Exhaust-Stack Energy Harvester Design

@miskinarati

Hi there, I have experience in mechanical design, CAD development, CFD/thermal analysis, and design optimization for energy harvesting systems. I can develop a robust exhaust-stack energy harvester that maximizes recoverable energy while ensuring durability, manufacturability, and reliable operation in high-temperature exhaust environments. Approach: • Concept development and feasibility assessment • CAD design of the harvester and mounting assembly • Thermal, structural, and flow analysis (CFD/FEA) • Material selection for high-temperature service • Design optimization for performance and manufacturability Deliverables: • Complete 3D CAD model (STEP/SolidWorks) • Manufacturing drawings • CFD/FEA validation report • Design recommendations and documentation Two critical questions: What is the exhaust gas temperature, flow rate, and stack diameter available for the energy harvester? Which energy conversion technology do you intend to use (thermoelectric, piezoelectric, turbine-based, or are you looking for recommendations)? Timeline and budget can be finalized after reviewing the project requirements. Best regards, Arati M.

@sakshis576

With over a decade of experience in CAD/CAM, including solid works and Fusion 360, I offer the skills necessary for the conceptual engineering and mechanical layout of your project. Additionally, my proficiency in electronics brings forth the advantage of an In-depth understanding of thermoelectric modules which plays a vital role in drawing usable power from intense heat. Having worked with 3D designs and 3D printing models extensively, I can create detailed CAD drafts that will directly lead to your prototype fabrication phase. When it comes to simulation and prototyping tools, I am well-versed in FEA, CFD, Luminos, Abaqus and Keyshot10 - all of which can aid significantly in modelling and performance prediction phase. These tools combined with my knowledge of waste-heat recovery, TEGs, micro-turbines, and catalytic reforming will ensure comprehensive simulation results for pressure drop, temperature gradients and expected wattage under different scenarios.

@youhana167

Mechanical Engineer Expertise in HVAC system & MEP Hi there, I will do this project in advance design and professionally by meeting your guidelines according to ASHRAE & SMACNA, NFPA and IPC Standards & Codes. I have done European, USA and Middle East Projects. I’m professional MEP mechanical engineer with have more than 6 years’ experience and expert in, HVAC systems Design & Drawings, HVAC/BIM Modeling, BMS & Automation System, firefighting system, plumbing & drainage system, , tendering of projects HVAC Load Calculation, Ventilation requirements, Dehumidification, ESP for Duct, Duct Size Calculation, Hydraulic Calculations for Water and air cool chillers Pipes, Chilled & Condenser Water Pump Head calculation and selection, central air conditioning system, maintenance, commissioning of all types HVAC units like chillers, AHU, FCU, VRF, VRV, AHU, FAHU, RTU, diffuser, Cassette etc, in domestic, residential and commercial buildings with professional engineer team. Can you share more information into chat box? I have gone thorough in your project description. I have worked on several similar projects. Please visit my portfolio to see past work. I’m interested in your project. I’m a full-time freelancer. I would give you quality work because your satisfaction and work quality is my first priority. I’m waiting for your message to discuss. Thanks!

@sahildogra222

Hello " Lets Gets Started, You are looking for Exhaust-Stack Energy Harvester Design I know you have several tempting proposals here, but I guarantee you to be impressed by my work. I have various skills in Engineering Drawing, Product Design, Electrical Engineering, Mechanical Design, Mechanical Engineering, Electronics, CAD/CAM and Fusion 360. If you give me this chance you will be impressed, because I guarantee that I will meet your expectations. I invite you to get a look at my portfolio You Can see it from here : https://www.freelancer.com/u/sahildogra222 If you have any questions or queries, do not hesitate to contact me. I hope to start working with you. With regards! Sahil

@OnkarGraphics

With a decade of comprehensive experience in 3D modeling, animation, mechanical CAD design and a profound understanding of industrial equipment and processes, I am the right candidate to transform your vision for the Exhaust-Stack Energy Harvester Design into a functional and efficient reality. My skillset is perfectly aligned with each aspect of your project's scope of work. In particular, my proficiency in SolidWorks, Autocad and Fusion 360 will ensure that all the mechanical layout challenges are properly addressed; from fitting the "thin circle" form factor, to designing a versatile mounting fixture that adapts to various exhaust sizes. Through our collaboration, I look forward to providing you a complete design package that includes 3D files, schematics and calculation reports that would serve not just the prototyping phase but also potentially navigate the journey to full-scale production. Let's create something impactful together!

@Penmate

This is an ambitious multidisciplinary engineering project that combines waste-heat recovery, energy conversion, fluid dynamics, thermal management, and mechanical design into a compact device. I can help develop a robust engineering concept by evaluating the most practical combination of technologies—such as thermoelectric generators (TEGs), compact heat exchangers, micro-expanders where appropriate, and other compatible energy-recovery methods—to maximize electrical output while minimizing exhaust restriction. The design process would include system architecture, mechanical packaging within the required circular profile, thermal and flow analysis, performance predictions, CAD development, and a prototype-oriented design package with manufacturing drawings, BOM, and supporting engineering calculations. Throughout the project, I will provide regular design reviews and iterate based on simulation results to ensure the concept remains technically practical and manufacturable. One additional question: do you have any maximum thickness, weight, or target power output (watts) for the device beyond the stated efficiency requirement, as these constraints will significantly influence the overall design approach? Bryson.

@sahadahmedk

Hi, Have you considered how the heat-recovery and gas-reprocessing stages can efficiently share the same compact housing? I can help conceptualize a design that maximizes performance without choking exhaust flow. I have prior experience working with waste-heat recovery systems, including thermoelectric generators (TEGs) and micro-turbines. I will utilize CAD software like Fusion 360 for mechanical layout and conduct simulations using CFD and FEA tools to ensure optimal performance and minimal back-pressure increases. My goal is to achieve over 5% conversion efficiency under specified conditions while providing you with a complete design package, including 3D files and schematics, ready for prototype fabrication. Let me know if you’d like to discuss this further! Best Regards, Engr. Sahad Ahmed K

@Aaleen110

I understand you need a thin, circular, flat-profile device to mount on vehicle tailpipes and industrial smokestacks, designed to draw usable electrical power from flue gas heat and re-process remaining combustible gases for extra output. I've previously designed a compact thermoelectric generator that achieved 15% efficiency converting waste heat into electricity for industrial applications. My approach will involve conceptual engineering of the heat recovery system using SolidWorks for 3D modeling and COMSOL Multiphysics for thermal and electrical simulations. I'll model a series of thermoelectric modules integrated with a heat exchanger optimized for exhaust gas flow. For the gas re-processing, I'll explore catalytic converters and micro-turbines, simulating their performance in a CFD environment using ANSYS Fluent. The final output will be a detailed CAD model, simulation reports, and a Bill of Materials. What is the target temperature range of the exhaust gases and the desired power output in watts per unit? Ready to start as soon as you confirm scope.

@graphicart466

Hello, I am confident in delivering a comprehensive design package for your Exhaust-Stack Energy Harvester project. With extensive experience in CAD/CAM, Solidworks, and Fusion 360, I excel in mechanical layout and detailed manufacturing drawings, ensuring your project’s requirements are met efficiently. My background includes designing innovative heat-recovery systems, working with thermoelectric modules, micro-turbines, and catalytic reformers, which aligns perfectly with your project scope. I will employ CFD and FEA tools to validate the performance, pressure drops, and temperature gradients, providing reliable predictions to optimize the system. I am well-versed in creating scalable mounting solutions, from small vehicles to large industrial stacks, ensuring minimal back-pressure and high conversion efficiency. I am prepared to deliver CAD models, schematics, and BOMs swiftly to facilitate rapid prototyping. I look forward to discussing how my expertise in waste-heat recovery and simulation tools like CFD and FEA can best serve your innovative project. Please share any reference materials or further details to expedite progress. What specific heat recovery technologies or design constraints are most critical for your project's success? Thanks, Gourav

@charlesr220

Hi, Trkisbestever! Your project to develop a compact, dual-function device for power generation and gas re-processing on vehicle and industrial exhaust systems is precisely the kind of challenge I enjoy. I’ve worked extensively with waste heat recovery concepts, including thermoelectric generators (TEGs), catalytic reformers, and integration of micro-turbines, so I am comfortable engineering advanced solutions within tight form factors. I’m also experienced in adapting designs across a range of pipe sizes, always mindful of flow restriction and mechanical constraints. Here’s how I can support your project: - Review all current concepts, requirements, and application scenarios - Engineering analysis and design for integrated heat and gas conversion, tuned for minimal pressure drop - Selection or custom design of modules—TEG arrays, hybrid systems, appropriate catalysts - Detailed mechanical layout of the “thin circle” unit, with modular mounting solutions - Advanced simulation: CFD for flow and heat, FEA for stress, plus thermal/electrical modeling to predict real output and efficiency - Preparation of 3D CAD models, manufacturing drawings, and full BOM for rapid prototyping To get started, I’ll need any current sketches, CAD files, target installation details, operational data, and notes from relevant codes or jurisdictions. Also, any lab data, competitor benchmarks, or prior attempts will be helpful. I am prepared to talk about your project and can begin right away. Best regards, Charles

@shepardc

Hi, I'm a licensed professional engineer with 20+ years of experience in mechanical and electrical design, including waste-heat recovery and thermoelectric generator (TEG) projects for vehicles and industrial applications. I understand you need a compact device that mounts on various exhaust stacks to generate electricity by harvesting heat and processing combustible gases, all while keeping back-pressure low and providing ready-to-build design files. - Develop concepts for integrated heat and gas conversion in a thin, circular form factor. - Select or design suitable TEG, micro-turbine, or hybrid hardware based on your efficiency needs. - Create mechanical layouts and adaptable mounting solutions for both small and large exhaust pipes. - Run CFD/FEA simulations to predict pressure drop, temperature, and expected power output. - Deliver complete 3D CAD files, electrical schematics, and a bill of materials for prototyping. I've worked on similar energy-recovery units using TEGs and catalytic reformers, and use Fusion 360 for CAD and ANSYS/SimScale for simulations. Could you confirm if you already have preferred suppliers for thermoelectric modules or should I include sourcing options? If you select me, I will satisfy you. Best Regards, Shepard

@kaykya3

Hello there, Thank you so much for considering my services for this innovative project! With my background in multidisciplinary engineering and a strong focus on mechanical design, electrical engineering, and product design, I believe I am an ideal fit for your exhaust-stack energy harvester gig. My experience transcending multiple engineering domains including MEP (Mechanical, Electrical, Plumbing), architectural design, and structural design is a valuable asset in conceptualizing the heat-recovery and gas-reprocessing stages of your harvester. Over the years, I have consistently delivered meticulous, practical designs that have met and exceeded local codes and industry standards. I guarantee to produce permit-ready drawings, 3D models, and detailed engineering calculations that not only encompass your minimum 5% conversion efficiency but also ensure a back-pressure increase of less than 2% of baseline. In conclusion, choosing me for this project is opting for an experienced engineer committed to delivering top-notch design solutions rooted in maximized efficiency and optimal functionality. Let's collaborate towards creating an exhaust-stack energy harvester that not only proliferates electrical output but also bolsters overall system efficacy. I look forward to hearing from you soon so we can embark on this exciting venture together.

@rbtech1984

Hello There!!! ★★★★ ( Designing compact exhaust energy harvesting system for efficient waste-heat recovery ) ★★★★ Project understanding: I understand you need a compact circular exhaust-mounted device that can recover heat energy and also reprocess combustible gases to generate electricity. The design must maintain low back-pressure, achieve ~5% efficiency, and include full mechanical, thermal, and electrical system modelling with CAD and simulation. Services: ⚜ Concept design for waste-heat + gas energy recovery system ⚜ Selection of TEGs, micro-turbines, catalytic or hybrid modules ⚜ Compact circular mechanical housing & mounting clamp design ⚜ CFD/FEA simulation for flow, heat gradient & pressure drop ⚜ CAD modelling in Fusion 360 / SolidWorks with drawings ⚜ Performance estimation & efficiency validation reports ⚜ Prototype-ready BOM and engineering documentation I have worked on energy recovery and thermodynamic system concepts, including heat exchange and hybrid power systems. My approach would combine CFD analysis with thermal-electrical modelling to balance efficiency and exhaust flow without choking back pressure. Tools I plan include Fusion 360, ANSYS/CFD tools and MATLAB-style calculations for validation. Looking forward to discuss feasibility and move toward prototype stage. Warm Regards, Farhin B.