Abstract Domestic gas burners are a significant source of indoor air pollution and contribute substantially to household energy consumption. While transitioning to carbon-free fuels, such as hydrogen, presents considerable safety challenges, blending hydrogen with conventional fuels can improve combustion efficiency and reduce emissions. However, factors like the differences in the Wobbe index, loading height, power input, and fuel blending complicate understanding the aerated burner performance. This is particularly relevant for large establishments like restaurants and canteens, where hydrogen blending can have a notable impact. This study evaluates four burner designs—commercial (A), straight holes (B), slots (C), and swirl (D)—across thermal inputs (0.8–1.6 kW), with a focus on the swirl burner using hydrogen blends (0%, 34%, and 52% by volume) and varying loading heights (5 mm, 10 mm, and 15 mm). Straight hole (B) and swirl (D) burners were 3D-printed using stainless steel metal powder, while the slot (C) burner was machined. Key performance metrics such as flame behavior, thermal efficiency, pressure drop, and CO emissions were analyzed. Improving primary aeration by reducing flow resistance and enhancing secondary aeration through swirl action resulted in better flame-load interaction and minimized heat loss. The slot burner (C) achieved a thermal efficiency of 63.5%, while the swirl burner (D) reached 65% efficiency at a 10 mm height. The swirl burner maintained high efficiency with up to 52% hydrogen by volume across a wide range of operational conditions, with some exceptions. Additionally, the use of hydrogen eliminated soot emissions. Optimal performance occurred at a 10 mm loading height, with stable efficiency and lower emissions across various power inputs and hydrogen blends. The complex interactions between primary aeration, secondary mixing, and flame-load dynamics during hydrogen blending require thorough evaluation before incorporating hydrogen into aerated LPG burners.
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