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Finned tube
Combustion chamber
Water flow passes
© 2008 ANSYS, Inc. All rights reserved. 3 ANSYS, Inc. Proprietary
CFD Modeling
Water inlet
Water outlet
Porous material:
Flue outlet -Solid-Fluid porosity
(heat transfer)
Combustion Chamber Water domain -Radial pressure drop
through finned tubes
© 2008 ANSYS, Inc. All rights reserved. 4 ANSYS, Inc. Proprietary
Finned Tube Simplification
Water inlet
Hot air inlet Detail fin: Simplified fin: Porous
Solid copper flue & copper
Sub-model
Finned tube
Air outlet Water outlet
Mesh
size Detail Simplified
Cells: 579,955 147,455
Faces: 1,345,868 319,893
Nodes: 208,231 42,209
© 2008 ANSYS, Inc. All rights reserved. 5 ANSYS, Inc. Proprietary
Finned Tube Simplification
Temperature Pressure Velocity
(oF) (Pa) (m/s)
Detailed Simplified
Outlet-water (ºF) 77.1 75.9
Outlet- flue (ºF) 1363 1785
Pressure drop (Pa) 0.054 0.053
© 2008 ANSYS, Inc. All rights reserved. 7 ANSYS, Inc. Proprietary
Simulation Methodology
Steady state, combustion on flue gas path and radiation effects
considered, phase change on the water side (boiling) not modeled,
fin space simplified as a porous material, no wall roughness effect
considered
Test A Test B
Temperature (oF) in a vertical plane Heat flux (W/m2) in inner finned tubes
Test A Test B
(water heater) (boiler)
Lab CFD Lab CFD
Water temp. increase (oF)
69 69.2 100 99
Mass flow rate of water
0.7630 0.7625 0.5234 0.5230
(kg/s)
Fuel consumption 0.13125 0.1367 0.13124 0.1367
(ft3/s) @ STD Natural gas CH4 Natural gas CH4
Thermal Efficiency (%) 84.31 83.78 83.88 82.48
Note: When operating as a water heater (Test A), the outlet water temperature will
be 140oF, while operating like a boiler (Test B) the outlet temperature will be 180
oF. There is no actual boiling (phase change) occurring within the water path of
the boiler.
© 2008 ANSYS, Inc. All rights reserved. 13 ANSYS, Inc. Proprietary
Proposed High- efficiency Boiler
Condensing in
finned tubes
Flue outlet
Condensing in
bottom surfaces
Condensing region in
the bottom chamber
with low temperature
(< dew point)
CFD Lab