Parametric Optimization of Thermoelectric Generators for Waste Heat Recovery

This paper presents a methodology for design optimization of thermoelectric-based waste heat recovery systems called thermoelectric generators (TEGs). The aim is to maximize the power output from thermoelectrics which are used as add-on modules to an existing gas-phase heat exchanger, without negative impacts, e.g., maintaining a minimum heat dissipation rate from the hot side. A numerical model is proposed for TEG coupled heat transfer and electrical power output. This finite-volume-based model simulates different types of heat exchangers, i.e., counter-flow and cross-flow, for TEGs. Multiple-filled skutterudites and bismuth-telluride-based thermoelectric modules (TEMs) are applied, respectively, in higher and lower temperature regions. The response surface methodology is implemented to determine the optimized TEG size along and across the flow direction and the height of thermoelectric couple legs, and to analyze their covariance and relative sensitivity. A genetic algorithm is employed to verify the globality of the optimum. The presented method will be generally useful for optimizing heat-exchanger-based TEG performance.