Design and Fabrication of Thermoelectric Waste-Heat Recovery System for Automotive IC-E...

Objective: To develop and demonstrate a thermoelectric generator-based system for recovering waste heat from internal combustion engine exhaust to generate supplemental electrical power.

India's transportation and industrial sectors rely heavily on internal combustion (IC) engines, which lose a significant portion of fuel energy as heat through exhaust gases, resulting in reduced efficiency and increased environmental impact. This affects vehicle operators, fleet managers, and industries seeking improved fuel economy and sustainability.

The proposed engineering solution involves designing and fabricating a thermoelectric generator (TEG) module integrated with the exhaust manifold of a standard IC-engine. The system will convert waste heat into electrical energy using thermoelectric materials and deliver supplemental power for onboard electrical loads or battery charging.

Key features include optimized heat exchanger design for maximum thermal transfer, selection of suitable thermoelectric materials, robust mechanical integration with the exhaust system, real-time monitoring of generated power, and validation through performance testing on a working engine setup. The project delivers a demonstrable working prototype and comprehensive technical documentation.

Industry and societal impact includes improved fuel efficiency, reduced carbon emissions, and scalable deployment in commercial vehicles, generators, and industrial engines. The solution has potential for widespread adoption in India's automotive and energy sectors, contributing to sustainability and cost savings.