The key is something called skutterudite

Thermoelectric Generators Purdue mechanical engineering doctoral student Yaguo Wang works with a high-speed laser at the Birck Nanotechnology Center to study thermoelectric generators. Purdue University/Mark Simons

Future cars may eat their own exhaust, converting heat from their emissions into electricity. The conversion can improve fuel economy by reducing an engine’s workload.

Purdue University researchers are working with General Motors to build thermoelectric generators, which produce an electric current when there is a temperature difference. Starting in January, the team will install an initial prototype behind a car’s catalytic converter, where it will harvest heat from exhaust gases that can reach 1,300 degrees F. The prototype involves small metal chips a few inches square.

The process requires special metals that can withstand a huge temperature differential — the side facing the hot gases stays warm, and the other side must stay cool. The difference must be maintained to generate a current, explains Xianfan Xu, a Purdue professor of mechanical engineering who is leading the research.

One of the group’s biggest challenges is finding a metal that conducts heat poorly, so heat is not transferred from one side of the chip to the other. GM researchers are currently testing something called skutterudite, a mineral made of cobalt, arsenide, nickel, or iron. Rare-earth metals can reduce skutterudite’s thermal conductivity even more, but we all know how problematic rare-earths can be; to solve the problem, researchers are hoping to replace them with “mischmetal” alloys.

Thermoelectric technology has applications beyond powering cars — they could also be used to harness waste heat in homes and power plants, and they could power new generations of solar cells, Xu said. The work is being funded with $1.4 million from the National Science Foundation and the Department of Energy.

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24 Comments

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Uhhhhh...there's a problem with the thinking process here "mischmetal" (dont know why it's in quotes) is an alloy containing rare earth metals. How does that replace rare earths.

@corwnb - You don't. There's plenty of REE's in the US (also Canada, Australia, Russia, RSA) - the problem is most mines closed down due to cheap Chinese exports.

The problem with REE's is not their abundance - it is the devastation the RRE mines bring to the environment. The strip mines in China are so large they are easily seen on satellite imagery.

Why is PopSci allowing all this spam in the comments? It really degrades your articles.

I have an even better idea! Start mass producing the electric cars that don't produce any exhaust in the first place... Ta-Da! Problem solved. Notice at the top of the article that Purdue University is working with General Motors on this tech, whom I'm sure have a vested interst with keeping their cars running mainly on petroleum. Money, money, money, mooooney... MOOOOOOOONEY!

REEs are also present in seafloor nodules, it seems. That may rejuvenate that industry.

great idea.

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thegunslingergirl007
The tech could still be used with converting more heat into electricity that is produced with the electric cars. Also many electric cars use rare earth metals so problem NOT solved.

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Thermo-electric devices can also be used as a heat pump; pushing a current through a thermo-electric circuit can force heat to flow from low to high like a heat pump (google thermo-electric cooler). However, existing thermo-electric devices have very low efficiency (less then 20%) more efficient devices would have a whole host of application.

thegunslinger007,

Pure electric vehicle technology is not mature enough for mass replacement of gas burners. The batteries are still too expensive and short ranged. Existing vehicle are good for short commutes, but do not have the range or power to haul the whole family to grandma's house [two states away] for the holidays, nor will they be replacing commercial vehicles any time soon.

The "Detroit automakers" are in bed with big oil" conspiracy theory was plausible before the Detroit auto makers got their butts kicked by foreign companies. The sad truth is they are too cash starved to develop the game changer tech needed for a fully EV transportation system.

@thegunslinger007 --

Electric cars are, at this point, merely an illusion of a solution. They move emissions back one step: to the power plant that generates the electricity to charge them. Even in areas where hydro-power is abundant (such as where I live), the production of electricity is pushed back to dams, which then required turbines to be spun longer. That lowers the head and leaves less water for the next day. Let's not even mention the damage that hydro-power has done to our fishing industry (which used to produce high-quality protein).

The energy used to move a car still has to come from somewhere and at this point that is generated by coal/oil/natural gas burning plants or dams.

I'm not saying electric cars are a bad start. But it is foolish to believe that they are a solution to anything at this point.

Now if only they can make pants that harvest electricity from our exhaust.

Too much junk comment over there!!! why is the popsci allowing them?

This is an OLD idea that never made it ...for good reason. It will use up resources and not provide much of a benefit - thermoelectric devices require a LOT of metal to convert properly so not only will we add weight to the car, the cost would go up quite a bit also. Also, restricting airflow in exhaust will diminish power and efficiency from the engine.

These damn spammers, they can't even do their adds correct, cutting off letters. And it makes me not even care to read this news!

The reason we wont go all the way electirc is because of the fuel industry. Think off all the jobs we as a whole would lose. THe economy in every countrie would go south. Thats why there r only a few all electrice car. Hybrids still use fuel so its good. plus theres noting like the roar of an engine and the horse power. Yes electrice is pure torque but still. ENGINES FOR EVER

The reason we wont go all the way electirc is because of the fuel industry. Think off all the jobs we as a whole would lose. THe economy in every countrie would go south. Thats why there r only a few all electrice car. Hybrids still use fuel so its good. plus theres noting like the roar of an engine and the horse power. Yes electrice is pure torque but still. ENGINES FOR EVER

The reason we wont go all the way electirc is because of the fuel industry. Think off all the jobs we as a whole would lose. THe economy in every countrie would go south. Thats why there r only a few all electrice car. Hybrids still use fuel so its good. plus theres noting like the roar of an engine and the horse power. Yes electrice is pure torque but still. ENGINES FOR EVER

The reason we wont go all the way electirc is because of the fuel industry. Think off all the jobs we as a whole would lose. THe economy in every countrie would go south. Thats why there r only a few all electrice car. Hybrids still use fuel so its good. plus theres noting like the roar of an engine and the horse power. Yes electrice is pure torque but still. ENGINES FOR EVER

Why are the terms Seebeck, Peltier, or thomson effect never mentioned? This is the same stuff that cools cupholders and stuff, just in reverse.

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