Experimental analysis of combustion and emission characteristics in hydrogen-enriched industrial premixed burners

The decarbonisation of the heating sector is critical for achieving Net Zero targets, with hydrogen fuel emerging as a promising alternative to natural gas. This study experimentally investigates the operational feasibility, combustion, and emissions characteristics of hydrogen-enriched fuel mixtures in an industrial burner. The PHOTON10 unit is used as an industrial burner. Experiments were conducted using methane (i.e., G20) enriched with hydrogen in different (% vol) quantities to assess flame behaviours like stability and emission profiles. Key challenges identified include flame flashback, thermal retraction, and diminished flame rectification signals, particularly under daylight conditions due to hydrogen’s low visible emissivity. To maintain rated thermal output, hydrogen consumption was increased by up to threefold when operating with 100% hydrogen. Emission analysis revealed significant reductions in CO 2 , NO, and NO x with increasing hydrogen concentration, while flame temperature decreased correspondingly. All the tested hydrogen-enriched mixtures met regulatory thresholds for CO, CO 2 , NO, and NO x emissions for industrial applications. The PHOTON10 burner demonstrated compatibility with hydrogen fuels with minimal design modifications, primarily in air intake parameters. In closed-loop operation, reliable flame monitoring was achieved via flue gas temperature and UV flame signal intensity. These findings contribute to the advancement of hydrogen-compatible burner technologies and support the broader transition toward low-carbon industrial heating solutions.