Experimental Assessment of a Passive Waste Heat Recovery System Using Thermosyphons and Thermoelectric Generators for Integration into District Heating Applications

The efficient recovery of waste heat is essential for improving sustainability in industrial and urban energy systems. This study presents the experimental evaluation of a passive heat recovery unit composed of finned thermosyphons and Bismuth Telluride (Bi2Te3) thermoelectric generators (TEGs). The primary objective was to characterize its simultaneous thermal recovery and electrical generation capabilities under airflow and temperature conditions simulating low-grade industrial exhaust streams. The system was tested in an open-loop wind tunnel simulating exhaust gases under air velocities of 0.6, 1.1, and 1.7 m/s. Heat was transferred to the TEGs through finned thermosyphons, enabling power generation via the Seebeck effect. The passive heat exchange mechanism successfully recovered up to 250.9 W of thermal power, preheating the inlet air by a maximum of 9.5 °C with a peak thermal effectiveness of 44.4%. Simultaneously, the system achieved a maximum temperature difference of 30.0 °C across the thermoelectric modules, generating a total electrical power of 163.7 mW (81.8 mW per TEG). This dual-purpose operation resulted in a maximum overall first-law efficiency of 9.38% and an electrical power density of 52.20 W/m2 from the low-grade thermal stream. These results confirm the technical feasibility of this compact, passive, and maintenance-free design, highlighting its potential for integration into applications like district heating or industrial ventilation, where balancing thermal and electrical outputs is crucial.