Optimizing thermoelectric energy recovery from gasoline engine exhaust: A computational approach using ansys

Abstract

This study explores the feasibility of recovering waste heat from a gasoline-powered internal combustion engine using a thermoelectric generator (TEG) system integrated into the exhaust line. A Toyota Corolla with a 1.6-L engine was utilized as the test platform, incorporating 22 TEC1-12706 thermoelectric modules arranged in a V-shaped configuration between the exhaust pipe and a water-cooled aluminum heat sink. Experimental measurements were conducted under static (idle) conditions at engine speeds ranging from 1500 to 4000 rpm. Key performance parameters, including exhaust gas temperature and velocity, cooling water temperatures, and the surface temperatures of the modules, were recorded alongside electrical outputs. The system exhibited a nonlinear increase in power output with engine speed, peaking at 17.08 W at 4000 rpm, with a maximum voltage of 7.3 V and current of 2.34 A. A strong correlation was identified between the temperature gradient across the modules and power generation, underscoring the importance of thermal management. Complementary thermal simulations using ANSYS validated the experimental thermal behavior and further demonstrated that increasing the temperature differential enhances electrical output. These results confirm the potential of TEG technology to improve energy efficiency in conventional vehicles by converting waste heat into useable electrical energy, particularly during idle operation