Efficient waste heat management using hybrid thermoelectric systems with phase change material and porous foam for sustainable energy conversion

The process of managing waste heat from various thermal sources shows promising outcomes in the field of energy conversion. Thermoelectric generators integrated with phase change materials containing porous foams are valuable means for converting waste heat into electricity. Installing these systems on common heat sources and implementing an effective strategy for managing waste heat fills a major gap in current research in this area. The goal of this study is to utilize a novel prototype hybrid configuration to manage waste heat from an industrial chimney for the first time. ten thermoelectric modules equipped with phase change material and copper foam were installed on the chimney body, serving as an energy storage unit on the hot-side of the module and as a heat sink on the cold-side. Therefore, continuous and fluctuating heat loads were imposed to the chimney initiating from ambient temperature. The findings of this study indicate that the proposed system was effectively powered by the waste heat from the chimney body. The phase change material on the hot-side prevented overheating and stabilized the cold-side's temperature, acting as a heat sink without using electrical energy. This created a sufficient temperature difference, enabling the system to generate voltage for an extended period. The system produced maximum output voltages of 3900 mV and 6100 mV under constant loads of 75 W and 125 W, respectively. Under fluctuating loads of 150 W and 200 W, it maintained effective performance with maximum output voltages of 4700 mV and 5300 mV. The hybrid case described offers an innovative approach to managing waste heat in industrial settings, resulting in enhanced cost savings. • Industrial chimney body waste heat management process • Thermoelectric generators integrated with phase change materials and porous foams • Ensuring optimal temperature gradient across both sides of the thermoelectric module • Long-duration electricity production in thermal management process • Innovative approach for managing waste heat and enhancing cost efficiency