Problem
Industrial gas-fired burners are widely used in high-temperature processes, providing consistent heat across diverse applications. However, achieving reliable flame performance across the full operating range can be complex. Flame liftoff, delayed ignition, incomplete combustion, and soot formation are persistent challenges that can arise due to variations in burner geometry, fuel composition, and operating conditions. These issues can lead to unstable operation, flame impingement, reduced thermal efficiency, and difficulty meeting emissions requirements.

Solution
Computational Fluid Dynamics (CFD) in STAR-CCM+ was used to simulate the behaviour of an industrial gas burner under a range of operating conditions. The modelling included detailed representations of fuel-air mixing, flame anchoring mechanisms, ignition characteristics, and emissions formation within the combustion zone. By resolving flow structures, temperature fields, and species concentrations, the CFD simulations offered a high-resolution view of the processes affecting flame stability, soot generation, and pollutant formation.

Result
The CFD modelling provided clear insight into how the burner geometry affected flame behaviour and pollutant formation. By visualising the interactions between the fuel and oxidant flows, it was possible to identify subtle causes of instability that would be difficult to detect experimentally. Adjustments to burner geometry and flow distribution were identified that would promote more stable flame attachment and improve mixing uniformity, reducing the likelihood of sooting and high local temperatures associated with NOₓ formation.