrial.panasonic.com/www-
data/pdf/AYA0000/AYA0000CE2.pdf
3. Meeting the Energy Needs of Future Warriors, National
Research Council (2005).