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.


Deeptech & Sciences

Equipment & Tools

Smart Manufacturing



2 → 3

Project duration:

3 months


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



Engineering R&D

Engineering R&D

Standard metrology calibration

Standard metrology calibration

CAD design engineering

CAD design engineering

BOM development

BOM development

Thermal stress analysis

Thermal stress analysis

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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.

Results and Benefits

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

9 PRM.

were considered in the multiparametric simulations model


max efficiency was achieved in the best burner design

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