Optimization of a hydrogen burner to minimize NO_x emissions using computational fluid dynamics and response surface methodology

The development of low-emission hydrogen combustion systems is critical for advancing carbon–neutral energy solutions. However, optimizing burner geometry to minimize NO_x emissions remains a complex challenge due to intricate interactions between fluid dynamics, heat transfer, and chemical kinetics. This study presents a systematic computational framework that integrates high-fidelity reacting flow Computational Fluid Dynamics (CFD) with Response Surface Methodology (RSM) to optimize a pure hydrogen-fueled burner. We employed high-accuracy CFD models proposed in previous work and performed a variance-based sensitivity analysis to identify key geometric parameters, achieving highly accurate response surfaces. The optimal design, validated through CFD simulation, exhibited strong agreement with RSM prediction, with a discrepancy in NO_x emissions of less than 1.2%. Notably, the optimized burner achieved a 38.2% reduction in NO_x emissions, attributed to enhanced fuel–air mixing and improved thermal management in the primary combustion zone. These findings highlight the effectiveness of CFD-driven optimization in significantly reducing NO_x emissions and present a robust methodology for designing high-performance hydrogen burners, thus advancing the development of more efficient and sustainable combustion technologies for a carbon–neutral energy future.