Thermoelectric Waste Heat Recovery from Industrial Exhaust Systems Using Nanostructured Hybrid Heat Exchangers

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Year : 2026 | Volume : 13 | 02 | Page :
By

Bibhu Prasad Ganthia,

Rosalin Pradhan,

  1. Assistant Professor, Department of Electrical Engineering, Indira Gandhi Institute of Technology, Sarang, Dhenkanal, Odisha, India
  2. Assistant Professor, Department of Electrical Engineering, Indira Gandhi Institute of Technology, Sarang, Dhenkanal, Odisha, India

Abstract

The efficient utilization of industrial waste heat has become a critical strategy for improving energy efficiency, reducing fossil fuel consumption, and minimizing greenhouse gas emissions in modern manufacturing sectors. This study proposes a thermoelectric waste heat recovery (TWHR) system integrated with a nanostructured hybrid heat exchanger to enhance heat transfer performance and maximize electrical power generation from high-temperature industrial exhaust streams. The proposed system employs nanostructured surface modifications combined with high- conductivity metallic fins to improve thermal contact, increase the effective heat transfer area, and reduce thermal resistance across the heat exchanger. A comprehensive numerical and experimental investigation is performed under exhaust gas temperatures ranging from 200 to 600 °C and varying mass flow conditions. The thermal behaviour is analysed using three-dimensional computational fluid dynamics (CFD), while thermoelectric performance is evaluated through coupled heat transfer and electrical generation models. Results demonstrate that the nanostructured hybrid heat exchanger enhances the overall heat transfer coefficient by 28.7% and increases thermoelectric power output by 31.5% compared with a conventional finned heat exchanger. The maximum electrical conversion efficiency reaches 9.8%, while the thermal recovery efficiency improves to 71.4% under optimal operating conditions. Furthermore, the proposed configuration reduces pressure drop by 14.2% through optimized flow channel geometry and maintains stable performance during prolonged thermal cycling, exhibiting less than 2.3% degradation after 1,000 operating cycles. Economic analysis indicates a potential reduction in industrial energy consumption of approximately 18% with a projected system payback period of 3.6 years. The findings demonstrate that integrating nanostructured hybrid heat exchangers with thermoelectric generators provides a promising, sustainable, and scalable solution for industrial waste heat recovery, offering significant improvements in thermal performance, energy conversion efficiency, operational reliability, and carbon emission reduction.

Keywords: Thermoelectric waste heat recovery; Nanostructured hybrid heat exchanger; Industrial exhaust systems; Heat transfer enhancement; Thermoelectric power generation; Energy efficiency.

How to cite this article: Bibhu Prasad Ganthia, Rosalin Pradhan. Thermoelectric Waste Heat Recovery from Industrial Exhaust Systems Using Nanostructured Hybrid Heat Exchangers. Journal of Thermal Engineering and Applications. 2026; 13(02):-.
How to cite this URL: Bibhu Prasad Ganthia, Rosalin Pradhan. Thermoelectric Waste Heat Recovery from Industrial Exhaust Systems Using Nanostructured Hybrid Heat Exchangers. Journal of Thermal Engineering and Applications. 2026; 13(02):-. Available from: https://journals.stmjournals.com/jotea/article=2026/view=253014

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Ahead of Print Subscription Review Article
Volume 13
02
Received 01/08/2026
Accepted 17/08/2026
Published 20/08/2026
Publication Time 19 Days

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