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Design and Development of a Fuel-Flexible Hydrogen Burner

Implementing Organization

Principal Investigator
Dr. Manu B V
Indian Institute Of Technology (Banaras Hindu University), Varanasi
manugowda787@gmail.com

Project Overview

combustion technology utilizes an array of micro-nozzles to inject fuel perpendicularly into the air stream, forming short flamelets that improve mixing and reduce peak temperatures, thus minimizing NOx formation (Sandoval et al., 2025). Studies by Kim et al. (2025) illustrated that redesigning burner geometry to reduce residence time and optimize air-fuel momentum can lead to more than 40% reduction in NOx emissions. Margarida Lorena (2023) demonstrated that swirl-based stabilization, when combined with staged air injection, enhances flame anchoring and reduces the risk of blow-off or flashback in hydrogen-natural gas blends. Further, research by Islam et al. (2025) introduced smart burner designs using additive manufacturing with embedded sensors for real-time flame diagnostics. These burners, fabricated from Inconel alloys via Laser Powder Bed Fusion (LPBF), can operate under high-pressure conditions with up to 70% CO₂ dilution. Building on these findings, our project proposes the design, fabrication, and experimental evaluation of a fuel-flexible burner capable of operating with pure hydrogen and hydrogen-natural gas mixtures. This project will explore advanced features such as staged air injection, micromix fuel delivery, swirl stabilization, and residence time control to address flame stability across a wide range of operating conditions. To support the design process, we will conduct preliminary Computational Fluid Dynamics (CFD) simulations to analyse flow fields, mixing quality, flame anchoring, and temperature distributions. These simulations will guide the optimization of geometric parameters such as nozzle diameter, swirl intensity, and air staging before moving to the fabrication and experimental validation stages. By integrating insights from contemporary research and simulation driven design, this project aims to produce a reliable, safe, and efficient hydrogen compatible burner system. The outcomes will include detailed flame stability envelopes, emission characterization, and tested burner prototypes, contributing significantly to the development of next generation, combustion technologies suited for the hydrogen economy.
Funding Organization
Quick Information
Area of Research
Engineering Sciences
Focus Area
Mechanical Engineering
Start Date
01 Dec 2025
End Date
30 Nov 2027
Status
ongoing
Output
No. of Research Paper
00
Technologies (If Any)
00
No. of PhD Produced
00
Publications
00
No. of Patents
Filed : 00
Grant : 00
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