Flare Systems
Emissions Reduction Equipment
WE SUPPLY A WIDE RANGE OF STANDARD AND CUSTOMER FLARE SYSTEMS.
Our custom flares are designed as per ISO 23251:2014/2019 (API 521), 40 CFR 60.18, and others. With flaring capacity up to 5,000,000 kg/h in all type of configurations. Staging systems by actuated valves or liquid seals, ignition, and monitoring systems, for any kind of smokeless performance requirements. Ongoing R&D ensures continuously upgraded technology.
Applications
- Utility Flares / Assisted Flares / Pressure Assisted Flares
- Derricks and Demountable Flares Systems
- Multi-Point Ground Flare Systems
- Enclosed Flares Systems and Biogas Flares
- Burn Pit Flares / Liquid Burners
- Pilot Burners and Ignition Systems
- Knock-out Drums and Liquid Seals
Features
- Tips equipped with proprietary stabilization tabs and rings for flame retaining and stabilization
- Purge reduction systems, dynamic or buoyancy seal
- Material selection as per specifications, in terms of material grade, properties and testing such as special alloys (UNS08811, UNS N0660), NACE, HIC and others
- Pilot burners are ISO 25457:2008 (API 537), self-inspirated and characterized by very low fuel consumptions and high reliability. Equipped with thermocouples or flame ionization rods with single or redundant ignition system. Built in stainless steel 310/316 with casted items
- Flame remote monitoring, smokeless control, retractability packages for thermocouples, pilot burners, aircraft warning lights (AWL), and many other turnkey solutions
Advantages
- Highly reliable and tested pilot burners
- Miscellaneous instrumentation for IR monitor, Sentinel
UV monitor, Smokeless monitor, and control - Instrumentation for flow monitoring (ultrasonic), remote
flame monitoring of both pilot flame and flare tip flame,
smokeless control via flame intensity optical monitors,
and many others - Solar panel systems
- FFG ignition systems with long venturi for induced air
suction - Aircraft warning lights, Ex-d, conforming to ICAO code
latest edition - Retractability packages for thermocouples, aircraft
warning lights, and pilot burners
Utility Flares
Utility flares (DU series) are one of the most common flare designs use for applications with no smokeless burning requirements. They are also utilized in applications where smokeless flaring can be achieved without the use of an additional assist medium.
Assisted Flares
To dispose of heavy waste gases, which have a greater tendency to smoke, in a smokeless manner, we provide three different design options, depending on customer requirements. Air Assisted Flares, which utilize forced air from blower(s) to provide assist air for combustion and promotes additional air entrain from the ambient due to the relatively high exit speed of the streams. Steam Assisted Flares based upon the injection of medium pressure steam at tip level, using peripheral steam rings (SA model), center steam spargers, and/or inner induction tubes (SAI model). Gas Assisted Flares technology allows attainment of smokeless performances through the injection of high-pressure gas via a peripheral ring, which is also utilized as veritable ring of fire at the perimeter of the flare tip to ensure proper ignition, and stable combustion, of waste gases characterized by high quantities of CO2, CO, or poor lower heating value. For applications with both high-pressure and low pressure flare gas streams, our proprietary technology DreamDUO is the perfect choice for cost-effective and high smokeless performance.
Pressure Assisted Flares: Mach 1 sonic / Start fire / SN / Variable slot VMSA
Our cutting-edge MACH-1 sonic flaring technology, suitable for both off-shore and onshore installations, utilizes high pressure flare gas to establish an exit velocity equal to the speed of sound to combust waste gas smokelessly. The very high exit speed promotes large air entrainment and efficient turbulent mixing for complete-low radiating combustion. Sonic flares can be designed as single nozzle, multiple nozzles, with fixed or variable exit areas (variable slots) and equipped with spider burner(s) for flame anchoring and stabilization. Our Variable Mach (VariMach) sonic flare tip(s) has a spring-actuated variable sonic nozzle which allows the exit area to vary with pressure, ensuring constant sonic velocity of waste gas in a wide range of flows with beneficial effects on the smokeless combustion and the purge rate, which is the lowest of any flare technology on the market. For extended smokeless range at low flows, in the sub-sonic regimes, our Air Mach 1 sonic is the solution as it combines an air assist design with the sonic one.
Derricks and Demountable Flares Systems
Our Titan Demountable Flares, also named demountable derricks, are derrick-supported flares with three, or four leg configurations and overall heights of up to 200 meters. Designed to accommodate several risers/tips on the same derrick structure. Each flare tip has its own set of pilots. The demountable system allows maintenance at grade on each flare tip while keeping the other flare systems in operation. Fixed derricks are also available within our portfolio.
Multi-Point Ground Flare Systems
We design and supply Multipoint Ground Flares (MPGF) when very large flows are required to be flared in an array enclosed configuration. This system is characterized by multiple stages, with first stage(s) provided with assist support such as gas, air, steam for high smokeless performance at low regimes, and the upper stages coming into operation depending on the header pressure and the flaring need with their smokeless operation attained by pressure. Each stage is composed of runners and burners. In some cases, the number of burners can be of up to 500 burners spaced properly to promote cross light and reduce the number of pilot burners. The flames are shielded by fence panels supported by structural frames in the range of 15-20 meters tall. The staging skids are designed with an actuated staging valve and a safety element such as rupture disk, buckling pin valve, total relief valve, etc.
Enclosed Flares Systems and Biogas Flares
We design Enclosed ground flares when waste gases are requested to be flared in an enclosed stack, with reduced flame visibility, minimal heat and noise, emissions sampling, ease, and smokeless combustion, in sensitive areas. The stack is internally refractory lined, designed for low and medium flows, has high destruction efficiencies relative to an open flare and designed as natural draft or forced draft systems. Operated with control louvers and dampers which are optional, or air blowers, respectively.
Burn Pit Flares
The Pit Flare (or “Burn Pit”) is usually constructed of an excavation lined with a non-combustible lining of rock or refractory material. Often coupled with a pit liner, our pit flares can be a cost-effective combustion option for an environmentally conscious user. Our high efficiency burner produces a mixture of vapor and liquid from a single source. While most often designed to operate nonsmokeless, through use of AEREON's various Pit Flare technologies (Chimera, Peackock, Triton), smokeless operation can often be achieved.
Liquid Burners: Chimera, Peacock, Triton
Our Peacock Oil Burners are designed to flare liquid hydrocarbons without liquid fallout or soot formation. These burners provide excellent service for well testing operations. When only oil is flared, a high-pressure air or gas source is required to provide additional mechanical atomization to ensure the mixture is a fine mist when it exits the burner nozzle which is designed to accept separate high-pressure oil and air/gas streams. If the waste stream is an oil/gas mixture, a “spider” burner will be installed instead of the atomizing burner nozzle. Chimera and Triton are other models available.
Pilot Burners and Ignition Systems
All our Pilot Burners are fuel efficient pilots, self inspirated type, characterized by their durability, reliability, and ease of installation (retractable). Available models are ignited via FFG - flame front generator system (model 245), or HEI - high energy Ignition System HEI (model 250) or combined FFG and HEI (model 255). They can be retractable from ground level (model 270 retrax), and function without support gas (model 100 Continuum). The CONTINUUM Ignitor allows a flare to function without a pilot utilizing the flare gas itself as pilot gas and a continuum sparking system which generates a spark every 20 seconds for 2 seconds duration.
Knock-out Drums and Liquid Seals
We design Knockout Drums (KO Drums) in both horizontal and vertical configurations, as gas-liquid separators with high efficiency of separation of liquid droplets, with maximum size in the range 300-600 microns. We also supply Liquid Seal Drums, including all accessories: anti-pulsation device, siphon, level control, liquid make-up, and instrumentation. These systems are designed for the protection of the upstream flare header against flashbacks/explosions, in the event of purge loss, withstanding a certain degree of vacuum upstream of the drum without seal break. Typical of hot flaring or low molecular weight scenarios; dis-entrainment of liquid droplets; stage the operation of multiple flares, by adopting liquid depth to the desired staging pressure.
