Effects of Operating Parameters on Combustion Characteristics of Hydrogen-Doped Natural Gas

The operational optimization of industrial boilers utilizing hydrogen-enriched natural gas is constrained by two critical gaps: insufficient understanding of the coupled effects of hydrogen blending ratio, equivalence ratio, and boiler load on combustion performance— compounded by unresolved challenges of combustion instability, flashback, and elevated NOx emissions—and a lack of systematic investigations combining these parameters in industrial-scale systems (prior studies often focus on single variables like hydrogen fraction). To address this, a comprehensive computational fluid dynamics (CFD) analysis was conducted on a 2.1 MW industrial boiler, employing the Steady Laminar Flamelet Model (SLFM) with a modified k-ε turbulence model and the GRI-Mech 3.0 mechanism. Simulations covered hydrogen fractions (f(H2) = 0–25%), equivalence ratios (Φ = 0.8–1.2), and load conditions (15–100%). All NOx emissions reported herein are normalized to 3.5% O2 (mg/Nm3 ) for regulatory comparison. Results show that increasing the hydrogen content raises the flame temperature and NOx emissions while reducing CO and unburned hydrocarbons; a higher equivalence ratio elevates temperature and NOx, with Φ = 0.8 balancing efficiency and emission control; and reducing load significantly lowers furnace temperature and NO emissions. Notably, the boiler’s unique staged-combustion configuration (81% fuel supply to the central rich-combustion nozzle, 19% to the concentric lean-combustion nozzle) was found to mitigate NOx formation by 15–20% compared to single-inlet burner designs, and its integrated cyclone blades (generating maximum swirling velocity of 14.2 m/s at full load) enhanced fuel–air mixing, which became particularly critical for maintaining combustion stability at low loads (≤20%) and high hydrogen blending ratios (≥20%). This study provides quantitative trade-off insights between combustion efficiency and pollutant formation, offering actionable guidance for the safe, efficient operation of hydrogen-enriched natural gas in industrial boilers.