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Thermal and mechanical optimization of condensing heat exchangers


State-of-the-art condensing heat exchangers are characterized by high efficiency, high reliability and low costs. We simulate the relevant physical variables like pressure loss, temperature distributions, heat flux and thermal efficiency. The resulting mechanical stresses are optimized with respect to maximum lifetime.

The simulation considers:

  • thermal conduction, convection and radiation
  • fluid dynamics and pressure loss of flue gas and water
  • mechanical stresses caused by temperature gradients
  • stationary as well as transient events

As an example, the top figure shows the temperature distribution for the heat transfer studs flown by flue gas. The resulting temperature distribution of the heat transfer studs is shown in the center figure and the bottom figure shows the distribution of stress along the heat exchanger.

The results give reliable information concerning the optimizing potential of condensing heat exchangers. Design modifications are derived from the simulations and verified by tests.

We offer support in designing your products. We optimize the performance, enhance the reliability, minimize development time and reduce production costs.

Free Consultation

Our specialists are always at your disposal to flexibly respond to your respective requirements and wishes.

Michael Elbs, Managing Director

+49 8341 966 127-0Mon - Fri   9:00 -
Michael Elbs
Brennwertgeraet 1

Air flow around heat transfer studs

Brennwertgeraet 2

Temperature distribution of heat transfer studs

Brennwertgeraet 3

Distribution of stress along the heat exchanger (heat transfer studs not shown)