In recent years, there has been a growing social interest towards achieving carbon neutrality from the perspective of environmental conservation. In 2020, the government set a goal of “reduce the overall greenhouse gas emissions in Japan to zero by 2050.” Approximately 1.12 billion tons of carbon dioxide (CO2) are emitted annually in Japan, of which 35% is from the industrial sector. In order to contribute to the reduction of CO2 emitted during the combustion process of industrial furnaces in these sectors, Taiyo Nippon Sanso Corporation developed the “hydrogen-oxygen burner.” We interviewed Mr. Masashi Yamaguchi, Chief Researcher, Development Division, Oxy-fuel Combustion Development Department, Yamanashi Technology Solution Center, and Mr. Akira Morokuma of the Engineering Division of the same department.
Mr. Morokuma Mr. Yamaguchi
Making best use of the knowledge and technologies in combustion we have developed over many years
Yamaguchi: As an industrial gas manufacturer, we have deepend our cooperation with various industries. Through the years, we have accumulated technologies and knowledge especially in the area of oxygen combustion. From 2014 to 2019, we participated in the Cross-ministerial Strategic Innovation Promotion Program (SIP), a national project led by the Cabinet Office, and developed the technology to use ammonia as fuel for industrial furnaces. On the other hand, while the development of hydrogen combustion technology was advanced by overseas companies, we have been quick to take the lead in the development of hydrogen combustion technology in Japan using our experience and and know-how. We have been striving to supply products that are useful to various industries and that have a low environmental impact.
Around 2020, we began the joint development of hydrogen-oxygen burners for glass melting furnaces with a major glass company in Japan. In 2022, after feasibility evaluations in Japan and overseas, we confirmed that these burners show no problems in performance. After taking these steps, we have now launched the hydrogen-oxygen burners in the market.
Benefits of hydrogen-oxygen burners
Morokuma: In general, burners are used in industrial furnaces for melting, heating, and thermal treatment in the steel, glass, and other industries mainly using hydrocarbon fuels such as natural gas. The hydrogen-oxygen burners that we have developed deliver the same level of combustion performance as the existing burners that use hydrocarbon fuels, and thus ensure stable operation. In addition, the use of hydrogen instead of conventional hydrocarbon as a fuel reduces CO
2 emissions to virtually zero.
Furthermore, with the hydrogen-oxygen burners, which enrich oxygen during combustion, the combustibility is controlled, and thus the fuel consumption can be reduced compared to combustion with normal air. In the aspect of facility management, installation of hydrogen-oxygen burners provides financial benefit as they can be used in conjunction with existing natural gas burners.
Mr. Yamaguchi (right) and Mr. Morokuma working on technology development
Repeating the PDCA cycle to solve problems
Yamaguchi: In development, we wanted to dispel the customers’ concerns about hydrogen-oxygen burners, while aiming towards supplying products with a high level of performance compared to existing burners. To achieve that, we have been steadily repeating the PDCA cycle of designing, prototyping, experimenting, and evaluating.
For example, customers tend to think hydrogen “carries a high level of risk and is difficult to handle,” and may cause a large-scale explosions when compared to natural gas and propane gas.
Therefore, we spent a great deal of time gradually scaling up the models starting with a small-scale model to examine the differences in combustion rates and fuel gas characteristics when designing burners. We also repeatedly experimented to improve on safety. Although this may have been a roundabout way of the development process, but we believe this was the fastest way of development in the end.
Hydrogen-oxygen burning flame
Aiming to be a company that can support customers and society
Morokuma: Through various experiments and evaluations, we were able to finalize the models of the hydrogen-oxygen burner products. The products can be customized according to the conditions of the customer’s facility and industrial furnace: from a burner with 100% oxygen set as the oxidizing gas to one where oxygen is appropriately enriched. We will continue consulting, cooperating and collaborating with customers to test durability and evaluate quality using security cameras and other available devices so that we can further improve the products to meet the specific requirements of different industries.
Yamaguchi: There is a growing trend of customers to choose products that use materials and technologies that support carbon neutrality, such as products that do not use hydrocarbon fuels, regardless of the size of the supplier. Using such products not only increases the added value of the products, but also improves the reputation of the company. Efforts toward carbon neutrality are making great strides around the world. Taiyo Nippon Sanso Corporation will continue to develop products that can contribute to a carbon-neutral society by applying our accumulated technologies, know-how and ideas, as seen in the case of developing hydrogen-oxygen burners, which greatly support the reduction of CO2 emissions from industrial furnaces.