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DoD - 2014.1 SBIR

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on-Demand Gas Water Heater


Heat Exchanger Optimization


A 13L DGWH was optimized to reduce cost. Metal content was reduced 30% with no penalties in performance or pressure drops. 

Optimization steps included: 

  1. Removal of copper to reduce cost 
  2. Symmetrical arrangement for adaptation to manufacturing tool 
  3. Removal of copper to reduce hot spots. This will allow the use of commercially-available lower temperature coatings
  4. Improved exposure of top tube to hot gas increased efficiency without penalty.

Fin optimization progression
Performance Simulation
Finished product