WO2023247681A1 - Ensemble kit de modernisation d'hydrogène pour brûleur à gaz - Google Patents

Ensemble kit de modernisation d'hydrogène pour brûleur à gaz Download PDF

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Publication number
WO2023247681A1
WO2023247681A1 PCT/EP2023/066921 EP2023066921W WO2023247681A1 WO 2023247681 A1 WO2023247681 A1 WO 2023247681A1 EP 2023066921 W EP2023066921 W EP 2023066921W WO 2023247681 A1 WO2023247681 A1 WO 2023247681A1
Authority
WO
WIPO (PCT)
Prior art keywords
sensor
combustion
hydrogen
kit assembly
gas
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/EP2023/066921
Other languages
English (en)
Inventor
Job Rutgers
Saskia BÖRGER
Jelmer Woudstra
Mehmet Kapucu
Andrea Pisoni
Siebe POSTMA
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
BDR Thermea Group BV
Original Assignee
BDR Thermea Group BV
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from EP22180337.2A external-priority patent/EP4296570A1/fr
Priority claimed from EP22180327.3A external-priority patent/EP4296568A1/fr
Priority claimed from EP22180361.2A external-priority patent/EP4296573A1/fr
Priority claimed from EP22180332.3A external-priority patent/EP4296569A1/fr
Priority claimed from EP22180353.9A external-priority patent/EP4296572A1/fr
Priority claimed from EP22180344.8A external-priority patent/EP4296571A1/fr
Priority claimed from EP22180366.1A external-priority patent/EP4296575A1/fr
Priority claimed from EP22180372.9A external-priority patent/EP4296576A1/fr
Priority claimed from EP22180363.8A external-priority patent/EP4296574A1/fr
Priority claimed from EP22188116.2A external-priority patent/EP4317778A1/fr
Priority claimed from EP22188124.6A external-priority patent/EP4317780A1/fr
Priority claimed from EP22188119.6A external-priority patent/EP4317779A1/fr
Priority claimed from EP22188115.4A external-priority patent/EP4317777A1/fr
Application filed by BDR Thermea Group BV filed Critical BDR Thermea Group BV
Priority to EP23733993.2A priority Critical patent/EP4544227A1/fr
Publication of WO2023247681A1 publication Critical patent/WO2023247681A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23D—BURNERS
    • F23D14/00—Burners for combustion of a gas, e.g. of a gas stored under pressure as a liquid
    • F23D14/02—Premix gas burners, i.e. in which gaseous fuel is mixed with combustion air upstream of the combustion zone
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N5/00—Systems for controlling combustion
    • F23N5/02—Systems for controlling combustion using devices responsive to thermal changes or to thermal expansion of a medium
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N5/00—Systems for controlling combustion
    • F23N5/02—Systems for controlling combustion using devices responsive to thermal changes or to thermal expansion of a medium
    • F23N5/08—Systems for controlling combustion using devices responsive to thermal changes or to thermal expansion of a medium using light-sensitive elements
    • F23N5/082—Systems for controlling combustion using devices responsive to thermal changes or to thermal expansion of a medium using light-sensitive elements using electronic means
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N5/00—Systems for controlling combustion
    • F23N5/24—Preventing development of abnormal or undesired conditions, i.e. safety arrangements
    • F23N5/242—Preventing development of abnormal or undesired conditions, i.e. safety arrangements using electronic means
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23C—METHODS OR APPARATUS FOR COMBUSTION USING FLUID FUEL OR SOLID FUEL SUSPENDED IN  A CARRIER GAS OR AIR 
    • F23C2900/00—Special features of, or arrangements for combustion apparatus using fluid fuels or solid fuels suspended in air; Combustion processes therefor
    • F23C2900/9901—Combustion process using hydrogen, hydrogen peroxide water or brown gas as fuel
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23D—BURNERS
    • F23D2203/00—Gaseous fuel burners
    • F23D2203/10—Flame diffusing means
    • F23D2203/101—Flame diffusing means characterised by surface shape
    • F23D2203/1012—Flame diffusing means characterised by surface shape tubular
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23D—BURNERS
    • F23D2203/00—Gaseous fuel burners
    • F23D2203/10—Flame diffusing means
    • F23D2203/102—Flame diffusing means using perforated plates
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N2231/00—Fail safe
    • F23N2231/10—Fail safe for component failures
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N2233/00—Ventilators
    • F23N2233/06—Ventilators at the air intake
    • F23N2233/08—Ventilators at the air intake with variable speed
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
    • F24H15/00—Control of fluid heaters
    • F24H15/40—Control of fluid heaters characterised by the type of controllers
    • F24H15/493—Control of fluid heaters characterised by the type of controllers specially adapted for enabling recognition of parts newly installed in the fluid heating system, e.g. for retrofitting or for repairing by replacing parts
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
    • F24H8/00—Fluid heaters characterised by means for extracting latent heat from flue gases by means of condensation

Definitions

  • the invention relates to a retrofit kit assembly for converting a hydrocarbon gas combustion appliance, in particular a gas boiler, and more particularly for a condensing gas boiler, to a combustion appliance for combustion of fuel gas comprising more than 20 mol% hydrogen. Additionally, the invention relates to a combustion appliance comprising said retrofit kit assembly. Furthermore, the invention relates to the use of the retrofit kit assembly for converting a natural gas combustion appliance, in particular a natural gas boiler, into a combustion appliance, in particular boiler, for the combustion of pure hydrogen and to a method for retrofitting a combustion appliance.
  • the emission of carbon dioxide is one of the most relevant factors contributing to the pollution in environment. Since the contribution from the building sector is continuously increasing in the last decades, there is the need to reduce CO 2 emissions from this sector. Heating of spaces and heating of water are the two major causes of energy consumption and CO2 emission from the building sector. Inefficient boilers and carbonintensive power can further worsen this problem.
  • gas boilers combust gas fuel to heat water for domestic use and/or central heating systems in buildings.
  • the market is looking into more sustainable alternatives with a lower C02-footprint to combusting natural gas.
  • One of these alternatives is combusting pure hydrogen.
  • gas boilers combusting pure hydrogen i.e. hydrogen boiler
  • gas boilers combusting pure hydrogen are boilers to which fuel gas is supplied that comprises at least 98 mol% hydrogen.
  • natural gas (or propane) boilers on the market which are only suitable to combust up to 20 mol% hydrogen into the gas blend (according to the specifications).
  • Poka Yoke ideally ensures that the product or process design itself prevents mistakes before they occur.
  • Good Poka Yoke devices in addition are simple and inexpensive.
  • KR 2007 0097930A is directed to providing a gas burner and a flame detection method which ensures safe use when using and allowing for a visual check of the flame when ionization does not occur during combustion, by adding a fuel additive for generating an ion current during combustion and discloses a mixing pipe in which an air supply pipe and a fuel supply pipe are installed in communication with each other, an air supply fan connected to one end of the air supply pipe, and a gas burner that is connected to the other end of the air supply pipe to burn the mixture.
  • a fuel additive supply pipe is installed in communication with the mixing pipe so that the fuel additive can be supplied and mixed.
  • the fuel additive supply pipes are installed in the air supply pipe of the gas burner.
  • the gas burner further comprises an air supply fan and a mixing pipe in which a fuel supply pipe for supplying fuel is installed, and a burner for generating a flame.
  • the air supply fan is coupled to one end of the air supply pipe of the mixing pipe to supply air to the air supply pipe.
  • the fuel supply pipe supplies hydrogen fuel, which is fuel.
  • the fuel additive supply pipe is installed on one side of the outer circumferential surface of the fuel supply pipe to communicate with the fuel supply pipe. So, hydrogen fuel as fuel is supplied through the fuel supply pipe in the fuel supply direction, and hydrocarbon fuel (LNG, LPG, propane gas, butane gas, etc.) as a fuel additive is supplied in the fuel additive supply direction. By being supplied through the fuel additive supply pipe, it is mixed with the fuel, hydrogen fuel.
  • the fuel supply pipe is installed on one side of the outer circumferential surface in communication with the air supply pipe, thereby supplying hydrogen fuel and a small amount of hydrocarbon fuel as a fuel additive to the inside of the mixing pipe.
  • the mixing pipe further is connected to the fuel additive supply pipes spaced apart from each other on the outer circumferential surface of the air supply pipe so that the fuel additive is added inward in the fuel additive supply direction.
  • a small amount of the supplied fuel additive is ionized during combustion in the burner combustion unit to generate an ion current in the flame, so that the flame detection unit can detect the ion current.
  • the ignition device unit is composed of an ignition rod and an ignition transformer
  • the flame detection unit is composed of a 22.06.2023 4 flame detection rod (frame rod) and an ion current measuring device.
  • the ion current measuring device is connected to the controller.
  • the ignition rod ignites the mixture discharged from the flame forming mat by high voltage discharge, and the flame detection rod senses ion current generated from the ignited flame.
  • the ion current measuring device detects the magnitude of the ion current generated when hydrocarbon fuel, which is a fuel additive, is burned through the flame detection rod, and transmits it to the controller so that the controller controls the burner.
  • KR 2007 0097930A discloses that by doing so, it is possible to ensure the safety of the burner.
  • the porosity is particularly preferably provided that this less than 60%, preferably between 40% and 50%.
  • the gas is also preferably provided that this at least 25%, preferably at least 50%, particularly preferably at least 75%, very particularly preferably more than 90% hydrogen is formed.
  • the each remaining portion preferably consists of natural gas or the like. 22.06.2023 5
  • US 2022/003406 A1 is directed to a system and process for hydrogen combustion for industrial or steam generation applications and a burner design that is retrofitted into existing burner systems and discloses a system and process for hydrogen combustion, and more particularly to a combustion burner or retrofit kit combustion system and process having at least one burner nozzle using pure hydrogen as a primary fuel source.
  • the system and process may also use the primary pure hydrogen fuel with one or more secondary fuels and/or a flame temperature reducing fluid for lowering a bulk flame temperature of the burner or retrofit kit combustion system.
  • the object of the invention is therefore to provide a retrofit kit assembly that is safe and easy to implement and that is effective in converting a natural gas combustion appliance, in particular a boiler (hydrocarbon gas boiler), into a hydrogen combustion appliance, particular a hydrogen gas boiler while reducing the risk of human error, in particular the simple, safe and effective reduction of the risk of flashbacks, in particular at the first operation of the retrofitted combustion appliance.
  • a natural gas combustion appliance in particular a boiler (hydrocarbon gas boiler)
  • a hydrogen combustion appliance particular a hydrogen gas boiler
  • Connected in the accordance with the invention means that it can be connected structurally, directly, indirectly and/or functionally.
  • the control unit can be attached to the frame structure and/or to a manifold discussed below or another component of the kit assembly. In all cases the control unit is connected to the frame structure.
  • Providing control unit for controlling the burner for hydrogen combustion has the advantage that the installer does not need to adapt and/or to exchange the control unit of the combustion appliance. Thus, there is no risk that hydrogen combustion will be controlled on the basis of control signals sued for hydrocarbon gas combustion avoiding risky situations.
  • the connection of the control unit and the frame structure can be such that the control unit is moved when the frame structure is moved.
  • a firmly connection between the control unit and the frame structure means that if one of said components is moved the other component is also moved.
  • the retrofit kit assembly according to the invention reduces a number of human error sources such as inadvertent error, misunderstanding, forgetfulness, misidentification, and inexperience by reducing the number of parts to be disconnected, replaced and connected to a minimum.
  • the present retrofit kit assembly is ready to be mounted in a combustion appliance, in particular a (natural) gas boiler, by simply fixing the frame structure to a suitable housing of the combustion appliance.
  • the modular nature of the assembly allows the possibility to provide a combination of different components suitable for a hydrogen gas combustion appliance depending on and optimized to the configuration and working principle of the respective (natural gas) combustion appliance to be converted.
  • the retrofit-kit assembly according to the invention has overall lower skill-requirements for the conversion which leads to increased safety and reduced conversion time.
  • Combustion appliances such as gas boilers using natural gas are criticized due to their carbon dioxide emissions.
  • the use of more than 30% hydrogen mixtures of natural gas up to 100 % hydrogen has the advantage to reduce the CO2 footprint in heating solutions.
  • the conversion needs to be sustainable. This is achieved by using the retrofit kit assembly and not exchange the entire combustion appliance, in particular boiler, which still has a lifespan of its own.
  • a retrofit kit assembly includes all the hardware and software that enables safely changing the content of the fuel supply line of an existing combustion appliance.
  • the retrofit kit assembly is contained to the appliance to be retrofitted itself. In other words, there is no need to undertake major modifications outside the appliance, such as the addition of additional fuel or fuel additive supply lines or sources.
  • the retrofit kit assembly is suitable for combustion appliances for providing domestic hot water and/or heating, in particular central heating.
  • the combustion appliance is a modulating combustion appliance, in particular boiler, meaning that the heating output can be adapted to a heating demand.
  • a modulating combustion appliance is able to modulate its power in real-time in order to provide the exact level of heat needed.
  • a modulating combustion appliance, such as a boiler is more energy-efficient than a non-modulating boiler in terms of fuel gas usage. The modulating combustion appliance therefore doesn’t continuously work at 100% of its power.
  • the modulating combustion appliance only uses a percentage of its power and only how much the modulating combustion appliance needs to maintain a set temperature. The amount the modulating combustion appliance uses depends on the ambient temperature, the external temperature, the number of people currently in the household, and other similar parameters.
  • the combustion appliance is a heating appliance wherein the output temperature is > 85 °C, in particular 90 to 100 °C. 22.06.2023 9
  • the combustion appliance has a output power of 4 kW to 2 MW, in particular 4 kWto 100 kW, 4 kWto 80 kW, 4 kWto 60 kW, 4 kWto 50 kW, 4 kWto 40 kW; in particular 6 kW to 100 kW, 6 kW to 80 kW, 6 kW to 60 kW, 6 kW to 50 kW, 6 kW to 40 kW; in particular 12 kW to 100 kW, 12 kW to 80 kW, 12 kWto 60 kW, 12 kWto 50 kW, 12 kW to 40 kW; in particular 20 kW to 40 kW; in particular 30 kW to 2 MW, in particular 30 kW to 150 kW, in particular 30 kW to 320 kW, in particular 40 kW to 150 kW, in particular 40 kW to 320 kW, in particular 45 kWto 150 kW, in particular 45 kWto 320 kW.
  • the retrofit kit according to the invention allows a constructively easy pre-determined orientation of the location of the manifold structure, in particular of the first and second connection, and thereby provides a technical behaviour-shaping constraint in view of safety critical parts for the combustion of hydrogen, thereby reducing safety risks, such as the incorrect connection of hydrogen and air.
  • Such an embodiment has the advantage that it also can ensure in an easy way that the requirements of the hydrogen-fire gas appliance guide PAS4444:2020 are fulfilled according to which a post blower mixing is needed.
  • the manifold structure is provided with a connection for fuel gas (i.e. for a gas valve) that is located downstream the connection for receiving air (i.e. for a fan element). Downstream refers to the air flow in the manifold.
  • the embodiment has the further advantage, that misidentification, forgetfulness, or inadvertent error are further reduced by way of product design, thus reducing defects caused by not following procedures, missing or wrong parts, improper setup, and errors in part setup itself.
  • the burner can be connected or is connected to the manifold structure at the outlet portion for receiving a gas mixture to be combusted.
  • a compact shape retrofit kit assembly is achieved.
  • this embodiment has the advantage that relevant parts are pre-mounted in production, which allows for thorough quality testing and thus leads to a lower number of parts needing to be assembled and tested during conversion. This decreases set-up time even further with associated reduction in set-up errors and thus even further improved quality and safety.
  • a functional connection can be by way of at least one signal of the control unit during setup which confirms the proper hydrogen parameter settings of the to the installer.
  • a gas burner configured for hydrogen needs be able to work at full power when there is a high heat demand.
  • the gas burner should also be able to work at a lower power level, for example at 50% or 25% or 20% or 10% of the maximum power level, when there is only a low heat demand, another property of hydrogen is that the combustion temperature is about 300°C higher than the combustion temperature of methane.
  • the burner deck temperature needs to stay below 585°C, the auto-ignition temperature of hydrogen at all times.
  • a stable flame needs to be present taking account the high flame speed of hydrogen.
  • the gas burner can preferably be a pre-mixed gas burner, in particular a surface stabilized pre-mixed gas burner.
  • Pre-mixed means, that a mixture of the fuel gas and the gas is supplied to the burner.
  • the pre-mix gas burner is a type of burner where the fuel gas and the combustion air are mixed together before entering a perforated area and/or the combustion chamber.
  • the fuel gas is preferably delivered at a constant pressure, and the combustion air is supplied through a separate air inlet.
  • the fuel and air are mixed to form a homogeneous mixture before combustion.
  • This burner has the advantage that it allows for efficient combustion, in particular by way of an easy control of the stoichiometric ratio.
  • the burner also allows for low emissions of e.g. nitrogen oxide (NOx) due to the homogenous mixture of the fuel and air. In addition, it allows for a stable flame.
  • NOx nitrogen oxide
  • Pre-mix gas burners have the further advantage that a retrofit kit comprising a pre-mix gas burner enhances safety by constructively allowing for pre-selected components and the right adjustment for hydrogen as well as a pre-selected end-design of the converted combustion appliance which allows optimized performance for the gas combustion in terms of efficiency and emissions. It further does not require additional secondary fuels or temperature fluids to reduce unwanted emission profiles.
  • the gas burner is a port injection burner.
  • Port injection also referred to as late mixing means within this application that fuel is injected into the intake manifold or port and mixes with air just before entering the combustion chamber. This is still considered late mixing, as the fuel and air are not premixed, but rather combined just prior to combustion. 22.06.2023 11
  • the gas burner is an injection or direct injection gas burner.
  • Injection gas burner means that operates by injecting fuel gas into the combustion chamber or burner nozzle separately from the combustion air. The fuel gas and air mix and ignite within a combustion chamber.
  • the gas burner is preferably not an injection or direct injection gas burner. Injection burners may require additional measures to ensure flame stability, especially at low firing rates or when using certain fuel types. In addition, the combustion tends to be less efficient compared to a pre-mix gas burner.
  • the burner deck geometry can be adapted such that the temperature stays below the auto-ignition temperature of hydrogen at all times and that avoids a flame lift off.
  • This can be achieved for example by a burner deck that comprises a sheet enclosing a chamber and having at least one protrusion with a through hole.
  • the through hole is fluidically connected with the chamber wherein the protrusion comprises a concave section and/or a convex section, in particular concave section and convex section.
  • the concave and convex sections determine a particular aerodynamic of the protrusion and the corresponding through hole.
  • a sort of Venturi effect is created when the gas mixture passes through the protrusion from the chamber of the burner to outside the gas burner.
  • This aerodynamic helps the mixed flow to pass with a reduced local pressure loss and the flow is guided towards the outside without any recirculation.
  • the gas mixture that passes through the through hole of the protrusion maintains the temperature below the auto-ignition of the fuel gas, i.e. hydrogen.
  • There are no local pressure drops that could cause hot spots like it happens with the thin edge of a natural gas burner deck that has an anchoring effect for the flame. In this way, a flame lifting behaviour is prioritized instead of an anchor-feature. Accordingly, using such burner deck, a better fluid dynamic and thermal behaviour is obtained when and where the gas expands due to the combustion. 22.06.2023 12
  • the protrusion can protrude in a direction away from the chamber.
  • the protrusion comprises a proximal portion close to the sheet, a distal portion away from the sheet and a middle portion located between the proximal and the distal portion.
  • the concave section of the protrusion includes the proximal portion and can include a part of the middle portion, whereas the convex section includes the distal portion and can include another part of the middle portion.
  • the area of the transverse cross section is decreasing in a direction away from the chamber.
  • the area of the transverse cross section is, in particular essentially, constant in the direction away from the chamber.
  • the area of the transverse cross section is increasing in the direction away from the chamber.
  • the transverse cross section corresponds with a plane that is orthogonal to a central axis of the protrusion.
  • the protrusion can have a Venturi shape and/or a double truncated cone shape. This is advantageous for further limiting the flashback.
  • the concave section and the convex section can be arranged coaxially.
  • the burner deck is configured such that the gas-air mixture can merely flow out through the protrusion from the chamber to a combustion chamber of the gas burner.
  • the protrusion can extend over a length comprised between 15% to 25%, preferably 20%, of a thickness value of the sheet of the burner deck, in particular in radial direction with respect to a burner central axis. In this way, the risk of flashback is further reduced.
  • less than 20%, in particular less than 19%, or less than 15%, for example less than 12.0% or for example less than 10.0% of the surface area of the burner deck is formed by a combined surface area of the holes. More than 5.0% of the surface area of the burner deck is formed by a combined surface area of the holes. Less than 7.0%, for example less than 5.0% or for example less than 4.0% of the surface area of the burner deck is formed by a combined surface area of the holes. More than 1 .0% 22.06.2023 13 of the surface area of the burner deck is formed by a combined surface area of the holes.
  • a preferred range of the combined surface area of the holes is less than 20% and more than 15%, in particular less than 19% and more than 16%.
  • the perforated area preferably has a combined surface area of holes ratio to the total surface area of the burner deck of more than 0% to up to 20%, in particular more than 0% to up to 15%, in particular more than 0 % to up to 10%, in particular more than 0% up to 7 %, in particular more than 0% up to 5%, of the surface area of the burner deck.
  • the ratio is 0,5% up to 10%, 0,5% up to 7%, 0,5% up to 10%, in particular 1 % to 2%.
  • Further suitable ranges are between 3% and 15%, preferably between 3% and 7% or between 5% and 15%.
  • the flow rate of the air-hydrogen mixture through the openings has to be chosen such that the combustion of the hydrogen can be stabilized on the burner deck of the gas burner.
  • Another property of hydrogen that has to be considered is that the combustion temperature is about 300°C higher than the combustion temperature of methane.
  • the burner deck becomes much too hot for materials typically used in gas burners. In particular, the burner deck can reach a temperature of about 585°C, so that hydrogen can auto-ignite.
  • the frame structure can be fixable to the housing of a heat exchanger present in a combustion appliance, in particular a (natural) gas boiler.
  • a heat exchanger facilitates the transfer of heat derived from the combustion 22.06.2023 14 of fuel gas and air present in circulating conduits. Therefore, the housing of the heat exchanger usually contains the burner of the combustion appliance, in particular gas boiler, for combusting the fuel gas. It is noted that the main factors distinguishing a natural gas combustion appliance from a hydrogen gas combustion appliance are related to the combustion aspects of the fuel gas and that the functioning of the heat exchanger itself remains basically the same.
  • the retrofit kit assembly can comprise a UV-sensor for flame detection.
  • the burner configured for hydrogen combustion can preferably be fixed to the frame structure.
  • the retrofit kit assembly reduces the work amount for converting the combustion appliance to a hydrogen combustion appliance and reduces the danger that the retrofit kit assembly is assembled incorrectly. In particular, more components can be mounted during production, further reducing the time needed for conversion and further reducing the risk of human error in assembly.
  • a further advantage is that fewer individual parts need to be connected and disconnected and thereby further reducing potential errors, in particular in making a proper connection, or connecting the right parts. Additionally, the pre-assembled parts can already be tested in the factory and checked on leakage.
  • the frame structure comprises a first portion and a second portion, wherein the burner is fixed to said first portion.
  • the second portion extends longitudinally from the first portion.
  • the frame structure being shaped as to cover at least partially, in particular fully, the housing, in particular a burner chamber, of the combustion appliance.
  • the frame structure, and specifically the second portion of the frame structure is formed as a plate i.e. as a front cover for the internal housing of the combustion appliance.
  • the frame structure can work as a front cover of said heat exchanger.
  • the first portion of the frame structure is interposed, in particular in flow direction of the air and fuel gas mixture, between the burner and the outlet portion of the manifold structure.
  • any misalignments or misplacements are at the same time made harder to do and at the same time makes detection very easy without requiring an in-depth analysis as would be required if all connections undone and done would need to be inspected to detect a defect in the conversion setup.
  • a further advantage is that fewer individual parts need to be connected and disconnected and thereby further reducing potential errors, in particular in making a proper connection, or connecting the right parts.
  • Fuel gas can comprise more than 20 mol% hydrogen.
  • fuel gas can comprise more than 50 mol%, in particular more than 90 mol% hydrogen or be pure hydrogen.
  • Pure hydrogen is defined as comprising at least 98 mol% hydrogen (hydrogen-fire gas appliance guide PAS4444:2020).
  • Natural gas is a naturally occurring hydrocarbon gas mixture, comprising methane and commonly further comprising varying amounts of among others higher alkanes, carbon dioxide, nitrogen, hydrogen sulfide or helium.
  • the hydrocarbon gas can also comprise or consist of propane.
  • a hydrocarbon combustion appliance is an appliance in which natural gas is combusted.
  • the control unit can be a processor or comprise at least one processor. Additionally, the control unit can comprise a printed circuit board.
  • the control unit preferably can comprise a safety control function - also referred to as control safety unit.
  • the safety control function controls the gas valve based on temperature signals and flame signal presence.
  • the safety control function is related to safety critical operations of the combustion appliance, such as ignition and operation of the burner.
  • the control unit can comprise a comfort control function - also referred to as primary control unit.
  • the comfort control function comprises at least a fan control, in particular P/l/d controlling of the fan, a control of the pump and controls eating of the heating medium (such as water) to be used for instance in a central 22.06.2023 16 heating (CH) circuit and/or a domestic hot water (DHW) production circuit.
  • CH central 22.06.2023 16 heating
  • DHW domestic hot water
  • the comfort control unit controls a heating request, temperature settings for domestic hot water and the like.
  • the control unit comprises at least the control safety unit and the primary unit.
  • the retrofit kit can optionally further comprise a burner configured for hydrogen combustion fixed to the frame structure.
  • a burner configured for hydrogen combustion fixed to the frame structure.
  • the retrofit kit comprises a manifold structure comprising means for providing an air/gas mixture and the manifold structure further comprising an inlet portion and an outlet portion, wherein the inlet portion is configured to receive the air/gas mixture and wherein the inlet portion comprises a first connection for receiving at least fuel gas, and a second connection located downstream from the first connection and wherein the outlet portion is arranged such that the air/gas mixture exits the manifold structure through the outlet portion and wherein the outlet portion is connected to the frame structure
  • the first connection can be integrally connected to the manifold structure and/or can protrude from the manifold structure.
  • the burner can be connectable or connected to the manifold structure at the outlet portion for receiving a gas mixture to be combusted.
  • the frame structure can cover the burner chamber in a sealing manner. Additionally or alternatively, the frame structure comprises a first portion and a second portion, wherein the burner is fixed to said first portion and the second portion extending longitudinally from the first portion, wherein the first portion of the frame structure is interposed between the burner and the outlet portion of the manifold structure. 22.06.2023 17
  • the manifold structure can comprise a suppressor structure.
  • the suppressor structure can be used to reduce the noise and/or the impact of flashback and/or can be an inlet silencer.
  • the first connection can be integrally connected to the manifold structure and/or can protrude from the manifold structure.
  • the retrofit kit assembly can comprise a gas valve fixed at the first connection of the manifold structure and connectable to a gas conduit. This has the additional advantage that the safety is even further increased as even fewer connections need to be made as the gas valve will only have to be connected to the (natural) gas boiler to be converted. Therefore, even more connections can be quality controlled already during production of the retro fit kit assembly itself. This further reduces defects caused by human error, such as inadvertent error, inexperience, misidentification, or forgetfulness and thereby further reduces defects in the gas valve connection safety.
  • the retrofit kit assembly can comprise a fan element fixed to the second connection of the manifold structure and connectable at least to an air conduit.
  • orientation and location of the fan element is predetermined such that the requirements of the hydrogen-fire gas appliance guide PAS4444:2020 are fulfilled by ensuring that ambient air is always sucked in in sufficient concentration I as needed. Additionally, it is prevented that an operator connects the fan element to wrong connection, namely the first connection resulting in pre blower mixing.
  • the gas valve is hydrogen ready. Due to the small size of hydrogen molecules, conventional gas valves are prone to leak. Therefore, the gas valve used in the present retrofit kit assembly is more leak tight compared to the commonly used burners for natural gas. For example, to reach the same load with hydrogen compared to natural gas, the volume flow of gas is about three times bigger. Similarly, the fan element is hydrogen ready, meaning that no electro-static discharge is present. In case of hydrogen comprising fuel gas combustion electrostatic discharge can lead to unwanted ignition of the fuel gas. 22.06.2023 18
  • the manifold structure can comprise a, in particular Venturi shaped, mixer placed downstream the second connection, i.e. downstream the fan element.
  • a, in particular Venturi shaped, mixer placed downstream the second connection, i.e. downstream the fan element.
  • the, in particular Venturi shaped, mixer is configured to handle these flows without too much pressure drop.
  • the mixer is the means for providing the air/gas mixture.
  • the gas valve is, in particular directly connected, to the, in particular Venturi shaped, mixer. That means, no further components are arranged in the gas flow path between the gas valve and the mixer. In this embodiment, even fewer parts need to be assembled during conversion making mounting even simpler and further reducing mounting errors.
  • a certain working principle can be chosen, i.e. a pneumatic system or an electronic controlled system.
  • the same working principle can be maintained or the working principle can be switched from pneumatic towards electronic or the other way around from electronic towards pneumatic.
  • the gas valve can be controlled electronically or pneumatically.
  • the fan and the gas valve can be controlled by the same electrical control unit or by separate control units.
  • the assembly further comprises a flame detector sensor, in particular a UV sensor and/or a thermal sensor, wherein the flame detector is located at the outlet portion of the manifold.
  • the ionization probe is the conventional flame detector for hydrocarbon combusting heating appliances, however, ionization probes do not detect hydrogen flames correctly or at all, in particular at high hydrogen concentrations.
  • a retrofit kit assembly comprising a UV sensor contains a further behavior-shaping constraint which facilitates that the correct safety critical sensor is included in the conversion without requiring additional checks and tests during conversion. 22.06.2023 19
  • the assembly can comprise at least one of an optical sensor, a temperature sensor, a thermocouple ora catalytic sensor to function as flame detector.
  • the assembly can further comprise a thermocouple placed in the burner.
  • the retrofit kit assembly can comprise at least one, in particular more than one, sensor.
  • the sensor can be a hydrogen detector.
  • the sensor can be an oxygen sensor and/or flow sensor and/or a temperature sensor and/or a thermocouple and/or a catalytic sensor.
  • the sensor or sensors can be used to detect the presence of hydrogen, in particular, the leakage of hydrogen which increases the safety in a simple and reliable way.
  • the combustion based on the sensor signals.
  • flow sensors, thermal conductivity sensors, O 2 sensor, UV sensor or temperature sensor/thermocouple, or catalytic sensor can be used instead of or additionally to an ionization electrode commonly used in natural gas combustion appliances.
  • a controller or control unit that controls either the entire combustion appliance, including at least safety control function and comfort control function, or (in some embodiments) that controls at least the burner can be configured to detect the presence of appropriate sensors for use with a hydrogen gas combustion appliance. For example, if an ionization sensor is detected by a controller or control unit that has been configured to control a hydrogen combustion appliance, then the retrofit has not been properly completed and the unit may still be configured for use with natural gas. In such a situation, control software for a hydrogen gas combustion appliance may refuse to function and/or raise an error. If the control software detects appropriate sensors, such as a hydrogen leakage detector and UV sensor, then the control software can operate the hydrogen gas combustion appliance.
  • appropriate sensors such as a hydrogen leakage detector and UV sensor
  • control software for a natural gas combustion appliance can refuse to operate and/or raise an error if sensors for use with a hydrogen gas combustion appliance are detected. This would indicate that a hydrogen retrofit kit has been installed, but the software and/or parameters have not been changed for use with a hydrogen combustion appliance or burner.
  • control software capable of controlling both a natural gas 22.06.2023 20 and a hydrogen gas combustion appliance may be used, with the detected sensors determining, at least in part, the mode in which appliance is operated.
  • the sensor type should be determinable by the controller or control unit, e.g., using software.
  • sensors that are able to report their own type via their connection to the controller or control unit may be used.
  • sensors may be connected to a sensor interface, which is able to determine the types of sensors that are attached and report this information to control software that operates the burner or appliance.
  • this sensor interface may be integrated with the controller or control unit.
  • the sensor type may be determined based on the signal provided by the sensor, without requiring further identification information. Additionally, the presence or absence of a sensor may be detected, which may permit use of, e.g., Poka Yoke sensor connectors to ensure that only appropriate sensors may be attached to particular sensor connectors on the controller or control unit. This permits the presence or absence of a sensor to be used as a detectable indication of the sensor type.
  • Poka Yoke designs within the meaning of the application are designs which either prevent or detect the occurrence of an error in the setup regarding safety critical parts for combustion of hydrogen.
  • the configuration of the Poka Yoke design in other words, needs to be configured such that safety critical errors regarding the combustion of hydrogen are prevented during retrofitting or for easy detection before operation of the 22.06.2023 21 retrofitted hydrogen combustion appliance, such as a hydrogen boiler.
  • Suitable examples of Poka Yoke designs comprise unique connectors which will allow for the fit of only the right e.g. sensor on the right board. This can be by hardware design, such as for example unique asymmetry or color coding which identifies the correct connection on both parts to be connected.
  • Poka Yoke designs include software designs that, e.g., identify the sensor that has been connected to a control unit and will prevent operation and/or raise an error in case the wrong connection has been made. Further suitable examples can also comprise combinations of software and hardware designs.
  • Unique connectors within the meaning of this application comprise, for example, unique shapes. Unique shapes or configurations ensure that a unique part only matches with its predetermined counterpart. This ensures that the part can only be connected in the correct orientation and to the correct mating part. Further suitable designs for unique connectors include predetermined different sizes, keying features such as notches, grooves, or tabs, mechanical interlocks that only engage when the correct parts are connected, and/or color coding to help users identify the correct connections. Color coding is often used in conjunction with other unique features to provide a visual aid and add an extra layer of error-proofing, but can also be used on its own. Further suitable examples of Poka Yoke designs, comprise asymmetrical designs of the unique connectors or mechanical restrictors. It is understood that for a Poka Yoke design within the meaning of this application, the unique connector preferably comprises a unique shape and a further Poka Yoke design, such as a color-coding which identifies the connector and the respective part or parts to be connected.
  • the outlet portion can comprise at least one receive portion for receiving a flame detector sensor and/or a sensor as discussed above.
  • the manifold can also comprise a receive portion for receiving the sensor.
  • the manifold can comprise a first receive portion for receiving a sensor.
  • the sensor can be gas flow sensor for sensing a gas flow.
  • the manifold can also comprise a second receive portion for receiving a sensor.
  • the sensor can be an air flow sensor for sensing an air flow.
  • the combustion appliance can comprise control components, in particular connecting cables, for the connection of the at least one of the above-mentioned additional components (i.e. flow sensors, thermal conductivity sensors, oxygen sensor, UV sensor or temperature sensor/thermocouple, or catalytic sensor) to the combustion appliance.
  • the control components, in particular connecting cables can be used to 22.06.2023 22 connect and/or connect sensors to a sensor interface which in turn is configured to be connected, in particular connected, to a control unit or controller or control unit.
  • the frame structure is provided with a plurality of through holes arranged along the perimeter of the frame structure for receiving connecting means, in particular screws, to fix said frame structure to the internal housing of the combustion appliance, i.e. to the housing of the heat exchanger.
  • the assembly can further comprise a suppressor structure provided at the inlet portion of the manifold. The suppressor structure is used to reduce the noise.
  • the burner is suitable for hydrogen combustion. In this way, the outflow velocity can be configured to be greater than the flame speed. In another example, the burner can be suitable for the combustion of both natural gas and hydrogen.
  • the retrofit kit assembly can further comprise a data carrier comprising information which, when the data carrier is read out cause a computer or a control unit to carry out a method for controlling the operation of the combustion appliance.
  • the method for controlling the operation of the combustion appliance preferably comprising parameters and/or parameter settings for the safe combustion of hydrogen such as lambda values, load values and/or settings for lambda and load for ignition and/or operation phase.
  • a suitable data carrier can for example be a QR code, an RFID carrier, or a label comprising a weblink.
  • the data carrier can be arranged on a surface of the retrofit kit assembly, including for example a housing, a frame or a packaging of the retrofit kit. This allows for a particularly simple, cheap, and effective Poka Yoke solution.
  • a computer readable data carrier is provided, the carrier having stored thereon the inventive computer program product.
  • This product comprises instructions which, when the program is executed by a computer or control unit, cause the computer or the control unit to carry out the inventive method.
  • the control unit is configured to perform the inventive method.
  • the control unit can comprise at least one processor or be a processor. 22.06.2023 23
  • a retrofit kit assembly is provided by means of which a natural gas combustion appliance can be retrofitted to a hydrogen gas combustion appliance.
  • the retrofit kit assembly is configured in the aforementioned manner in order to reduce leakage and/or explosion risks.
  • a combustion appliance and more particularly for a condensing gas boiler, is provided, the combustion appliance comprising an inventive retrofit kit assembly that is fixed to the housing.
  • a combustion appliance comprises a housing that has an interface configured to be connected with the retrofit kit assembly.
  • the interface can be a mechanical interface so that the retrofit kit assembly can be mechanically connected to the housing of the combustion appliance.
  • the connection can be a form-fitting or force fitting connection.
  • the connection can be releasable. That means the connection can be released without destroying the retrofit kit assembly and/or the housing.
  • combustion appliances can include furnaces, water heaters, boilers, direct/in-direct make-up air heaters, power/jet burners and any other residential, commercial or industrial combustion appliance.
  • a combustion appliance can be modulated over a plurality of burner loads, with each burner load requiring a different flow rate of fuel resulting in a different heat output. At higher burner loads, more fuel and more air are typically provided to the burner, and at lower burner loads less fuel and less air are typically provided to the burner.
  • the at least one flame detector sensor and/or least one sensor be positioned such on the retrofit kit assembly that they sense physical values from the burner chamber.
  • the burner chamber is at least partly delimited by the housing of the combustion appliance.
  • the retrofit kit assembly can comprise means for fixing the kit assembly to the housing, in particular the interface of the housing, of the combustion appliance. Accordingly, an operator would have all the required elements for converting a natural gas combustion appliance into a hydrogen combustion appliance. 22.06.2023 24
  • the retrofit kit assembly can further comprise a spacer for the housing of a combustion appliance to be retrofitted.
  • the spacer can be fitted between a front cover of the combustion appliance and a housing part containing combustion relevant parts of the combustion appliance. Thereby, it is constructively easily possible to add additional volume to the mounting volume of the housing.
  • a hydrocarbon combustion appliance such as a natural gas or propane combustion appliance
  • a hydrocarbon combustion appliance such as a natural gas or propane combustion appliance
  • a pre-blower mixing configuration which is to be changed to a post-blower mixing configuration.
  • pre-blower mixing refers to a process wherein the fuel and the air are mixed before entering a fan (also referred to as blower).
  • a fan also referred to as blower
  • hydrogen is fairly easily ignitable and therefore, the post-blower mixing is preferred for hydrogen appliances.
  • Post-blower mixing within the context of this application therefore means that the fuel and the air are mixed after the air has passed through the fan.
  • the retrofit kit assembly can comprise a cable, in particular being part of a cable harness, that is electrically connected with at least one component of the kit assembly.
  • the kit assembly comprises a cable, in particular being part of a cable harness, that is electrically connected with at least one component of the kit assembly and is connectable with an electrical component of the combustion appliance.
  • a combustion appliance in particular a gas boiler, and more particularly a condensing gas boiler, is provided, wherein the kit assembly according to the invention and a housing is provided, wherein the combustion appliance comprises a combustion chamber wherein the kit assembly is fixed to the housing.
  • a combustion appliance is provided with a housing 22.06.2023 25 comprising an interface configured to be connected with the retrofit kit assembly according to the invention.
  • the use of the inventive retrofit kit assembly for converting a hydrocarbon gas combustion appliance into a combustion appliance for the combustion of pure hydrogen is provided.
  • the combustion appliance conversion can be easy to realize and can be carried out in a very short time (for example less than one hour). Also, the conversion can be safe and effective for the operation of a hydrogen combustion appliance.
  • a method for retrofitting a combustion appliance in particular a gas boiler, and more particularly for a condensing gas boiler, is provided.
  • the combustion appliance has a burner for combusting a gas mixture including gaseous hydrocarbons, in particular natural gas or propane, and the method comprises: removing a front cover from an internal housing of the combustion appliance and removing the burner, installing an inventive retrofit kit assembly in the combustion appliance by fixing the frame structure to the internal housing of the combustion appliance.
  • the Poka Yoke behavior-shaping constraints by way of contact, meaning the use of shape, size, or other physical attributes for detection, ensures that the right conditions exist before a process step is executed, and thus preventing defects from occurring in the first place.
  • the value of using the Poka Yoke is that they help people and processes work right the first time, which prevents in a simple and reliable way an improper part setup.
  • the polarity or orientation of a connector is correct as this is not sufficient to prevent human error in e.g. connecting the wrong sensor with the wrong control unit or an incorrect port on a control unit and thereby creating a safety risk.
  • the control unit of the natural gas boiler is to be replaced with a hydrogen control unit, it would be insufficient if only polarity or orientation would be considered a Poka Yoke design for this invention.
  • the polarity or orientation e.g. of a connector of a UV sensor could not prevent connection of the UV sensor to the natural gas control unit.
  • Poka Yoke designs within the meaning of the application are designs which either prevent or detect the occurrence of an error in the setup regarding safety critical parts for combustion of hydrogen.
  • the configuration of the Poka Yoke design in other words, needs to be configured such that safety critical errors regarding the combustion of hydrogen are prevented during retrofitting or for easy detection before operation of the retrofitted hydrogen combustion appliance, such as a hydrogen boiler.
  • Suitable examples of Poka Yoke designs comprise unique connectors which will allow for the fit of only the right e.g. sensor on the right board. This can be by hardware design, such as for example unique asymmetry or color coding which identifies the correct connection on both parts to be connected.
  • Poka Yoke designs include software designs that, e.g., identify the sensor that has been connected to a control unit and will prevent operation and/or raise an error in case the wrong connection has been made. Further suitable examples can also comprise combinations of software and hardware designs.
  • Unique connectors within the meaning of this application comprise, for example, unique shapes.
  • Unique shapes or configurations ensure that a unique part only matches with its predetermined counterpart. This ensures that the part can only be connected in the correct orientation and to the correct mating part.
  • Further suitable designs for unique connectors include predetermined different sizes, keying features such as notches, grooves, or tabs, mechanical interlocks that only engage when the correct parts are connected, and/or color coding to help users identify the correct connections. Color coding is often used in conjunction with other unique features to provide a visual aid and add an extra layer of error-proofing, but can also be used on its own.
  • Further suitable examples of Poka Yoke designs comprise asymmetrical designs of the unique connectors or mechanical restrictors.
  • the method can further comprise the step of updating the setting parameters of the combustion appliance for the combustion of pure hydrogen. By updating of setting parameters an improper operation can be prevented.
  • updating the setting parameters occurs automatically by detecting the presence of hydrogen being above a predetermined value, in particular 20 mol% or pure hydrogen, in the gas mixture. This can be carried out by measuring the amount of hydrogen in the gas mixture using for example a hydrogen detector conveniently placed in the combustion appliance.
  • updating the setting parameters can occur automatically based on the presence of appropriate sensors, for example by 22.06.2023 27 connecting an additional sensor to the appliance.
  • updating the setting parameters can occur by detecting the absence of a ionization signal and by detecting a flame detection signal generated by a flame detector, in particular a UV sensor and/or a thermal sensor, and/or a ionization probe.
  • a switch or electrical jumper on the controller or control unit may be used to indicate that the parameters should be updated.
  • electrical contacts on the frame structure may serve as a switch to indicate that the retrofit kit has been installed, and the parameters should be updated for the combustion of hydrogen.
  • a combination of these means for determining that the parameters should be updated may be used. For example, updating the parameters may be carried out when the appropriate sensors are detected, and an electrical contact on the frame structure indicates the retrofit kit has been installed.
  • a conversion and control unit is provided.
  • the conversion and control unit is used for converting a hydrocarbon gas combustion appliance to a hydrogen combustion appliance combusting more than 20 mol% hydrogen, configured to take over control of the gas combustion appliance or to override a natural gas combustion control unit of the gas combustion appliance and/or to be inserted in between a natural gas combustion control unit of the hydrocarbon gas combustion appliance to be converted and at least one hydrogen combustion sensor.
  • This unit can be comprised in the retrofit kit assembly. 22.06.2023 28
  • the natural gas combustion control unit may be configured to refuse to operate and/or to raise an error if the presence of a hydrogen retrofit kit is detected, e.g., through use of an electrical contact on the frame structure, but the conversion and control unit is not properly connected.
  • the UV sensor and/or an 02 sensor is connected to the control unit.
  • the conversion and control unit comprises at least one communication line configured for connection to the natural gas combustion control unit.
  • an electronic safety unit is provided.
  • the electronic safety unit is used for converting a hydrocarbon combustion appliance to a hydrogen combustion appliance combusting more than 20 mol% hydrogen, configured to monitor combustion parameters and configured to prevent ignition and/or stop combustion of the hydrocarbon combustion appliance to be converted, wherein the electronic safety unit is configured to check that at least one hydrogen combustion parameter sent by a natural gas control unit for controlling a hydrogen burner is met.
  • This unit can be comprised in the retrofit kit assembly.
  • the electronic safety unit can comprise or is a printed circuit board or processor.
  • the electronic safety unit can be any unit that is configured to prevent an ignition and/or to stop a combustion dependent on the monitored combustion parameter.
  • the electronic safety unit can comprise mechanical and/or electric and/or electronical means for preventing ignition and/or stopping the combustion.
  • control unit is configured to detect the presence of at least one component of the retrofit kit assembly by detecting at least the presence of a flame detector sensor for hydrogen combustion, in particular an optical sensor, in particular a UV sensor, a temperature sensor, a thermocouple or a catalytic sensor; additionally or alternatively a hydrogen detection sensor, in particular a thermal conductivity sensor, in particular a temperature sensor and/or a thermocouple, and/or a catalytic sensor and/or an electrochemical sensor; additionally or alternatively a hydrogen combustion control sensor, in particular a flow sensor, thermal conductivity sensor, 02 sensor, UV sensor or temperature sensor/thermocouple, or catalytic sensor; additionally or alternatively by detecting by determining electrical contact with the frame assembly closed; additionally or alternatively by detecting the position of a switch and/or jumper.
  • a flame detector sensor for hydrogen combustion in particular an optical sensor, in particular a UV sensor, a temperature sensor, a thermocouple or a catalytic sensor
  • a hydrogen detection sensor in particular a thermal conductivity sensor,
  • control unit for a combustion appliance wherein the control unit is configured to control a hydrogen combustion appliance only if a retrofit kit assembly, in particular a retrofit kit as described above, is completely and correctly installed and/or a control software and/or control parameters for hydrogen combustion are operational on the control unit.
  • Figure 1 shows a schematic representation of a retrofit kit assembly according to an embodiment of the invention.
  • Figure 2 shows a perspective representation of the retrofit kit assembly according to another embodiment of the invention.
  • the inlet portion 11 of the manifold structure 10 is provided with a first connection 4 for receiving at least a first fluid, i.e. fuel gas (vertical arrow in the figure), and with a second connection 17 for receiving at least a second fluid, i.e. air (horizontal arrow in the figure). It is noted that the first connection 4 is located downstream the second connection 17 with respect to the air flow. Also, the first connection 4 is integrally connected to the manifold structure 10 and protrudes (extends longitudinally) from the manifold structure 10.
  • the retrofit kit assembly 1 consists of different components, which are connected to each other and in some cases are integrated in one single block element (i.e. the manifold structure 10, the frame structure 5 and the first connection 4). In this case, it is easy to replace the elements of the gas boiler to be converted with the present retrofit kit 22.06.2023 33 assembly 1. Specifically, the burner (i.e. from a burner suitable only for natural gas combustion to a burner suitable for pure hydrogen) as well as the arrangement of the connections for the inlet of gas and air (for hydrogen boilers, it is preferred a post blower mixing) are changed in order to carry out the conversion. The operator can simply remove the components to be replaced, i.e. the burner and the manifold, and fix the retrofit kit assembly 1 to the combustion appliance 2 (gas boiler), thereby modifying the general operation of the appliance.
  • the burner i.e. from a burner suitable only for natural gas combustion to a burner suitable for pure hydrogen
  • the arrangement of the connections for the inlet of gas and air for hydrogen boilers, it is
  • FIGS. 3A and 3B illustrate a front view and a rear view of the retrofit kit assembly of figure 2.
  • the control unit 23 is attached to the frame structure 5, in particular to the second portion 14 of the frame structure 5.
  • the control unit 23 is firmly connected to the frame structure 5 so that the control unit 23 moves together with the frame structure 5 when the retrofit kit assembly is moved.
  • the housing 3 is the housing of a heat exchanger of a gas boiler.
  • the frame structure 5 is shaped to fit the edges of the housing 3 and to completely cover the burner chamber 18.
  • the burner 6 is inserted in the burner chamber 18, thereby replacing a burner previously present in the combustion appliance, i.e. in the housing of the heat exchanger.
  • the manifold structure 10 i.e. the gas valve 13 and the fan element 8
  • the components connected to the manifold structure 10 are located outside the housing 3, thereby allowing possible connections for example with the gas conduit 15 and ambient air.
  • Figure 4 schematically illustrates the steps of a method 100 for retrofitting a combustion appliance 2.
  • the method 100 can be used to convert a combustion appliance such as a natural gas boiler into a hydrogen boiler.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Regulation And Control Of Combustion (AREA)
  • Feeding And Controlling Fuel (AREA)

Abstract

L'invention concerne un ensemble kit de modernisation (1) pour convertir un appareil de combustion de gaz hydrocarboné (2), en particulier une chaudière à gaz et, plus particulièrement, une chaudière à gaz à condensation, en un appareil de combustion pour la combustion de gaz combustible comprenant plus de 20 % en moles, en particulier 30 % en moles, d'hydrogène. L'ensemble kit (1) comprend une structure de cadre (5) pouvant être fixée à un boîtier (3) de l'appareil de combustion (2) pour recouvrir, en particulier complètement, une chambre de brûleur (18) de l'appareil de combustion (2). Une unité de commande (23) est également conçue pour commander un brûleur (6) conçu pour une combustion d'hydrogène, l'unité de commande (23) étant reliée, en particulier fermement, à la structure de cadre (5).
PCT/EP2023/066921 2022-06-22 2023-06-22 Ensemble kit de modernisation d'hydrogène pour brûleur à gaz Ceased WO2023247681A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP23733993.2A EP4544227A1 (fr) 2022-06-22 2023-06-22 Ensemble kit de modernisation d'hydrogène pour brûleur à gaz

Applications Claiming Priority (26)

Application Number Priority Date Filing Date Title
EP22180344.8 2022-06-22
EP22180353.9 2022-06-22
EP22180363.8 2022-06-22
EP22180332.3 2022-06-22
EP22180332.3A EP4296569A1 (fr) 2022-06-22 2022-06-22 Ensemble kit de rattrapage d'hydrogène pour un brûleur à gaz
EP22180353.9A EP4296572A1 (fr) 2022-06-22 2022-06-22 Ensemble kit de rattrapage
EP22180327.3 2022-06-22
EP22180344.8A EP4296571A1 (fr) 2022-06-22 2022-06-22 Ensemble kit de rattrapage
EP22180366.1A EP4296575A1 (fr) 2022-06-22 2022-06-22 Dispositif électronique de sécurité et ensemble kit de rattrapage comprenant le dispositif électronique de sécurité
EP22180372.9A EP4296576A1 (fr) 2022-06-22 2022-06-22 Ensemble kit de rattrapage d'hydrogène pour un brûleur à gaz
EP22180337.2A EP4296570A1 (fr) 2022-06-22 2022-06-22 Ensemble kit de rattrapage d'hydrogène pour un brûleur à gaz
EP22180363.8A EP4296574A1 (fr) 2022-06-22 2022-06-22 Ensemble kit de rattrapage
EP22180361.2 2022-06-22
EP22180327.3A EP4296568A1 (fr) 2022-06-22 2022-06-22 Ensemble kit de rattrapage d'hydrogène pour un brûleur à gaz
EP22180366.1 2022-06-22
EP22180361.2A EP4296573A1 (fr) 2022-06-22 2022-06-22 Ensemble kit de rattrapage
EP22180372.9 2022-06-22
EP22180337.2 2022-06-22
EP22188116.2A EP4317778A1 (fr) 2022-08-01 2022-08-01 Ensemble kit de rattrapage
EP22188119.6 2022-08-01
EP22188116.2 2022-08-01
EP22188124.6 2022-08-01
EP22188115.4 2022-08-01
EP22188124.6A EP4317780A1 (fr) 2022-08-01 2022-08-01 Ensemble kit de rattrapage
EP22188119.6A EP4317779A1 (fr) 2022-08-01 2022-08-01 Ensemble kit de rattrapage
EP22188115.4A EP4317777A1 (fr) 2022-08-01 2022-08-01 Ensemble kit de rattrapage

Publications (1)

Publication Number Publication Date
WO2023247681A1 true WO2023247681A1 (fr) 2023-12-28

Family

ID=87001737

Family Applications (13)

Application Number Title Priority Date Filing Date
PCT/EP2023/066921 Ceased WO2023247681A1 (fr) 2022-06-22 2023-06-22 Ensemble kit de modernisation d'hydrogène pour brûleur à gaz
PCT/EP2023/066926 Ceased WO2023247686A1 (fr) 2022-06-22 2023-06-22 Ensemble kit de rattrapage
PCT/EP2023/066923 Ceased WO2023247683A1 (fr) 2022-06-22 2023-06-22 Ensemble kit de modernisation
PCT/EP2023/066934 Ceased WO2023247691A1 (fr) 2022-06-22 2023-06-22 Ensemble kit de rétro-installation
PCT/EP2023/066933 Ceased WO2023247690A1 (fr) 2022-06-22 2023-06-22 Ensemble kit de rattrapage
PCT/EP2023/066918 Ceased WO2023247679A1 (fr) 2022-06-22 2023-06-22 Ensemble kit de modernisation d'hydrogène pour brûleur à gaz
PCT/EP2023/066922 Ceased WO2023247682A1 (fr) 2022-06-22 2023-06-22 Ensemble kit de modernisation à hydrogène pour un appareil de combustion de gaz
PCT/EP2023/066920 Ceased WO2023247680A1 (fr) 2022-06-22 2023-06-22 Ensemble kit de rattrapage d'hydrogène pour brûleur à gaz
PCT/EP2023/066925 Ceased WO2023247685A1 (fr) 2022-06-22 2023-06-22 Ensemble kit de modernisation
PCT/EP2023/066929 Ceased WO2023247687A1 (fr) 2022-06-22 2023-06-22 Ensemble kit de modernisation d'hydrogène pour brûleur à gaz
PCT/EP2023/066935 Ceased WO2023247692A1 (fr) 2022-06-22 2023-06-22 Ensemble kit de rétro-installation
PCT/EP2023/066932 Ceased WO2023247689A1 (fr) 2022-06-22 2023-06-22 Ensemble kit de rétro-installation
PCT/EP2023/066924 Ceased WO2023247684A1 (fr) 2022-06-22 2023-06-22 Ensemble kit de rattrapage

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PCT/EP2023/066926 Ceased WO2023247686A1 (fr) 2022-06-22 2023-06-22 Ensemble kit de rattrapage
PCT/EP2023/066923 Ceased WO2023247683A1 (fr) 2022-06-22 2023-06-22 Ensemble kit de modernisation
PCT/EP2023/066934 Ceased WO2023247691A1 (fr) 2022-06-22 2023-06-22 Ensemble kit de rétro-installation
PCT/EP2023/066933 Ceased WO2023247690A1 (fr) 2022-06-22 2023-06-22 Ensemble kit de rattrapage
PCT/EP2023/066918 Ceased WO2023247679A1 (fr) 2022-06-22 2023-06-22 Ensemble kit de modernisation d'hydrogène pour brûleur à gaz
PCT/EP2023/066922 Ceased WO2023247682A1 (fr) 2022-06-22 2023-06-22 Ensemble kit de modernisation à hydrogène pour un appareil de combustion de gaz
PCT/EP2023/066920 Ceased WO2023247680A1 (fr) 2022-06-22 2023-06-22 Ensemble kit de rattrapage d'hydrogène pour brûleur à gaz
PCT/EP2023/066925 Ceased WO2023247685A1 (fr) 2022-06-22 2023-06-22 Ensemble kit de modernisation
PCT/EP2023/066929 Ceased WO2023247687A1 (fr) 2022-06-22 2023-06-22 Ensemble kit de modernisation d'hydrogène pour brûleur à gaz
PCT/EP2023/066935 Ceased WO2023247692A1 (fr) 2022-06-22 2023-06-22 Ensemble kit de rétro-installation
PCT/EP2023/066932 Ceased WO2023247689A1 (fr) 2022-06-22 2023-06-22 Ensemble kit de rétro-installation
PCT/EP2023/066924 Ceased WO2023247684A1 (fr) 2022-06-22 2023-06-22 Ensemble kit de rattrapage

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WO2025168719A1 (fr) * 2024-02-06 2025-08-14 BDR Thermea Group B.V Procédé de fonctionnement d'un appareil de combustion dans un mode de mise en service de l'appareil de combustion
EP4600554A1 (fr) * 2024-02-06 2025-08-13 BDR Thermea Group B.V. Unité de rattrapage pour le rattrapage d'un appareil de combustion à un appareil de combustion adaptatif au gaz

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WO2023247691A1 (fr) 2023-12-28
EP4544226A1 (fr) 2025-04-30
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WO2023247685A1 (fr) 2023-12-28
WO2023247687A1 (fr) 2023-12-28
EP4544232A1 (fr) 2025-04-30
EP4544228A1 (fr) 2025-04-30
WO2023247686A1 (fr) 2023-12-28
WO2023247683A1 (fr) 2023-12-28
WO2023247689A1 (fr) 2023-12-28
EP4544236A1 (fr) 2025-04-30
EP4544230A1 (fr) 2025-04-30
WO2023247682A1 (fr) 2023-12-28
EP4544237A1 (fr) 2025-04-30
EP4544233A1 (fr) 2025-04-30
WO2023247679A1 (fr) 2023-12-28
EP4544229A1 (fr) 2025-04-30
EP4544235A1 (fr) 2025-04-30
EP4544225A1 (fr) 2025-04-30
WO2023247692A1 (fr) 2023-12-28
WO2023247690A1 (fr) 2023-12-28
EP4544227A1 (fr) 2025-04-30
WO2023247680A1 (fr) 2023-12-28
EP4544231A1 (fr) 2025-04-30

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