Title: Development Prospects of Waste Thermal Energy Harvesting from Gas Flaring System using Thermoelectric Generators
Authors: Baribuma Gbaarabe
Volume: 10
Issue: 8
Pages: 23-32
Publication Date: 2026/08/28
Abstract:
This study explores the development prospects of waste thermal energy harvesting from gas flaring systems using thermoelectric generators (TEGs). Thermal analysis indicates that radiative heat transfer is the primary mode of heat flux to the plate heat exchanger (PHE), consistent with elevated flare stack operating conditions. Although the radiative input of 970 kW is reduced to a net convective-conductive transfer rate of 489 kW due to cumulative thermal resistances, the system maintains a thermal effectiveness of 1.4%. Despite this relatively low effectiveness, the high flare thermal energy release of 106 MW translates into a recoverable waste heat potential of about 15 MW. The integrated thermoelectric harvesting (TEH) system is capable of generating 1.1MW of DC electrical power using 37,000 TEGs arranged in a series-parallel configuration, yielding 26MWh of usable energy per day, which can be stored in a 30MWh containerized energy storage system (CESS). Thermal simulations confirm effective heat propagation, with temperatures decreasing from 1200K at the flare tip to 600K across the PHE-TEG interface, ensuring uniform distribution and minimizing mismatch losses. Economic evaluation estimates a capital investment of $3.76 million with a simple payback period of 3 years, while environmental assessment projects an annual reduction of 5.44 million kg of CO? emissions. The findings demonstrate that TEH integration with flare systems is technically feasible, economically viable, and environmentally advantageous, offering a pathway for renewable power generation from flare waste heat while mitigating thermal pollution and carbon emissions.