A Waste Heat Recovery (WHR) from Exhaust system captures heat from an engine/genset/furnace exhaust and converts it into useful hot water and/or electric power (with thermoelectric generators—TEGs). It demonstrates heat exchangers, energy balance, power electronics (MPPT), back-pressure management, and safety—ideal for diploma/degree projects.

Parts Used:

1. Exhaust Interface – SS304 tube-in-tube or finned wrap heat exchanger; flanges, clamps, high-temp gasket; bypass valve to limit back-pressure during cold start.
2. Hydronic Loop (Variant A) – Food-grade tank (20–60 L), circulation pump, non-return valve, air-vent, thermostatic mixing valve (48–50 °C), insulation.
3. TEG Stack (Variant B) – 8–24 TEG 40×40 mm modules, copper spreader plate, spring-loaded clamp frame, thermal paste, cold-side water block/radiator + fan.
4. Controls & Power – Arduino/ESP32, MPPT DC–DC (buck/boost) for TEGs, relays/SSR, main switch, fuses.
5. Instrumentation – K-type thermocouples (exhaust in/out, water in/out, TEG hot/cold), differential pressure sensor (exhaust ΔP), flow meter, volt/amp/watt meter, data logging display.
6. Safety & Hardware – Pressure relief on water side, drain/bleed, high-temp insulation (ceramic/mineral wool), CO detector (lab), earthing.