This paper investigates the design of a thermoelectric generator for exhaust gases from internal combustion engines. Experimentally validated CFD methodology was employed. Different issues are studied, such as the influence of the replacement of the exhaust pipe for the TEG, the recirculation produced, and the influence of fins. The results show that an enlarged inlet cone reduces the recirculation and the pressure drop of the TEG, but more heat is lost across the cone walls, reducing the heat available for the thermoelectric modules. Internal straight fins aligned with the flow achieved a 3% increase in heat transfer, did not significantly increase the pressure drop in this type of device, and reduced the effects on pressure of the recirculation, lowering the overall pressure drop by 10%. An energy production of 175.9 W with 16.2 W of pressure drop power losses resulted in a net energy production of 160.7 W. A comparison with a flat-type thermoelectric generator under the same hot source conditions is also provided.
