FINAL REPORT ON

CFD ANALYSIS ON HYBRID HEATING ELEMENT

INSIDE ELECTRIC WATER HEATER

DE ZG628T: Dissertation

by

RUCHIKA SAWANT
2017HT30053

Dissertation work carried out at

PENTA AUTOFEEDING INDIA LTD,
MUMBAI, MAHARASHTRA
Introduction: Electric water heater
 Electric water heater is the appliances which is used for heating water.
 Electric water heater use electricity to heat water and they resemble a
small or middle size a reservoir which works on the principle of conversion
of Electrical energy into heat through the use of heating element to raise
the temperature of water to a certain degree.
 Two types of electric water heaters are available in market:
1. Storage type water heater
2. Tankless water heater
Basic component of storage water heater :
• Tank
• Thermostats and Heating
Elements
• Inlet, Outlet, and Valves
TYPE OF Electric water element:
• Open Electric Heating Coils • Covered Electric heating Coils
EOpen coils leave the elements Exposed elements are not
exposed. There is no need for them appropriate for all heating
to heat up a protective covering, so applications. In direct heating, for
they have rapid heat up times. They instance, open coils are susceptible
are low maintenance and have to damage and corrosion. To prevent
inexpensive, easy to replace parts. this, heater coils use a protective
The downside is that the exposed sheath. This sheath protects the
elements are more vulnerable to elements while also reducing risks of
damage. electrocution or fires.
Working of water heater :
• In Electric Water heater, there are two pipelines, one for inlet of cold water
and the other for outlet of the hot water. The water tank is fitted with
heating element/s which is/are controlled by thermostats. The function of
the thermostat is to set the temperature to a certain value so that water is
not heated above that value.
• The tank is normally covered with some insulating material such as glass
wool , PUF and entire assembly is enclosed inside a metal casing or plastic
casing which can be hanged on the wall or wherever required. The
sacrificial anode is used to protect the tank from corrosion by sacrificing
itself and helps to prolong the life of the tank.
Problem Definition:
• While studying water heater & it’s working, we understood that the major
portion of heat & energy is lost. When we turn off water heater major
portion of heated water is still remain inside water tank which we may use
after an interval of time. For the next time when we turn on water heater it
will take same time or less than previous cycle of water heating. That
means there is portion of heat energy which is still inside that water heater.
• To improve the efficiency of water heater by alternating various factors
such as coil heating element parameter, & its design, direction of flow, inlet
outlet temperature, pressure drop across fluid.
• To check sustainability of different material used for partition inside water
heating tank under various condition using cfd – to find alternative for
material of partition
Objective:
• In this work, we make attempt to improve the performance of electric
water heater by making distinct improvements on basis of design,
using hybrid heating coil and can widely use for commercial and
industrial application.
• Finalized the material used for partition inside water heating tank
which acts as insulator & prevents heat dissipation .
Concept formation:
• To reduced cycle time required for water
heating, we decided to divide 4.5 kW of
heating elements into 2 parts. One with
smaller kW ratings & other one with
slightly higher kW ratings i.e. 1.5 kW & 3.0
kW respectively shown in fig 4. One lower
heating element can heat up the water
which is coming from inlet tube around 16°
C. As warm water goes up it will take
slightly less time to heated unto 60° C. In
this way we can split high voltage rating
elements into two, and reduced time
requirement to heat the water during its
peak demand time.
• As we discussed in first concept time required
for heating water gets reduced but hot water
continue to lose its energy after first usage. To
utilize this energy we added one partition
inside water tank which acts as black body &
prevents maximum amount of heat loss.
• A provision is made inside tank so that internal
hot water can mixed with incoming cold water
.Mixing aids temperature of cold water coming
from inlet pipe .
Experimental Setup :

SR NO Description

1 Inlet water temperature 10°C

2 Outlet water temperature 70°C

3 Thermostat settings 45 – 78°C

4 Heating element 4.5 kW

5 Inlet flow rate 3 gallons per min

6 Time Slots 20 min

Experimental Data :
Experimental data of existing storage water heater temp & time:
Time & temperature reading for existing heating element for Time & temperature reading for existing heating element for Time & temperature reading for existing heating element for
1st cycle 2nd cycle after 30 min 3rd cycle after 30 min

Time Temperature °C Temperature °C Temperature °C

1 13.8 13.8 14.1
2 19.5 18.7 21.4
3 23.2 23.2 20.8
4 25.7 25.7 26.1
5 25 25 28
6 28 27.4 33.5
7 30 29 33.5
8 29 28.4 35
9 33 31 36.9
10 35 34 38.4
11 35.6 34.5 40.3
12 38 37.6 40.3
13 38.9 40.3 44
14 42 41 45.2
15 45.7 45.7 45.6
16 47.8 47.8 48
17 50 45 49.6
18 50.23 49.8 52.4
19 52 52 53
20 56 55.4 54.6
Cfd analysis : Inlet conditions
Cfd analysis : Project solver
Cfd analysis : Result Temperature vs time
Comparison of experimental & analytical
results :
• From CFD results, we are fail to generate the required results, as time
required to conduct same experiment is relatively large we have studied
this experiment practically .
• Few images of set up is attached for your reference .
 Experimental Data :
Experimental data of new storage water heater temp & time:

Time & temperature reading for existing heating element Time & temperature reading for existing heating element Time & temperature reading for existing heating element
for 1st cycle for 2nd cycle after 30 min for 3rd cycle after 30 min

Time Temperature °C Temperature °C Temperature °C

1 13.8 18 22
2 14.5 20.3 22.6
3 15.9 25 27
4 19.3 25.4 31.8
5 22.4 28 36
6 28 32.5 37
7 30.5 36 39.8
8 33.5 39.6 42
9 35 42.5 42.5
10 38.9 46.6 45.8
11 42 49.8 50.6
12 45.6 50.3 52.4
13 47 53.6 58
14 51.1 55.4 60.5
15 55 59 65.3
16 59 59.2 65.4
17 62 62.3 65.3
18 63.5 66.5 66
19 62 66 66.4
20 63 66.9 66.3
Future scope :
• We can still improve in terms of design of partition which we made
inside steel tank
• We can monitor water flow direction which may lead to improve
water heaters efficiency
Thank you