To enhance the efficiency of waste heat recovery, a coupled power generation system integrating thermoelectric generator (TEG) with diesel particulate filter (DPF) is proposed and optimized for engine exhaust applications. The system harnesses both the exhaust heat and the substantial thermal energy generated by DPF regeneration for thermoelectric conversion. Effects of key parameters, such as exhaust gas velocity Ve, heat sink setting, porosity Pe of multi-layer porous media, and two-stage TEG design, on system thermal and working performance are tested and analyzed. The results demonstrate that the augment of Ve enhances the electrical power output of the TEG-DPF system, while the advantages diminish at high Ve and are accompanied by a reduction in thermoelectric conversion efficiency. Enhancing heat dissipation can be achieved by increasing fin height while reducing fin spacing and thickness to effectively mitigate the negative impact of high Ve, enabling the system to maintain efficient operating condition. Additionally, the arrangement of multi-layer porous media in the DPF significantly influences gas-solid heat transfer, and the DPF with a porosity gradient Pe = 0.3 + 0.4+0.5 is more conducive to improving the energy conversion and efficiency of the integrated system. Furthermore, the implementation of the two-stage thermoelectric modules further boosts electrical output, where the generator with PbTe-Bi2Te3 modules significantly broadens the operational temperature range and achieves the maximum output power of 15 W at Ve = 20 m/s. These findings provide a theoretical foundation and technical reference for the efficient integrated design of thermoelectric and waste heat recovery systems.
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