Performance Evaluation of Thermoelectric Generator Based Waste Heat Recovery system in Industrial Water Tube Boilers

– Industrial water tube boilers release a substantial amount of waste heat through flue gases and external surfaces, leading to significant energy losses and reduced system efficiency. This study presents the performance evaluation of a thermoelectric generator (TEG)-based waste heat recovery system designed to convert low- and medium-grade thermal energy into useful electrical power. The system utilizes the Seebeck effect, where a temperature difference across TEG modules generates a direct current output. TEG modules are installed on high-temperature regions of the boiler, while an aluminum heat sink with forced air cooling maintains the required temperature gradient. Experimental analysis is carried out by measuring temperature difference, voltage, current, and power output under varying thermal conditions. A DC boost converter is used to enhance the low output voltage, and the generated power is stored in a battery and utilized for auxiliary loads. The results indicate that the system effectively recovers waste heat and produces a stable electrical output, improving overall energy utilization. The proposed system offers a compact, reliable, and eco-friendly solution for industrial waste heat recovery, contributing to reduced fuel consumption, lower emissions, and enhanced sustainability in boiler operations.