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A considerable number of Combined Heat and Power (CHP) systems continue to depend on fossil fuels like oil and natural gas, contributing to significant environmental pollution and the release of greenhouse gases. Two V-gutter flame holder prototypes (P1 and P2) with the same expansion angle, fueled with pure hydrogen (100% H2) or hydrogen–methane mixtures (60% H2 + 40% CH4, 80% H2 + 20% CH4), intended for use in cogeneration applications, have been designed, manufactured, and tested. Throughout the tests, the concentrations of CO2, CO, and NO in the flue gas were monitored, and particle image velocimetry (PIV) measurements were performed. The CO, CO2, respectively, and NO emissions gradually decreased as the percentage of H2 in the fuel mixture increased. The NO emissions were significantly lower in the case of prototype P2 in comparison with prototype P1 in all measurement points for all used fuel mixtures. The shortest recirculation zone was observed for P1, where the axial velocity reaches a negative peak of approximately 12 m/s at roughly 50 mm downstream of the edge of the flame holder, and the recirculation region spans about 90 mm. In comparison, the P2 prototype has a length of the recirculation region span of about 100 mm with a negative peak of approximately 14 m/s. The data reveal high gradients in flow velocity near the flow separation point, which gradually smooth out with increasing downstream distance. Despite their similar design, P2 consistently performs better across all measured velocity components. This improvement can be attributed to the larger fuel injection holes, which enhance fuel–air mixing and combustion stability. Additionally, the presence of side walls directing the flow around the flame stabilizer further aids in maintaining a stable combustion process.

A new afterburner installation is proposed, fueled with pure hydrogen (100%H2) or hydrogen–methane mixtures (60% H2 + 40% CH4, 80% H2 + 20% CH4) for use in cogeneration applications. Two prototypes (P1 and P2) with the same expansion angle (45 degrees) were developed and tested. P1 was manufactured by the classic method and P2 by additive manufacturing. Both prototypes were manufactured from Inconel 625. During the tests, analysis of flue gas (CO2, CO, and NO concentration), PIV measurements, and noise measurements were conducted. The flue gas analysis emphasizes that the behavior of the two tested prototypes was very similar. For all three fuels used, the CO2 concentration levels were slightly lower in the case of the additive-manufactured prototype P2. The CO concentration levels were significantly higher in the case of the additive-manufactured prototype P2 when 60% H2/40% CH4 and 80% H2/20% CH4 mixtures were used as fuel. When pure H2 was used as fuel, the measured data suggest that no additional CO was produced during the combustion process, and the level of CO was similar to that from the Garrett micro gas turbine in all five measuring points. The NO emissions gradually decreased as the percentage of H2 in the fuel mixture increased. The NO concentration was significantly lower in the case of the additive-manufactured prototype (P2) in comparison with the classic manufactured prototype (P1). Examining the data obtained from the PIV measurements of the flow within the mixing region shows that the highest axial velocity component value on the centerline was measured for the P1 prototype. The acoustic measurements showed that a higher H2 concentration led to a reduction in noise of approximately 1.5 dB for both afterburner prototypes. The outcomes reveal that the examined V-gutter flame holder prototype flow was smooth, without any perpendicular oscillations, without chaotic motions or turbulent oscillations to the flow direction, across all tested conditions, keeping constant thermal power.