CFD computer simulations for New type Gas burner

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.

Industry:

Deeptech & Sciences

Equipment & Tools

Smart Manufacturing

TRL:

2 → 3

Project duration:

3 months

Challenge

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.

Our Role

  • Computational Fluid Dynamics
  • Thermal Stress Analysis
  • Design Optimization
  • Engineering R&D
  • Industrial Design
  • 3D CAD modeling
  • BOM development

Technologies Used

CFD simulations  analysis

CFD simulations / analysis

Thermal stress analysis

Thermal stress analysis

ANSYS/CFX

ANSYS/CFX

Engineering R&D

Engineering R&D

Standard metrology calibration

Standard metrology calibration

CAD design engineering

CAD design engineering

BOM development

BOM development

EnCata offers comprehensive hardware and IoT product development services at a fraction of the cost

For Enterprises

R&D + design + manufacturing under ONE roof
Scale up and down your team
Intergrated hardware + software development
New technologies and research 

CORPORATIONS click HERE for more info

For Startups

MVP and POC prototypes
Affordable consultancy rates
All IP is yours
In-house batch production

STARTUPS click HERE for more info

Approach & Solution

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.

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.

Drone Station case
Drone Station box
Autonomous Drone Station Box

Results

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.

300+

experiments were run on the computer cluster

9 PRM.

were considered in the multiparametric simulations model

84,9%

max efficiency was achieved in the best burner design

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