This study presents the idea of using a porous media burner to improve the oxy-methane combustion reaction rate and broaden the stability limit. Numerical studies on the premixed combustion of CH₄/O₂/CO₂ in a two-layer porous medium burner using a two-dimensional symmetrical volume-average model with the skeleton mechanism based on OpenFOAM. The combustion characteristics of burners with variable cross-sectional (VC) and straight cylindrical (SC) structures were compared, including stable range, temperature field, thermal cycle efficiency, and CO emissions. It is confirmed that the cross-sectional structure is effective for broadening the stable range, and the broadening rate is more than 4 times. As more heat is lost from the outlet due to the increased cross-section, the solid-phase temperature of VC is lower than that of SC. As a result, the flame temperature of VC will be about 200 K lower than that of SC under the condition of insulated walls. It also leads to a reduction of about 2% in thermal cycle efficiency compared with SC. Meanwhile, it is shown that the VC structure slightly increases CO emissions at low thermal power but is smaller than that of SC at high power. When the wall heat loss of the burner is considered, the VC structure is still effective for improving the stable range. In addition, the VC structure slightly affects flame tilt and temperature uniformity at the burner outlet when the thermal power is large. It is confirmed that the VC structure is effective for increasing the power adjustment range and reducing pollutant emissions at high power.

Combustion in a porous medium can be beneficial for enhancing reaction rate and temperature uniformity. Therefore, considering the combination with oxy-fuel combustion can address some shortcomings in oxy-fuel burners, a cylindrical two-layer porous burner model is established based on OpenFOAM in this paper. A two-temperature equation model is adopted for the simulation of the heat transfer process. The CH₄ skeletal kinetic mechanism is adopted for complex chemistry integration based on OpenSMOKE++. Corresponding experimental methods were used for complementary studies. The walls of the burner are wrapped with three types of thermal insulation materials to present different levels of heat loss. The results show that considering the convection and radiative heat loss of the burner wall, the temperature near the wall is reduced by more than 300 K compared to the adiabatic condition. As a result, the flame propagation speed and CO oxidation rate slowed down. The stable range will be destructively narrowed by more than 50%, and CO emissions will increase by more than 10 times. These defects will be aggravated by increasing the diameter of the burner. It is observed that when the diameter of the burner increases from the initial 5 cm to 10 cm, the effect of heat loss on the stable range is insignificant.

In the steel industry, reheating furnaces are a significant source of carbon emissions. Co-firing natural gas and ammonia in reheating furnaces reduces carbon emissions and mitigates ignition difficulties and the limited flammability range of ammonia. This research develops a three-dimensional model for combustion, fluid dynamics, and heat transfer in a reheating furnace to investigate slab heating and emission with a natural gas/ammonia blended fuel. Numerical results demonstrate that, under constant calorific value conditions, the average temperature of the discharged slab decreases following ammonia blending, with the greatest temperature differential of 110 K achieved at a 10% ammonia blending ratio. Moreover, as the ammonia blending ratio increases from 0 to 40%, the mass fraction of CO first rises and subsequently declines, ultimately decreasing by 18%. Meanwhile, the CO₂ emissions at the outlet decrease by 17.6% to 40.7%. The mass fraction of unburned NH₃ rises to 0.0271, whilst NO_x emissions diminish from 49.47 ppm to 14.23 ppm. These changes are attributed to the low combustion efficiency and burning rate of ammonia, coupled with the reduced furnace temperature during ammonia-blended combustion, which weakens radiative heat transfer. Thus, optimizing the equivalence ratio along with applying hydrogen can improve the thermal efficiency of the reheating furnace. This study provides insight into the operational characteristics of a full-scale walking-beam reheating furnace operating under natural gas-ammonia co-firing conditions, providing theoretical guidance for enhancing the thermal efficiency of furnaces.

As a renewable hydrogen carrier with a high volumetric energy density, ammonia has emerged as a potential zero-carbon alternative fuel to fossil fuels in the pursuit of carbon neutrality. However, the narrow ignition range and high pollutant emissions limit the application of ammonia in the heating furnaces. This study develops a 3D pore-scale mathematical model for ammonia-methane premixed combustion in a double-layer porous medium rather than a traditional burner. After the numerical model was validated for feasibility and accuracy, the combustion performance of methane/ammonia blends in a double-layer porous medium is examined under various operating conditions. The numerical results indicate that an equivalence ratio of 1.0 is most beneficial for the complete combustion of double-layer porous media, whereas the amount of ammonia has little effect on the peak combustion temperature, which is close to 1920 K. In addition, the ammonia concentration notably influences CO and CO₂ emissions; however, NO_X emissions exhibit a nonmonotonic trend, increasing initially and then decreasing, peaking at approximately 10% ammonia concentration. In fuel-rich conditions (equivalence ratio >1.0), NO_X emissions are effectively suppressed due to the enhanced reduction of NO by CO, H₂, and other radicals. This study aims to provide scientific guidance for enhancing the application of porous medium methane/ammonia combustion technology in industrial furnaces.