Harnessing solar power: Innovations in nanofluid-cooled segmented thermoelectric generators for exergy, economic, environmental, and thermo-mechanical excellence

Addressing the imperative need for advancements in thermoelectric generation, this study pioneers an analysis of nanofluid-cooled solar segmented thermoelectric generators with non-uniform cross-sections. Insights into thermal management, structural integrity, and economic efficiency in thermoelectric systems are provided, employing a numerical model that accurately represents thermoelectric effects by accounting for temperature dependencies of semiconductor materials. Through research, exploration of diverse coolant strategies, including TiO2, Fe3O4, Al2O3, and graphene, offers key insights into their impact on cooling dynamics. Findings demonstrate that graphene nanofluid, operating at a flow velocity of 2 m/s, outperforms others, achieving optimal power generation of 221.77 mW and an exergy efficiency of 8.99 %. Additionally, at a concentrated irradiance of 595 kWm−2, graphene leads in environmental benefits, with the highest CO2 savings of 0.38 kgyr−1, and demonstrates economic advantages with a cost-effective dollar per mW value of 3.79×10−6 $mW−1. Furthermore, the study verifies the structural integrity of these systems, with graphene achieving an optimal von Mises stress of 1.35 GPa at a semiconductor height of 0.2 mm. These advancements contribute to environmentally friendly and high-performance generators for sustainable energy solutions, paving the way for future innovations in thermoelectric technology. •Graphene nanofluid yields 221.77 mW power and 8.99 % exergy efficiency at 2 m/s.•At 595 kWm−2, graphene saves highest CO2 of 0.38 kgyr−1.•Optimal von Mises stress of 1.35 GPa at 0.2 mm leg height•Minimized cost of electric power is 3.79×10−6 $mW−1.•Non-uniform TEGs assessed for sustainable, efficient energy practices.