Sizing – Chimney – Laboratory
Project description
The main aim of this study is to understand and improve the performance of flue pipes in combustion systems, with particular emphasis on reducing pressure drops and eliminating condensation risks. Flue pipes, if not properly designed, can create barriers in the flow, increasing the need for additional power to maintain the required flow, resulting in significant energy inefficiency. This is a crucial issue, as it affects not onlyoperational efficiency but also the overall sustainability of systems.
In addition, thebuild-up of condensation inside pipes can lead to corrosion problems, shortening the service life of the infrastructure. This calls forin-depth study of the thermal and dynamic behavior of fluids within pipes, in order to propose suitable design solutions that succeed in minimizing these undesirable effects. Ultimately, the project aims to promote the safety and sustainability of flue gas management systems.
Design and calculation of pressure drops in laboratory flue pipes
Year
2025
Customer
French national metrology and testing laboratory (LNE)
Location
France
Typology
Porcess Industriel
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Reducing pressure drop and condensation in combustion systems
Diagnosis of flue constraints for optimum performance
When temperatures fall below the dew point of the flue gases, condensation can occur, leading to a build-up of potentially corrosive liquid. This not only damages the pipes, but can also compromise the safety of the entire system. Industry and regulatory standards also impose strict safety and sustainable performance requirements to prevent these risks. Finally, practical constraints such aslimited space for pipe installation,access for maintenance and compliance with local regulations can significantly influence system design and installation.
Technical criteria for maximizing flue pipe efficiency
To ensure theefficiency and reliability of flue pipes, various technical and design criteria must be strictly adhered to. First of all, reducing pressure losses requires a design that favors the smoothest, most constant smoke flow possible, minimizing bend angles and avoiding obstacles in the flow path. This structural optimization limits the need for additional energy to move the fumes, thereby reducing energy costs.
In addition, adequate thermal insulation is essential to keep internal pipe temperatures above the calculated dew points for the various flue gas components. This helps prevent any form of condensation that could not only deteriorate the pipes, but also lead to leaks and unforeseen damage. The choice of materials is also crucial, requiring corrosion-resistant metals or coatings designed to withstand the acidic conditions potentially caused by fumes.
CFD modeling: a revolution in flue gas analysis
Improving flue gas performance with CFD technology
Computational Fluid Dynamics (CFD) modeling is proving to be an indispensable tool for this study, providing analytical solutions to the complex challenges posed by smoke management. CFD offers the possibility of accurately recreating the internal conditions of flue pipes, enabling detailed visualization of fluid flows. Thanks to this technology, it is possible to assess the impact of each design element on pressure losses, optimize configurations to limit these losses, and thus improve theoverall energy efficiency of the system. Simulations can also predict temperature variations along pipe walls, identifying critical areas where the risk of condensation is highest, and enabling interventions to be tested without the costs associated with manufacturing and installing a physical prototype.
By providing valuable data on the dynamic behavior of fluids, CFD makes it possible to explore different design scenarios before they are implemented, considerably reducing the time and costs associated with the development of new installations. In addition, the ability to model pipe performance under different operating conditions enables potential failures to be predicted and mitigated before they occur, contributing to system reliability and safety.
Pipe routing optimization strategies for enhanced energy efficiency
When designing the pipes, particular attention was paid to the choice of route to minimize pressure losses.Optimizing the route required careful analysis of possible configurations, taking into account spatial constraints and the inherent characteristics of installation sites. Bends were kept to a minimum, with a preference for gentle three-segment bends rather than sharp angles, to reduce turbulence which increases flow resistance. Pipe sections were designed to maintain diameter homogeneity, avoiding abrupt constrictions that could create bottlenecks. In addition, the coherent layout of the pipe segments has optimized the overall routing, reducing the overall length of the conduits and lowering the head losses associated with internal friction.
By integrating a CFD modeling approach into the design process, simulations were used toidentify the most efficient configurations, ensuring laminar and continuous flow while minimizing theenergy required to evacuate fumes. Thanks to these design strategies, the proposed system not only complies with regulatory requirements but also improves overall energy performance, ensuring greater plant sustainability and efficiency.
EOLIOS optimizes flue gas in piping systems
EOLIOS is renowned for its advanced technical expertise and its ability to carry out rigorous flue gas engineering projects. With a wealth of experience in CFD modeling, EOLIOS uses the latest technologies to analyze and optimize smoke flows, ensuring that flues are both efficient and comply with the most demanding standards. EOLIOS engineers and specialists have an in-depth understanding of fluid dynamics and thermal constraints, enabling them to propose innovative, customized solutions that incorporate industry best practices.
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Video summary of the study
Video summary of the study
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