Hydrogen Co-Firing Pilot Outcomes

Co-firing hydrogen in process heaters has been tested across multiple configurations, with hydrogen substituted at 5–20% by energy content. Results show stable operation in many cases, but flame behavior shifts—leading to higher flame temperatures and narrower operability windows under high hydrogen ratios.

Emissions profiling indicates lower CO₂ but increased NOx formation, demanding adjusted combustion air staging or selective catalytic reduction support. Flame imaging and online emissions monitoring help operators identify instability thresholds and optimize burner modifications for mixed-fuel operation.

Fuel gas system modifications often arise: hydrogen’s high diffusivity can increase leak risks and require upgraded gasketing and sealing materials. Storage, metering, and blending equipment must meet stringent purity and pressure control standards to prevent operational upsets.

Pilots underscore that success depends on real-time control logic, dynamic burner tuning, and pre-combustion planning. Full conversion would require hardware upgrades, but even modest co-firing delivers meaningful carbon savings and valuable operational data for future scale-up.