Hydrogen Burners for Industrial Decarbonization

In the public debate, hydrogen (H2) has become a beacon of hope for the future energy mix, given its potential in industries difficult to decarbonize (steel, cement, chemicals) and mobility (shipping, aviation, automotive) is enormous. Unlike electricity from solar and wind, H2 can be easily stored - as gas or liquid. In the summer of 2020, the German federal government (awaiting Polish) adopted the "National Hydrogen Strategy," and the European Commission aims for real systemic change through the Green Deal: by 2030, CO2 emissions should be reduced by 40%, and by 2050, Europe should become a climate-neutral continent.
By 2024, clean hydrogen production is expected to increase to one million tons, and by 2030, to ten million tons. Thus, H2 should not only be a lifeline for climate and energy transformation but also a driver of technological innovation.

The Technology is Proven and Readily Available

Incorporating hydrogen into the energy basket requires experience and specialized knowledge. SAACKE, as a technological leader for decades, has been producing low-NOx combustion systems, also in combination with hydrogen, the so-called "H2 Ready."
We can immediately support you in transitioning to heat generation based on H2 to harness the potential of climate-neutral and ultra-modern energy economy. Here we step into the game where there is real technology for efficient processing of large quantities of "blue" or "green" H2 in industrial thermal processes. And it's already happening today - for example, as a byproduct in the chlor-alkali industry or in titanium dioxide production, as well as in propulsion and heating systems on ships. Using existing H2 instead of additional natural gas or diesel for ships not only reduces emissions but also cuts costs.

Injecting H2 into the Natural Gas Grid - Ensuring Operational Safety

Significant increase is expected in the amount of H2 as a complementary fuel to natural gas. Currently, the permissible H2 content added to the existing natural gas grid is up to 20%. Two-thirds of the current German gas infrastructure (awaiting Polish) could potentially be used for hydrogen blending in the future. This places demands on both installation operators and the technology itself. Those using H2-compatible burners today avoid the need for future upgrades and ensure the long-term operation of their installations.

Heading Towards Hydrogen

What are the characteristics of this promising energy source, in what variants does it occur, and what else needs to be considered?

• Gray Hydrogen H2 - Product of steam reforming of natural gas (emits CO2); currently about 90% of hydrogen produced for industrial purposes
• Blue Hydrogen H2 - Hydrogen production from natural gas, then underground/subsea storage or CO2 storage (CCS technology)
• Green Hydrogen H2 - Obtained through (relatively expensive) electrolysis/powering by renewable energy sources

Characteristics of Hydrogen Combustion

• Hydrogen atom H is the lightest and smallest element in the periodic table
• H2 is colorless, odorless, and tasteless
• It is 8 times lighter than natural gas
• Calorific value is 3 to 3.5 times lower than most commercially available natural gases
• The flame burns about 8 times faster than natural gas
• Extremely wide flammability range (4-77% by volume compared to 4-16% by volume of natural gas)
• 15 times less spark energy required for ignition than natural gas (0.02 mJ)

H2 has enormous potential for environmental protection and CO2 reduction

Example calculation: A 7.5 MW burner operating continuously at maximum capacity (24 hours a day) and running on hydrogen can save about 35 tons of CO2 emissions per day compared to burning natural gas.

Power-To-Gas Process - How Green Hydrogen H2 is Produced

Power-to-X: SAACKE Combustion Technology is Ready for Hydrogen

The European Union aims to achieve climate neutrality by 2050. According to current knowledge, widespread use of hydrogen can play a crucial role in achieving this goal and is therefore currently receiving significant attention from the media and politicians. Especially in the area of industrial heat generation, the thermal utilization of green hydrogen presents a real alternative to fossil fuels.

In industrial heat generation, hydrogen as a fuel is not a new area. For example, hydrogen generated as a by-product of chlor-alkali electrolysis has already been extensively burned in air-recirculation burners. The first installations of this kind by SAACKE were commissioned as early as 1981. So far, such applications have been special installations with high demand for individual engineering. Hydrogen as a fuel poses additional requirements for both the burner and connected systems. Many hydrogen projects have been successfully implemented so far. From small hydrogen admixtures in natural gas to 100% hydrogen content. Various types of burners are used depending on the requirements.

All SAACKE burners are already capable of processing up to 20% hydrogen admixture in natural gas without any problems. If the H2 content is higher (up to 100%) and variable, our SSB and ROTONOX series burners are also suitable and proven for this purpose. By the way: Mixed combustion of hydrogen and natural gas (or EL fuel oil) in variable proportions is also possible and often used. This means that the customer can switch back to "reserve fuel" in the form of natural gas, biogas, or fuel oil at any time in case of bottlenecks in hydrogen supplies.

Of course, even with 100% H2, SAACKE burners meet all NOx limits, and in some cases, they fall significantly below them (> 50%). Generally, standard gas burners operating on 100% hydrogen have emissions three times higher than when operating on natural gas.

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SAACKE Hydrogen Burners

SAACKE has been researching H2 for about 40 years, and thanks to this technological advantage, it is one of the few suppliers in the world that can already offer safe and low-emission hydrogen burners on the market, providing CO2-neutral heat - both in industry and maritime shipping. With experience in special plant engineering, SAACKE can offer a wide range of steam generation burners based on natural gas that can utilize alternative fuels such as H2.

With us, you get everything from one source because we are your comprehensive service point for complete H2 combustion systems - whether it's engineering, installation, modernization, or spare parts service.
Our technological advantage lies in sophisticated flue gas recirculation and special gas injection design. These two key components ensure that higher flame temperatures and higher NOx emissions from hydrogen combustion compared to natural gas are minimized by up to 3 times.

Applications of SAACKE Burners

Industries for Hydrogen Burner Applications

Plant Modernization + Plant Automation - Transitioning to Hydrogen

Responsible use of fossil fuels is more important today than ever before. A modern combustion installation must therefore achieve maximum efficiency from the available fuel. The key to this is high operational efficiency. Optimize your system with SAACKE modernization modules!

The SAACKE portfolio includes:

• Speed-regulated motors providing energy savings of up to 80%.
• CO-/O2 controllers improving efficiency by approx. 1-2
• Economizers and heat exchangers increasing efficiency by up to 11% while reducing emissions.
• Calculation of cost and emission reduction potential
• Optimization of operating mode and control parameters

Thermal Hydrogen Air Purification

Lowest emission values and low energy consumption

Odorous exhaust air, generated for example in the food industry, refineries, or chemical industry, must be freed from unpleasant odors through exhaust air purification before being released into the environment.

There are basically two methods for purifying exhaust air: thermal and biological exhaust air purification. The advantage of the former is that it can be used even when the composition of the exhaust air is different, and when large quantities of exhaust air are involved. In the case of thermal exhaust air purification, the exhaust air is heated to a temperature above 750°C.

The SAACKE portfolio includes both individual and complete solutions for exhaust air purification while utilizing the energy for exhaust air and vapors. The main goal is always to minimize the energy needed to heat the exhaust air and reduce the corresponding emission values. SAACKE has the necessary products, experience, and comprehensive engineering knowledge to achieve these goals.

The SAACKE portfolio includes:

• Burner, combustion chamber, and recovery boiler
• Combustion technology for low-load exhaust air utilization

SAACKE solutions combine exhaust air purification with the use of generated heat. In this process, odorous exhaust air is heated and combusted. The heat obtained is then thermally utilized in a downstream boiler. This way, emissions from meat and potato processing plants not only get disposed of but also replace other energy sources by providing process heat. Even for very difficult exhaust air, such as in waste incineration plants, SAACKE offers solutions for vapor removal.

Hydrogen Water Tube Boiler

Increased efficiency and best emission values

Water tube boilers are used in many different industries, such as power generation, heating, or the paper industry. Over the 30-40 year operational period of a boiler system, burners must be modernized several times to ensure compliance with emission regulations, especially NOx. Therefore, both for new installations and retrofits, the following principles apply: State-of-the-art low NOx combustion technology is an absolute necessity, and its operational safety is maintained.

For water tube boilers, SAACKE offers individual burners, as well as fittings, burner controls, and complete solutions. In SAACKE, you will find the right products and services for a new system or the modernization of an existing system. All these offerings aim to make the water tube boiler combustion system as efficient and low-emission as possible.

The SAACKE portfolio includes:

• Burners and ignition systems for standard and special fuels, such as lean gas, converter gas, or molasses
• Low NOx combustion systems (e.g., for very low NOx emissions)
• Backup and pilot burners for fluidized bed boilers (e.g., for waste-to-energy plants)
• Modernization of existing boiler plants by installing new burners and/or further modernization measures

Hydrogen Hot Oil Heaters

Oil heaters are mainly used in the chemical and pharmaceutical industries to supply heat to processes at high temperatures (from 300 to 450 °C). They are often fueled by special fuels such as gas or liquid by-products of the process. In addition to using these fuels, a particular challenge is often the thermal utilization of exhaust air.

One advantage of all SAACKE burners is that they can operate with preheated combustion air and still ensure low NOx combustion.

The SAACKE portfolio includes:

• Low-emission burners for standard fuels such as natural gas, light and heavy oil, and special fuels such as liquid or gaseous by-products from the chemical industry
• Combustion systems for backup heat supply to solar thermal power plants to ensure continuous operation in case solar energy is not available

Auxiliary Gas Turbine Firing - Rational Use of Gas Turbines

Generating electricity using a gas turbine and steam by using hot exhaust gases is environmentally friendly and efficient - in principle. However, in practice, such combined processes achieve a fuel utilization rate of about 75% and leave significant unused reserves. Auxiliary gas turbine firing (GTA) between the turbine and the waste heat boiler utilizes residual oxygen contained in the turbine exhaust gases and improves the fuel utilization rate in the plant to over 96%.

The SAACKE portfolio includes:

• Burners and combustion systems for waste heat and water tube boilers, and isolated combustion chambers with exhaust gas heat exchangers.
• Burners and combustion systems for heating turbine exhaust gases in power plants and for heating process air in dryers.
• Individual arrangements/constructions according to customer requirements
• Use of proven standard burners for gas and liquid fuels

In general, both surface burners (GDG series) and pressure atomizer burners (e.g., DDZG A and DDZG GT series) are available for auxiliary GTA firing systems in various configurations, which can be perfectly adapted to any installation. Thus, neither high GTA temperatures up to 650°C nor particularly low pressures of only a few mbar behind the turbine pose an obstacle to utilizing the valuable energy contained in the exhaust gases. They are always individually tailored to the gas turbine installation and enable efficient use even in small installation spaces.

In addition to simultaneous operation of the turbine and burner, individual operation of both components is also possible. In any case, an advanced control system ensures optimal burner operation, complete combustion, and the lowest emission values. SAACKE GTA technology guarantees maximum availability and very long service life, whether it is for simple emergency firing or heavy continuous operation with 4 burners and a capacity of 160 MW.

Hydrogen Drying Processes

Focus on efficiency and environmental friendliness
Direct drying processes are used in many industries, such as gypsum, wood, sugar, cement, potash, or phosphate industries. In this drying process, flue gases from combustion come into direct contact with the material being dried.

For drying processes, SAACKE offers hot gas generators and suitable burners for a wide range of fuels. SAACKE has many years of experience in combustion for drying processes and can therefore offer suitable low NOx solutions for standard and special fuels, as well as extremely efficient hot gas generators. Increased efficiency and environmental friendliness are always the focus when developing combustion systems.

The SAACKE portfolio includes:

Hot gas generators with standard fuels for:

• Drying phosphates
• Drying potassium or sodium chloride
• Drying and calcining gypsum
• Drying gypsum and fly ash in FGD systems
• Other thermal processing of materials in flash dryers or fluidized bed, fluidized bed or other process engineering devices

Hot gas generators with dust burners for:

• Drying ore
• Drying sugar beet pulp
• Drying and calcining gypsum
• Drying sand (also for asphalt mixing plants)
• Drying chipboards

Hot gas generators with gas burners for:

• Iron ore pelletizing plants
• Coal grinding installations (PCI process in the steel industry)
• Installations for grinding and drying blast furnace slag