Impact of structural and CFD analysis on the cost of biogas-fueled gas engine exhaust pipes

In this study, the effects of exhaust pipe design used in biogas-fueled cogeneration systems on engineering performance and cost were investigated. First, the existing system was analyzed by field work, and then structural analysis was applied with CFD (Computational Fluid Dynamics). The exhaust pipe route, pipe diameter, and material thickness of the existing system were evaluated, and design improvements were suggested. It was determined that the shorter pipeline application with the changes made in the pipe route and layout reduced pressure losses. Despite the use of an exhaust pipe with a smaller diameter and made of thinner material in the proposed new design, compliance with the standards was ensured, and it was shown to be safe against wind loads with finite element analysis. Considering the calculated maximum wind load of 5.52 kN and the weight of the system, the maximum stress value was calculated as 108.691 MPa as a result of the Von Mises stress analysis applied to the exhaust pipe system in the finite element analysis. This value showed that the system was 1.56 times safer. In the deformation analysis, the maximum displacement value was measured as 0.13 mm, and this value is ideal. In the cost analysis, it was determined that the proposed new system provides a cost reduction of approximately 53% compared to the existing system. The results obtained emphasize the importance of engineering analysis in exhaust pipe design, and show the applicability of the approach to increase economic and environmental sustainability in industrial facilities.