High temperatures, low emissions: The AdReku research project has developed an innovative recuperative burner that can make a decisive contribution to the energy transition in industry. The key components come from the 3D printer.
In the research laboratory, the innovative AdReku burner shows what it can do: As it gradually switches from natural gas to hydrogen, a camera analyzes the flame to ensure that it delivers the required heat and quality for industrial processes.
What makes AdReku special is that it can use natural gas and hydrogen in parallel. This means that companies can continue to use natural gas and prepare for the transition to hydrogen at the same time. This makes the burner an important bridge between fossil fuels and a more climate-friendly hydrogen future.
Advanced gas mixing system: less nitrogen oxides, more efficiency
At the heart of the burner is a two-channel mixing unit that enables the parallel use of natural gas and hydrogen. It ensures that fuel gases and air are optimally mixed, which significantly reduces nitrogen oxide emissions. At the same time, the design enables combustion at higher temperatures, which makes heat transfer more efficient.
Calculations show that optimized burner systems with a preheating temperature of 1,000 degrees Celsius can save up to 12 percent energy compared to conventional systems with 600 degrees Celsius. Compared to cold air burners, the savings are even up to 50 percent.
Improved heat transfer thanks to innovative materials
A central component of the AdReku burner is the recuperator, which ensures efficient heat transfer. It is made from three different materials, which are used depending on the temperature:
- Ceramic near the burner, where temperatures are highest.
- Stainless steel at medium temperatures.
- Copper, which ensures optimum thermal conductivity at lower temperatures.
This combination of materials significantly improves the efficiency of the system.
3D printing: the key to increasing efficiency
Both the mixing unit and the recuperator were manufactured using 3D printing. This makes it possible to create complex structures that offer a larger transfer surface with the same amount of space and significantly increase heat transfer.
Although 3D printing is currently still time-consuming and cost-intensive, production costs are falling as the technology develops. At the same time, the improved systems reduce fuel consumption, which means that the higher acquisition costs are quickly amortized.
Awards for innovation and sustainability
In 2024, the AdReku team was awarded the Innovation Prize of the state of North Rhine-Westphalia in the “innovation2business” category for this groundbreaking development. The AdReku burner was already a finalist for the German Future Prize in 2023 - proof of the importance and future viability of this project.
