The performance of a thermoelectric power generation (TEPG) module and a device designed to convert engine exhaust heat directly into electricity was studied under different operating conditions using a proposed thermoelectric (TE) model in this work. The proposed model was obtained from the first law of thermodynamics, Ohm's law, nonlinear analytical solution of thermoelectric transport equation, and a control volume that represents a typical TEPG module or device such that the temperature dependent material properties of, the spatial-dependent heat flow rate through the TE element, and the interfacial electrical and thermal losses can be taken into account in the performance calculation. The performance of a typical TEPG module under a broad range of cold-side temperatures and the temperature differences between its hot-side and cold-side was calculated by the proposed model and the results agree very well with the existing model predictions. Comparison between the model predictions and the experimental results confirmed that reducing the interfacial electric resistance can enhance the module performance. The inter-dependence of the key thermal and TEPG system design and optimization parameters was examined for a real TEPG device using the proposed model and an optimal module fill factor of 0.35 was found within the given mass flow rates between 0.0154 and 0.052 kg/s of exhaust stream. (C) 2016 Elsevier Ltd. All rights reserved.