Hydrogen Boiler Modulation Control for Flashback Prevention

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Solution Overview

Problem

Existing methods for controlling gas boilers, particularly those using hydrogen fuel, are complex and do not effectively prevent flashback during changes in power output, which is exacerbated by the higher flame speed of hydrogen compared to other fuels.

Innovation Solution

A method for controlling a hydrogen gas boiler that switches to a modulation operating mode, adjusting the air-to-fuel ratio (lambda) to a higher level and varying the air and fuel flows based on predefined functions to prevent flashback, using actuators like fans and gas valves controlled by a control unit.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If the flame speed is increased to improve heating efficiency, then the power output is improved, but the risk of flashback increases

Engineering Contradiction:
Improvepower outputVSAvoidflashback risk
Core Design Contradiction:
PowerVSReliability

Solution Approach 1:

The patent applies parameter changes by dynamically adjusting the air-to-fuel mixture ratio (lambda) based on the desired power output. When high power is demanded, the system increases the fuel proportion in the mixture, which increases flame speed and power output. When power demand decreases, the system increases the air proportion, which reduces flame speed and prevents flashback. This continuous parameter adjustment resolves the contradiction between maintaining high power output and preventing flashback.

Inventive Principle:
Principle #35Parameter changes

2Reliability

If the air-to-fuel ratio is increased to prevent flashback, then the safety is improved, but the power output decreases

Engineering Contradiction:
ImprovesafetyVSAvoidpower output
Core Design Contradiction:
ReliabilityVSPower

Solution Approach 1:

The patent implements dynamics by making the air-to-fuel ratio adjustable and responsive to changing power demands rather than fixed. The control unit continuously monitors the desired power output and dynamically adjusts the mixture ratio accordingly. This allows the system to achieve high power output when needed (by increasing fuel proportion) while maintaining safety by reducing flame speed through increased air proportion when power demand is low, thus resolving the static contradiction between safety and power output.

Inventive Principle:
Principle #15Dynamics

3Adaptability or versatility

If the boiler operates in on/off cycles to match heating demand, then the adaptability is improved, but the equipment wear and energy loss increase

Engineering Contradiction:
Improveheating demand adaptationVSAvoidcycle losses
Core Design Contradiction:
Adaptability or versatilityVSLoss of energy

Solution Approach 1:

The patent applies continuity of useful action by enabling the boiler to operate continuously at varying power levels through modulation of the fuel-air mixture ratio, rather than switching on and off. The control unit adjusts the proportion of fuel and air in the mixture to match the desired power output, allowing the boiler to maintain steady combustion at any level between minimum and maximum capacity. This eliminates the energy losses and equipment wear associated with repeated startup and shutdown cycles while maintaining adaptability to changing heating demands.

Inventive Principle:
Principle #20Continuity of useful action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The method efficiently reduces the risk of flashback by maintaining a higher air-to-fuel ratio during power output changes, improving safety and efficiency by minimizing cycle losses and equipment wear.

Implementation Method 1

Gas boilers combust gas fuel to heat water for domestic use and/or central heating system facilities in buildings

Methodology Applied
Scientific EffectCombustion: Combustion

Data Source

PatentEP4352414B1Method for controlling the operation of a gas boiler
Publication Date: 2026.04.01 BDR THERMEA GRP
  • EP4352414B1 patent drawingFigure 1
  • EP4352414B1 patent drawingFigure 2
  • EP4352414B1 patent drawingFigure 3

AI summary

The invention relates to a method (100) for controlling the operation of a gas boiler (1), in particular a hydrogen boiler, the method comprising acquiring (S101) a heat change demand, switching (S102) into a modulation operating modus due to the acquired heat change demand, and controlling (S103) one or more actuators (15, 16) of the boiler (1) to regulate the air flow and/or the fuel gas flow, wherein controlling (S103) the one or more actuators (15, 16) is such that during the modulation operating modus an air to fuel gas ratio of a mixture is increased.