Numerical Investigation on the Performance of an Automotive Thermoelectric Generator with Exhaust-Module-Coolant Direct Contact

Energy conservation and environmental protection have typically been a concern of research. Researchers have confirmed that in automotive engines, just 12–25% of the fuel energy converts into effective work and 30–40% gets wasted in the form of exhaust. Saidur et al. (Energy Policy 37:3650, 2009) and Hasanuzzaman et al. (Energy 36:233, 2011). It will be significant to enhance fuel availability and decrease environmental pollution if the waste heat in the exhaust could be recovered. Thermoelectric generators (TEGs), which can translate heat into electricity, have become a topic of interest for vehicle exhaust waste heat recovery. In conventional automotive TEGs, the thermoelectric modules (TEMs) are arranged between the exhaust tank and the coolant tank. The TEMs do not contact the hot exhaust and coolant, which leads to low heat transfer efficiency. Moreover, to provide enough packing force to keep good contact with the exhaust tank and the coolant tank, the framework required is so robust that the TEGs become too heavy. Therefore, in current study, an automotive TEG was designed which included one exhaust channel, one coolant channel and several TEMs. In the TEG, the TEMs which contacted the exhaust and coolant directly were inserted into the walls of each coolant channel. To evaluate the performance of the automotive TEG, the flow field and temperature field were computed by computational fluid dynamics (CFD). Based on the temperature distribution obtained by CFD and the performance parameters of the modules, the total power generation was obtained by some proved empirical formulas. Compared with conventional automotive TEGs, the power generation per unit volume exhaust was boosted.