In order to utilize waste heat from passenger vehicles by a thermoelectric generator (TEG), a lab-scale TEG with a sufficient low-pressure drop was designed and tested. The waste heat from a 2.0 L petrol engine was simulated by using an air-circulation channel with an adjustable electric heater and a speed control motor. The TEG consisted of an integrated molding designed aluminum-finned heat collector, twenty thermoelectric modules, and a set of water-cooled heat sinks. Experiments were conducted in terms of power load feature, pressure drop, heat collection efficiency, thermoelectric efficiency and overall efficiency. It was found that the hot-end temperature was much lower (46.9%) than the flue gas temperature because the trade-off between fin area and pressure drop had to be considered. The obtained maximum electric power was 36.4 W, and the corresponding pressure drop was 36 Pa. The corresponding heat collection efficiency was 46.5%, and the thermoelectric efficiency was 2.88%, which agreed well with the theoretical prediction of 3.38%. As a result, an overall efficiency of 1.21% was reached. The present work firstly demonstrated a waste-heat-recovering TEG prototype with a balanced overall efficiency of over 1%, and a pressure drop of less than 50 Pa. On the other hand, the maximum electric power was difficult to fully extract. The charging power to a battery with a maximum power point tracking direct current-direct current converter was experimentally verified to work at a much higher conversion efficiency (15.3% higher) than regular converters.
Keywords: heat collection efficiency; overall efficiency; pressure drop; thermoelectric generator; waste heat recovery.