Innovative Semiconductor-Based System for Converting Waste Heat from Industrial Gases into Electrical Energy

This study presents the design and implementation of an innovative, cost-effective, and high efficiency semiconductor-based system for converting waste heat from industrial gases especially methane into usable electrical energy. The proposed system achieves a conversion efficiency of 48%, an output voltage of 300 V DC, and a power capacity of 1.5 kW per unit. It integrates modified thermoelectric generators (TEGs) based on bismuth telluride-antimony telluride (Bi₂Te₃-Sb₂Te₃), custom-engineered MOSFET transistors (TIP41C) enhanced with a silicon nitride insulating layer, high-efficiency dual-transformer boost converters, and high-sensitivity methane sensors with a detection range of 0–2000 ppm. The system was developed through five iterative phases from July 2023 to January 2025, evolving from a 5 V prototype to a full-scale industrial model. Field experiments conducted in cement and petrochemical plants in Egypt and Saudi Arabia demonstrated 94% operational stability under harsh temperature ranges (200–600°C). Simulations using MATLAB/Simulink and COMSOL Multiphysics validated heat transfer, voltage dynamics, and gas response behavior. Results indicated a significant improvement in voltage output and efficiency compared to conventional TEG and organic Rankine cycle (ORC) systems. The system also demonstrated a CO₂ emission reduction of 0.18 kg/kWh, translating to 1.8 tons annually per unit, and aligns with SDGs 7, 9, and 13, as well as ISO 14001 standards. With a scalable manufacturing cost of  5.2 per dollar over three years. Recommendations include scaling to other industries, integration with machine learning algorithms, and the use of enhanced thermoelectric materials such as PbTe to improve low-temperature efficiency.