The thermoelectric generator system is regarded as an advanced technology for
recovering waste heat from automotive exhaust. To address the issue of uneven
temperature distribution within the heat exchanger that limits the output
performance of the system, this study designs a novel thermoelectric generation
system integrated with turbulence enhancers. This configuration aims to enhance
convective heat transfer at the rear end of the heat exchanger and improve
overall temperature uniformity. A multiphysics coupled model is established to
evaluate the impact of the turbulence enhancers on the system's temperature
distribution and electrical output, comparing its performance with that of
traditional systems. The findings indicate that the integration of turbulence
enhancers significantly increases the heat transfer rate and temperature
uniformity at the rear end of the heat exchanger. However, it also leads to an
increase in exhaust back pressure, which negatively affects system performance.
At lower exhaust flow velocities, the gains in output power attributable to the
turbulence enhancers considerably outweigh the increases in exhaust back
pressure. Specifically, under conditions of 550 K and 20 m/s, the output power,
net output power, and temperature uniformity coefficient increase by 39.2%,
33.6%, and 8.5%, respectively. As exhaust temperature rises, the gains from the
turbulence enhancers become even more pronounced. Nevertheless, under high flow
conditions, the rise in exhaust back pressure can potentially degrade the
system's net output performance. Therefore, it is recommended that exhaust flow
be appropriately diverted in practical applications to ensure optimal
performance. This research provides essential theoretical guidance for the
design and performance optimization of automotive thermoelectric generation
systems.