Exhaust waste heat recovery system using thermoelectric generator: a prospective of novel simulation technique toward low-carbon technology

Abstract This study numerically optimizes energy harnessing in vehicle engines using three heat exchanger fin designs: wall to wall, pyramid, and hexagonal. Two thermoelectric generator (TEG) array configurations are compared for electrical power generation. Results show the wall-to-wall fin provides the highest heat transfer, producing 161 W of power from 13 590.53 W of heat. Both TEG configurations generate similar output, with the series offering slightly higher voltage. The flow direction has minimal impact, but increasing the number of heat exchangers boosts efficiency. The total system output reaches 27 763.60 W with a four-parallel exchanger setup and an efficiency of 1.72.