Design optimization and thermal management of a thermoelectric upper hose radiator system

• A novel annular thermoelectric upper hose radiator is introduced. • The effect of various fluid, thermal, and geometry design parameters is considered. • The conductive and radiative heat losses around the ATE legs are considered. • ATEGs exhibit conversion efficiencies and exergy of 2.6% and 3.72%, respectively. • Net TE power of 10.9 W can be generated at a temperature difference of 60 °C. This study examines the potential of installing annular thermoelectric generators (ATEGs) on the upper radiator hose for the first time. The ATE modules are designed to be attached to the hot-fluid upper hose pipe through which ethylene glycol flows, while a water-cooling channel surrounds the modules to create thermal gradients. A multi-physics numerical model was employed to simulate the conversion of waste heat into thermoelectric (TE) power. The dimensions of ATE modules, the total number of modules, the upper hose geometry, and the temperatures and flow rates of ethylene glycol and water were optimized. The results reveal that a maximum power output of 10.9 W can be generated from 720 TE modules when a temperature difference of approximately 60 °C exists between the hot and cold fluids at higher IC engine load conditions. Meanwhile, a power of ∼ 1 W is required to pump 10 L/min of cooling water at a head elevation of 50 cm. Harvesting thermal energy from combustion engines using a TE upper hose radiator enables energy recovery and improves the design of the IC engine cooling system.