Petrochemical Industries Elevated Flare System For Oil & Gas Refinery With EPC Contracting Service

Petrochemical Industries Elevated Flare System For Oil & Gas Refinery With EPC Contracting Service

 

Flare System is to handle the discharged combustible gas under the conditions of normal operation, start-up, shut-down and emergencies, which ensure the gas to be flared out instantaneously, safely and reliably and to meet the demand of environmental protection.

 

Flare System is a kind of safety equipment comprised of pipeline, knock out device, fire retardant equipment, flare burner, ignition system, flare riser and other components.

 

Flare Categories:

* Based on the vent gas media’s physical parameters (mainly for toxicity of the vent gas media), discharge pressure, flow rate and so on, the flare shall be divided into two categories – elevated flare and ground flare.

 

* The elevated flare, based on the support way, shall be divided into self-supported flare, inhaul supported flare and derrick supported flare. The derrick supported flare, based on types of the riser to be fixed, shall be divided into fixed derrick supported flare, demountable derrick supported flare.

 

* The ground flare, based on vent gas treatment capacity, shall be divided into enclosed ground flare and open ground flare.

 

* Based on structure of flare burner, the flare shall be divided into steam-assist flare, forced draft assist flare, defused flare, LHV flare, multi-hole collision flare, sonic flare, etc.

 

Options of flare types

Elevated flare	Ground flare
▽ Media attribute: unlimited   ▽ Industry: unlimited ▽ Capacity: unlimited	▽ Media attribute: The media which is no extremely harmful. ▽ Industry: mainly focus on chemical field ▽Capacity: up to 150t/h for enclosed ground flare and unlimited for open flare

 

Options of support way for elevated flare system:

Self-supported	Inhaul	Derrick supported
		Fixed flare	Demountable flare
▽Industry: Natural gas processing plant   ▽Capacity: small ▽Height: not higher than 20m	▽Capacity: small ▽Height: up to 40m.	▽Industry: refinery, coal-chemical, LNG, off-shore, etc. ▽Capacity: large ▽Height: 40-160m ▽Application: The devices matching up the flare system need “same-time start-up & shut-down”	▽Industry: refinery, coal-chemical, LNG, off-shore, etc. ▽Capacity: large ▽Height: 40-160m ▽Application: The devices matching up multi sets of flare system can’t be “same-time start-up & shut-down”, need to reserve extra flare system for expansion and save land investment.

 

 

 

Options of ground flare system

Enclosed ground flare system	Open ground flare system
▽ Media attribute: toxic flare gas, but not extremely or highly harmful ▽ Industry: focus on chemical industry
▽Capacity: not exceed 150t/h for single stack ▽Discharge pressure: up to 10kpag within BL (subject to the media)	▽Capacity: unlimited   ▽Discharge pressure: up to 80kpag within BL (subject to the media)

 

 

Options of flare burner

 

Steam assist type	Forced draft type	Diffused type	LHV type	Multi-hole collision type	Sonic type
▽Industry: Unlimited ▽Media: Heavy Hydrocarbon ▽Discharge pressure: lower, need assist for smokeless combustion ▽Utility: Steam available	▽Industry: Unlimited ▽Media: Heavy Hydrocarbon ▽Discharge pressure: lower, need assist for smokeless combustion ▽Utility: Non-steam ▽Location: applicable for cold area.	▽Industry : Coal chemical	▽Media: LHV or hard-combustible media like sour gas or ammonia	▽Industry: Natural gas ▽Media: Light hydrocarbon composition	▽Media: Off-shore platform     ▽Discharge pressure: Higher ▽Defect: Noisy

 

 

 Working principle / flow process

Elevated Flare System: The combustible gas is discharged from production equipment, flows into the battery limit of flare through vent pipe network, flows into the knock-out drum for separation of liquid drops probably contained in vent gas, flows into the water seal drum and breaks through the water seal, and then flows into the flare riser, goes through the molecular seal and finally is flared out by the burner.

 

 

 

Specifications

Process Data
Flow rate of flare gas (min/normal/max)
Composition of flare gas
Temperature of discharged gas (℃)
Back pressure of flare battery limit (Kpa)
Utility Data
Source of fuel gas
Pressure & temperature of fuel gas
Consumption of fuel gas (Nm3/h)
Purge gas	Nitrogen
Pressure & temperature of purge gas
Consumption of purge gas (Nm3/h)
Pressure & temperature of steam
Consumption of steam
Instrument air
Pressure & temperature of instrument air
Power supply	380VAC / 50Hz / PH3
Site Condition
Ambient condition (design/operation)
Min temperature
Max temperature
Humidity
Max wind speed
Main wind direction (Y/N) / direction
Max solar radiation (W/m2)
Flare radiation plus solar radiation (Y/N)
Technical Requirement
Design code & standard	API537 / API521
Flare type	Elevated flare: self-supported / inhaul / fixed derrick supported / demounted derrick supported Ground flare: enclosed / open
Aircraft warning light (Y/N)
Smokeless combustion (Y/N)
Method of smokeless combustion	Steam / forced draft
Requirement for thermal radiation
Max ground thermal radiation
Allowed thermal radiation at *m from sterile limit
Requirement for noise
Near the bottom of flare riser: xxdBA
At *m from flare riser: xxdBA
Burner
Type of burner	Steam assist
Design temperature(℃)/pressure(Kpag)	1200 / Atmospheric
Spec (Dia/H)
Material	310/304
Outlet Mach number
Resistance drop (Kpag)
Muffler
Windshield
Flame stabilizer ring
Smoke elimination measures	Steam assist / forced draft
Size of smoke elimination interface
Service life
Molecular Seal
Type	Dynamic seal
Design temperature(℃)/pressure(Kpag)	1200 / Atmospheric
Spec (Dia/H)
Material	304
Resistance drop (Kpag)
Service life
Flare Riser
Type
Design temperature(℃)/pressure(Kpag)	200 / Atmospheric
Spec (Dia/H)
Material
Resistance drop (Kpag)
Service life
Pilot & Ignition System
Pilot Qty
Type	Energy-saving
Method of flame detection	Thermocouple / Ultraviolet ray
Type of ignition (manual / automatic)	Sky ignition + Inner flame ignition
Service life
Water Seal Drum
Type	Full water seal / semi water seal
Design temperature(℃)/pressure(Kpag)
Spec (Dia/H)
Material
Height of water seal
Service life
Knock-out Drum
Type
Design temperature(℃)/pressure(Kpag)
Spec (Dia/H)
Material
Ability of knock out
Service life
Aircraft Warning
Qty
Position
Color / Type (flash / beacon / paint)
Demountable (Y/N)
Code of painting

 

Advantages

1. Use international engineering software like FLARESIM, FLARENET, FLUENT, etc.;

2. Own combustion test platform to simulate combustion conditions based on various types of flare gas;

3. Own numbers of patent technologies and know-how;

4. Have professional engineering design qualification;

5. Have high-qualified engineering design team & research and development team;

6. Have plentiful and comprehensive experiences of engineering construction;

7. Have professional & high efficient after-sale service system.

 

 

 

Typical Project

22,000,000T/y Refinery Project at CNOOC Huizhou Refinery

Phase #1 - 10,000,000T/y Refinery Project: The flare system consists of HP flare (DN1600), LP flare (DN1600) and Sour gas flare (DN500), and a reservation for DN1600 flare riser. The height of flare system: 150m.

Phase #2 – 12,000,000T/y Refinery Project: Based on the reserved space of phase #1 for DN1600 flare riser and the optimized design of system, SMDERI took full advantage of “on-line assembly & system expansion” of the demountable common derrick flare to realize the reconstruction & expansion of phase #1 flare system and reach the target of multi-risers being set on a common derrick. For the best utilization of land, SMDERI provided his technical support so that the land investment was saved.

The flare gas recovery system was equipped with a 20,000M3 Gas Holder, 2 units of 600,000M3 screw compressors and 2 units of 300,000M3 screw compressors.

 

Patent Technology:

l Demountable & common derrick elevated flare and its assembly & disassembly system (Utility Model Patent No.ZL200620048466.X)

l The Assembly & disassembly system of demountable & common derrick elevated flare and its method of assembly & disassembly (Invention Patent No.ZL200610119032.9)

l Staged discharge combustion system for combustible waste gas (Utility Patent No.ZL200620048087.0)

l Staged discharge combustion system for combustible waste gas and its method of usage method (Invention Patent No.ZL200610118674.7)

l Steam-assist flare burner (Invention Patent No.ZL200610118675.1)

l Water seal structure for flare system (Invention Patent No.ZL200810041594.5)

l Open ground flare (Utility Model Patent No.ZL201020529360.8)

l Multi-side demountable & common derrick elevated flare (Utility Model Patent No.ZL201120233838.7)

l New large stream of enclosed ground flare (Utility Model Patent No.ZL201120227204.0)