Heat transfer computer simulations and design of a new type of ceramic gas burner employing IR-irradiation effect. The novel industrial gas burner design demonstrated superior efficiency in comparison with conventional heating modules.
Industrial Deeptech & Sciences
Custom Equipment & Tools
2 → 3
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.
Computational Fluid Dynamics
Thermal Stress Analysis
3D CAD modeling
CFD simulations / analysis
Thermal stress analysis
Standard metrology calibration
CAD design engineering
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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:
heat exchanger dimension and tube curvature vs ceramic burners size
tube diameters of the heat exchanger
overall setup-up efficiency
bottom-up vs top-down gas flows
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.
We came up with an idea to design an additional component element - a partition to separate the radiative and convective zones of the burner. Thus we managed to reduce the radiation flux into the chimney and increase gases path in the heat exchanger tubes which lead to a 1.5% increase in efficiency of a new gas burner.
Following computer simulations, EnCata delivered the detailed 3D CAD model and drawings for burner prototype manufacturing and validation tests.
When simulating gas burners, one must take into account the aerodynamics of in-take and up-take gases. These gases have their own heat capacity and they dynamically impact heat transfer, which, in turn, depend on burner physical dimensions.
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.
experiments were run on the computer cluster
were considered in the multiparametric simulations model
max efficiency was achieved in the best burner design