A startup developed a novel ceramic gas burner capturing IR radiation for higher efficiency. EnCata validated the concept with industrial computer simulations and CFD modeling, proving 84.9% efficiency after 300+ experiments.
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A startup team comprised of talented material scientists and physicists created a new method of capturing residual heat energy from a conventional gas burner. Their scientific development suggested capturing IR radiation (typically underutilized in conventional designs) with some new ceramic materials they invented.
The customer’s initial understanding of the burner design was rather empirical before they reached out to EnCata. The innovative new burner design required, thorough numerical computer simulations and engineering R&D.
EnCata started the project from burner optimal design search and optimization. This required developing a detailed heat transfer simulations model and then plan and run iterative CFD analysis, optimizing multiple variables:
Simulation of radiant heat transfer with a high content of triatomic gases mixture and a small optical thickness of the medium required the use of a more complex heat transfer model - by radiation. The selected technology for a spiral heat exchanger production also introduced limitations on the design parameters.
Following computer simulations, EnCata delivered the detailed 3D CAD model and drawings for burner prototype manufacturing and validation tests.
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A parametric simulations model enabled EnCata to run a large set of computer experiments to help the Client better understand burner physics and provide engineers unequivocal guidelines for further burner and heat exchanger mechanical design. EnCata has delivered to the Client the optimized geometry design of the burner cavity, 3D CAD model, and a full standard CFD analysis report.
Need expert help with computer simulations or industrial product development? Get in touch with us, and we’ll provide you with a project estimate quickly.
experiments were run on the computer cluster
were considered in the multiparametric simulations model
max efficiency was achieved in the best burner design
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