Hydrogen Burner Module With Integral Flashback Arrestor Channels

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Solution Overview

Problem

Existing burners are incompatible with hydrogen concentrations above 20% in natural gas, leading to flashback, safety hazards, and high NOx emissions due to extreme adiabatic flame temperatures, and require significant modifications for fuel flexibility and emissions control.

Innovation Solution

A burner design incorporating a fuel-distribution element, a flashback arrestor element with channels narrower than the critical flame quench diameter, and a combustion element with apertures wider than the arrestor channels, using ceramic or plastic materials to guide and output hydrogen-containing fuel and oxygen-containing gas, along with a secondary flashback arrestor element for enhanced safety and emissions control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional burners are used with hydrogen concentrations above 20%, then fuel flexibility is improved, but flashback and safety hazards occur

Engineering Contradiction:

Improvefuel flexibilityVSAvoidflashback prevention

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

A flashback arrestor element is introduced as an intermediary component between the fuel distribution element and combustion element. This arrestor element with narrow channels (smaller than critical flame quench diameter) acts as a mediator that allows fuel and oxidant to pass through while blocking flashback propagation, thus enabling safe operation with high hydrogen concentrations

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The burner employs different aperture sizes at different locations: narrow channels in the flashback arrestor element upstream and wider apertures in the combustion element downstream. This local variation in geometry optimizes each zone for its specific function - the narrow section prevents flashback while the wide section enables stable combustion of hydrogen-rich fuels

Inventive Principle:

Principle #3Local quality

2Power

If conventional flame burners are used, then combustion is achieved, but high nitrogen oxide (NOx) emissions are produced

Engineering Contradiction:

Improvecombustion efficiencyVSAvoidNOx emissions

Core Design Contradiction:

PowerVSObject-generated harmful factors

Solution Approach 1:

The invention changes the combustion parameters by using the flashback arrestor element to control mixing and combustion characteristics. The narrow channels create specific flow conditions that lower combustion temperature and reduce thermal NOx formation, while still maintaining efficient combustion of hydrogen-containing fuels

Inventive Principle:

Principle #35Parameter changes

3Reliability

If flashback arrestor element with narrow channels is used, then flashback is prevented, but device complexity increases

Engineering Contradiction:

Improveflashback preventionVSAvoidburner structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The flashback arrestor element is designed as an integrated component that combines multiple functions: it serves as both a flashback prevention mechanism and a flow distribution element. The arrestor element with its pattern of narrow channels is incorporated directly into the burner structure, merging the safety function with the existing burner architecture rather than adding a separate complex subsystem

Inventive Principle:

Principle #5Merging (Combining)

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 burner design safely handles hydrogen concentrations up to 100%, reduces NOx emissions, maintains stable combustion, and enhances energy efficiency by using infrared heat transfer, while maintaining safety and flexibility across varying fuel compositions.

Implementation Method 1

A mean width of the flashback arrestor element channels is smaller than a critical flame quench diameter of the hydrogen-containing fuel

Methodology Applied

Scientific EffectFlame quenching:

Implementation Method 2

configured to output the primary oxygen-containing gas and the hydrogen-based fuel from inside to outside of the burner, to cause the burner to produce a flame and/or infrared heat

Methodology Applied

Scientific EffectCombustion: Combustion

Implementation Method 3

produce a flame and/or infrared heat

Methodology Applied

Scientific EffectInfrared radiation: Infrared Radiation

Data Source

PatentUS12504166B2Fuel flexible combustion module with integral flashback arrestor

Publication Date: 2025.12.23 UT BATTELLE LLC

AI summary

A burner includes a primary input port configured to receive hydrogen-containing fuel and primary oxygen-containing gas. A fuel-distribution element comprises a plurality of distribution openings. A flashback arrestor element comprises a plurality of flashback arrestor element channels with a mean width that is smaller than a critical flame quench diameter of the hydrogen-containing fuel. A burner housing can be provided, and the burner housing, fuel distribution element, and flashback arrestor element can be made of plastic and by 3D printing. A combustion element includes a plurality of combustion element apertures configured to cause the burner to produce a flame and/or infrared heat, wherein a mean width of the combustion element apertures is 2-4 times larger than the mean width of the flashback arrestor element channels. A method of heating and a heating system are also disclosed. The combustion element can also be equipped for resistive heating.