Correct design of air manifolds applied in biomass-fired batch boilers allows to avoid excessive emissions and high flow resistance, as well as helps achieving the required parameters of the fan supplying air to the boiler. The paper describes the process and the results of the optimization performed using selected methods based on the response surface analysis. An experimentally validated CFD model of the state of the art air manifold has been geometrically parametrized, in order to find the shape that is optimal from the point of view of the objective function. In each analysis, the objective function was linked to air flow characteristics. Selected algorithms of the interpolation of design points that were obtained as the result of the numerical experiment have been compared and evaluated. Optimization using the response surface generated using various algorithms has been performed and verified by further direct CFD computations. The obtained optimal values of the input parameters were applied in the final model of the prototype. The flow characteristics of the prototype and the reference state have been compared and discussed. Significant improvement of the operation conditions has been achieved.

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