Flare system
38. What is flare stack
A flare stack is used to burn off flammable gas in certain events. There are many certain
events that can lead to burn off flammable gas at flare stack.
Unused gas, known as “waste gas,” is collected and sent through a system of pipes. A knock-
out drum removes liquid from gas, and it is sent to the drain.
39. What is Aspen flare system analyzer?
Complete flare system design, rating, and debottlenecking with Aspen Flare System Analyzer
for optimal flare system analysis of projects.
With Aspen Flare System Analyzer
Flare system sizing projects
Flare system design, to generate new header systems
Flare system rating, to ensure existing flare header designs can accommodate changes
to relief scenarios
Debottlenecking of existing systems in revamp projects
40. Flare system components
Every flare system is unique and different
Every flare system contains differential components
Series of collection header from sources
Knockout drum
Stack
i) Flare tip
ii) Liquid seal
iii) Stack seal
Integrated pilot system
Monitoring and operation instrumentation
Flare hydrocarbon recovery system
Knock out drum
Separate liquid from gas (2 phase seperation)
Prevents liquids from being discharged to atmosphere
Prevent or reduce smoke because of reduced liquid in the flame
Prevent flare tip life
Liquid seal
Flashback prevention
Prevent air infiltration
Helps maintain positive header pressure
Stoaging device
Flare system purge requirements
Purge gas composition
Non-condensing – typically Nitrogen or natural gas
Non-corrosive
Non-reactive to other gases in the system
Purge gas locations
Upstream or downstream of liquid seal
Purge gas must be continous and measurable
Purge Reduction Devices (Stack seal)
Integrated pilot ssytem
Pilots
Premix burner
Pilot igniters
Direct spark
Flame Front Generator (FFG)
Pilot monitors
Heat: Thermocouples
Light: Infrared camera
Sound: Accoustic monitoring
Flame ionization
41. What is the purpose of flare header.
A flare system is defined as the controlled burning of natural gas that cannot be
processed for sale or use because of technical or economic reasons.
API 537 defines a flare system as the system provided in a refinery or petrochemical
plant to ensure the safe and efficient disposal of relieved gases or liquids.
Application of Flare System
Flares are primarily used for burning off flammable gas released by pressure relief
valves during any over-pressure scenario of plant process unit/equipment, due to process
upset or during startups & shutdowns, and for the planned combustion of gases over
relatively short periods.
When any equipment in the plant is over-pressured, the pressure relief valve is an
essential safety device that automatically releases gases and sometimes liquids.
The height of the flame depends on the volume of released gas, while brightness and
color depend upon composition.
The released gases and liquids are routed through large piping systems called flare
headers to the flare. The released gases are burned as they exit the flare stacks.
Commonly, flares are equipped with a vapor-liquid separator (also known as
a knockout drum – KOD) upstream of the flare to remove any large amounts of liquid
that may accompany the relieved gases to avoid fireballs.
Steam is very often injected into the flame to reduce the formation of black smoke.
When too much steam is added, a condition known as “over-steaming” can occur
resulting in reduced combustion efficiency and higher emissions.
To keep the flare system functional, a small amount of gas is continuously burned,
like a pilot light, to assure that the flare system is always ready for its primary purpose
as an over-pressure safety system.
