Design Optimization and Thermal Analysis of a Submersible

Water Heater Coil

Sumanth Shetty1, a, Atharva1, b, Santosh Billur2, c, Gireesha R. Chalageri2, d,

¹Student, School of Mechanical Engineering, KLE Technological University, Hubli, Karnataka, India – 580031
²Assistant Professor, School of Mechanical Engineering, KLE Technological University, Hubli, Karnataka, India –580031
.
a)
01fe22bme041@[Link]
b)
01fe22bme108@[Link]
c)
santosh@[Link]
d)
gireesha@[Link]

Abstract- Water heater coils often suffer from performance loss over time due to uneven heating and the
buildup of scale on their surfaces. In this project, we focused on improving the thermal efficiency and
durability of heating coils by experimenting with different coil designs and materials. Using CATIA V5, we
developed one base model and three design iterations with slight changes in geometry to explore how shape
influences heat distribution. To understand how these designs perform under real conditions, we carried out
steady-state thermal analysis in ANSYS Workbench. The goal was to identify which geometry helps spread
heat more evenly and reduces hotspots that often lead to scale buildup. Our material focus was on copper
alloy and nichrome, both commonly used in heating applications. By comparing the simulation results, we
gained valuable insights into how coil design and material choice can improve heating performance and
extend coil life. This project takes a practical step toward creating more efficient and long-lasting water
heating systems with fewer maintenance issues.

Key words: Steady-state thermal analysis, CATIA V5 coil modeling, ANSYS thermal simulation, copper
alloy coil, nichrome heating element, heating coil design iterations.

INTRODUCTION
Water heaters are a vital part of everyday life—used in homes for basic needs like bathing and washing, and in
industries for processes such as cleaning and heating. At the heart of these systems is the heating coil, which
converts electrical energy into heat. Although simple in appearance, the coil operates under tough conditions: high
temperatures, long hours, and exposure to hard water.
One of the most common and damaging issues faced by heating coils is scale formation. When hard water is
heated, minerals like calcium and magnesium settle on the coil surface, forming a stubborn residue that blocks heat
transfer. This buildup increases power consumption, shortens the coil’s lifespan, and can lead to overheating or
failure.
This study focuses on two widely used materials: nichrome and a copper alloy. Nichrome is known for its
resistance to oxidation and scale, while copper alloys offer better thermal conductivity but are more prone to
corrosion and residue buildup. Rather than relying on water treatment or external control systems, this research
explores how the material choice and coil geometry alone influence scaling and heating efficiency.
By analysing the thermal and mechanical behaviour of these two materials under heating conditions, the study
aims to identify designs that can reduce scale formation, improve energy efficiency, and extend the service life of
water heater coils.
LITERARTURE SURVEY

Several studies have shed light on the challenges and solutions related to water heater coil degradation from a
material and design perspective. Commonly used materials like copper and stainless-steel offer specific advantages
and disadvantages. Copper, with its excellent thermal conductivity, ensures rapid heating but is prone to corrosion
and scaling, especially in hard water environments [1].

Stainless steel, particularly SS304 and SS316, offers better corrosion resistance but has comparatively lower thermal
conductivity, which may affect heating rates [2].

Emerging alternatives such as nickel-chromium alloys and FeCrAl (iron-chromium-aluminum) have gained
attention for their high-temperature resistance and low scaling tendencies [3].

These materials form stable oxide layers that protect the core metal from corrosion and reduce residue adherence.
Additionally, surface treatments like ceramic or polymer coatings have demonstrated the ability to significantly
reduce the adhesion of scale-forming minerals, thereby enhancing the service life of the heating element [4].

Geometry also plays a vital role in residue management. Helical and spiral coil configurations are often preferred
due to their ability to maximize the heat exchange surface area in compact spaces. However, design variables such
as pitch, coil diameter, and flow path length can lead to variations in heat distribution and flow dynamics, indirectly
influencing the scale formation [5]. Designs that promote turbulent flow typically reduce scale buildup due to
continuous scouring action, while those that create stagnant zones or hot spots tend to accelerate deposition.

Some studies have also evaluated the long-term performance of these materials and designs under real-world
conditions. The consensus is that while many materials and coatings offer excellent initial performance, their
resistance to scaling diminishes over time due to wear, thermal fatigue, and chemical attack [6]. Thus, a successful
design must account for both short-term efficiency and long-term durability.

Other promising research directions include bimetallic coil structures where the inner layer provides high
conductivity and the outer layer offers corrosion and scale resistance, as well as integration of smart sensors to
detect scaling in real time. However, these solutions are still in experimental stages and require more in-depth
validation.

Given this background, our study proposes a systematic evaluation of various materials and geometrical designs
using advanced simulation tools. The objective is to identify optimal configurations that resist scale formation,
distribute heat evenly, and maintain mechanical integrity under cyclic thermal loads.

METHODOLOGY

The methodology begins by clearly identifying the problem of mineral scale buildup on heating coils, which
affects efficiency and durability. The study focuses on two commonly used materials—nichrome and a copper alloy
—chosen for their contrasting thermal and scaling characteristics. Different coil geometries such as straight, helical,
and spiral shapes, with variations in pitch and diameter, are modeled using CAD software. These designs are then
evaluated through thermal and structural analysis to observe heat distribution, temperature uniformity, and potential
stress zones that may lead to surface damage or promote scaling. By comparing material behavior and design
performance, the study identifies which combinations best resist residue formation and provide reliable, long-term
operation in hard water conditions.

CAD MODELLING

The CAD model shows a submersible water heater coil with two straight extensions at either end. The coil has a
constant pitch and diameter.

FIGURE 1. Steady-State thermal analysis results of baseline model.

 STEADY-STATE THERMAL ANALYSIS OF BASE MODEL
The steady-state thermal analysis of the baseline heating coil model is carried out to evaluate the temperature
distribution under continuous operation. In this analysis, internal heat generation is applied to the coil body to
simulate electrical heating, based on the material’s resistive properties. Additionally, radiation heat transfer is
considered from the coil surface to the surrounding environment to closely replicate real-world heat dissipation. The
model uses appropriate thermal properties for nichrome, depending on the material selected (Table 1). Fixed
boundary conditions such as ambient temperature are applied to capture the operational scenario realistically. This
analysis helps identify temperature gradients, and thermal efficiency, forming a reference point for evaluating
improved material or geometric alternatives (Figure 2).

FIGURE 2. Steady-State thermal analysis results of baseline model.

TABLE 1. Heat Flow and Temperature Distribution Results of the Baseline Coil Model.

Parameter Value
Maximum temperature 324.74 k
Minimum temperature 324.16 k
Average temperature 324.56 k
Radiation + Internal heat
Boundary condition used
generation
Heat Flux 377.63W/m2
Mass of the coil 0.4908 kg
Material selected Nichrome
 3D CAD REPRESENTATIONS Of COIL GEOMETRY VARIANTS FOR THERMAL
PERFORMANCE EVALUATION

Design 2 Design 3 Design 4

Figure 3 – CAD models of variant coil geometry

Design 2 Multi-Leg U-Bent Coil -

This configuration introduces multiple vertically oriented U-bent legs to improve surface area contact with water
and enhance uniform heat distribution.

Design 3 Concentric U-Bent Coil-

This design features closely spaced concentric U-bends aimed at maximizing surface area within a compact volume,
promoting efficient and uniform heat transfer.

Design 4 Helical Coil Configuration-

This design adopts a helical coil layout to maximize surface area and improve heat dissipation efficiency through
extended path length and natural convection.
 Steady-State Thermal Analysis of Coil Design Iterations

Design 1 Design 2 Design 3

Figure 3- Steady state thermal analysis of iterated design models.

TABLE 2. Heat Flow and Temperature Distribution Results of the design iteration Coil Model

Parameter Baseline Iteration 1 Iteration 2 Iteration 3

Maximum temperature (k) 324.74 324.12 323.57 399.13

Minimum temperature (k) 324.16 322.67 321.56 391.06
Average temperature (k) 324.56 323.76 322.57 398.73
Heat flux (W/m2) 377.63 282.95 323.68 172.3
Mass of the coil (kg) 0.4908 0.3548 0.5013 0.2317
Material Selected Nichrome Nichrome Nichrome Nichrome

CONCLUSION
Thermal analysis of various coil geometries was conducted to identify the most efficient design for electric water
heating applications. Among the configurations studied, Design 3 exhibited superior performance, achieving higher
thermal output and effective heat distribution across the coil surface. Its ability to reach a peak temperature of
399.13 K while maintaining a manageable temperature gradient makes it highly suitable for applications requiring
fast and uniform water heating. Based on the results, Design 3 is concluded to be the most favorable geometry for
optimized electric heating coil systems.

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