Design and Performance Optimization of Automotive Thermoelectric Generator System Integrated with Heat Pipes

In the field of static power generation, thermoelectric technology has become an important solution for utilizing automotive exhaust waste heat. This study presents a new design for a heat exchanger integrated with heat pipes, aimed at augmenting the installation area of thermoelectric modules and improving the hot end temperature by high heat transfer rate. Moreover, the number of heat pipes in each region is optimized to reduce the temperature gradient along the direction of exhaust flow and maximize overall output performance. A comprehensive numerical model of the thermoelectric generator system is developed to conduct the performance prediction and parameter optimization. The results reveal that the integration of heat pipes substantially boosts the performance of the automotive thermoelectric generator system, characterized by enhanced heat transfer, increased power output, and improved conversion efficiency. And the optimization yields an optimal configuration with 5 heat pipes per thermoelectric module. Under the test conditions of an exhaust temperature of 600 K and a mass flow rate of 30 g/s, the new automotive thermoelectric generator system demonstrated an output power of 146.28 W and an output voltage of 166.26 V. These outputs represent a remarkable increase of 53.76% and 75.16%, respectively, compared to the conventional one without heat pipes. This work not only underscores the potential of heat pipe integration in thermoelectric systems but also offers a foundational framework for the optimal design of automotive thermoelectric generator systems equipped with heat pipes.