Flare System- A Detailed Overview

Introduction

The flare distribution system in a petrochemical complex is a critical safety mechanism

Flare systems are classified based on their design, location, and operational conditions:

A. Elevated Flare

- Description: The flare stack is elevated, allowing gases to be released high into the
atmosphere where combustion takes place.

- Uses: Suitable for continuous or emergency flaring of large volumes of gas.

- Advantages: Reduces the risk of radiant heat exposure and disperses combustion
products higher in the atmosphere, reducing environmental impact.

B. Ground Flare

- Description: Gas is burned at ground level in an enclosed or open chamber.

- Uses: Used where noise and light pollution need to be minimized, typically for smaller gas
volumes.

- Advantages: Reduces noise and visual impact while keeping combustion near the ground.

C. Enclosed Flare

- Description: The flare is enclosed in a combustion chamber, and the flame is not visible.

- Uses: Common in urban or sensitive environments where visible flames and noise need
to be minimized.

- Advantages: Controls emissions more efficiently and reduces light pollution.

2. Operating Conditions of Flare Systems

-Temperature: The combustion temperature inside the flare system can reach up to
1,200°C to 1,600°C. This high temperature ensures the complete combustion of
hydrocarbons and minimizes the formation of harmful emissions like carbon monoxide
(CO) or unburned hydrocarbons.

- Pressure: Flare header systems typically operate at low pressures ranging from 0.5 to 5
bar. The low pressure ensures that gases can be safely vented without excessive
backpressure on the process equipment.

- Flow Rate: Flare systems are designed to handle varying flow rates, depending on normal
and emergency flaring conditions.
3. Knockout Drum (KOD)

Purpose:

The Knockout Drum (KOD) is an essential component of the flare system, designed to
remove liquid droplets and heavier hydrocarbons from the gas stream before it reaches the
flare stack.

Function:

- Phase Separation: The KOD separates liquid and vapour phases, ensuring that only
gaseous hydrocarbons reach the flare.

- Preventing Liquid Carryover: By removing liquids, the KOD prevents dangerous flame
instability or liquid entrainment, which could lead to a violent flare.

Design:

- Vertical or Horizontal: Depending on the space and process requirements, KODs can be
vertical or horizontal.

- Capacity: The drum must be sized to handle the largest liquid slugs that could be
generated during upset conditions.

4. Flare Header Diameter and Pressure

Flare Header Diameter: The diameter of the flare header is critical in ensuring that gases
are safely transported from process units to the flare stack without excessive pressure drop
or backpressure. The size of the flare header is typically calculated based on:

- Flow Rate: The maximum anticipated flow of gases during emergency situations.

- Pressure Drop: A low pressure drop is essential to avoid excessive backpressure on the
upstream process.

- Material Considerations: The header must be made from materials that can withstand the
corrosive environment and high temperatures.

Flare Header Pressure: The operating pressure in a flare header typically ranges between
0.5 bar and 5 bar, with larger systems designed to handle surges in pressure during
emergency flaring scenarios.

5. Pilot Burner

Purpose: The pilot burner is a critical safety feature designed to continuously ignite the
gases as they are released through the flare stack. A reliable pilot flame ensures that flared
gases are combusted efficiently and prevents the release of raw hydrocarbons into the
atmosphere.

Design Features:

- Continuous Ignition: The pilot burner must be capable of maintaining a stable flame
under varying flow rates and environmental conditions.

- Dual Fuel Capability: In some systems, the pilot burners can operate using natural gas or
propane to ensure consistent operation.

- Monitoring: Pilot burners are equipped with flame monitoring systems (such as
thermocouples) to ensure continuous ignition.

6. Flame Arrestor

Purpose: A flame arrestor is used to prevent flashback (the flame traveling back down the
flare header) by extinguishing flames at key points in the flare system.

Function:

- Safety Device: Flame arrestors prevent the flame from traveling back into the gas line,
reducing the risk of explosions or damage to process equipment.

- Design: Flame arrestors are designed with a metallic mesh or baffle system that allows
gases to pass through but extinguishes flames by dissipating heat.

7. Water Seal

Purpose: The water seal in a flare system acts as a liquid barrier between the flare header
and the flare stack, maintaining a positive pressure in the flare header and preventing air
ingress into the system.

Function:

- Air Exclusion: The water seal prevents oxygen from entering the flare system, which could
create an explosive mixture.

- Pressure Maintenance: It helps maintain the required backpressure in the flare header
and ensures stable operation.

8. Use of Steam and Nitrogen in the Flare System

Steam:- Flame Stability: Steam is injected into the flare to enhance the mixing of gases and
improve flame stability.
- Smoke Suppression: Steam assists in reducing the formation of black smoke by providing
better combustion and oxidizing soot particles.

- Cooling: In some cases, steam is used to cool the flare tip and protect it from overheating.

Nitrogen:

- Purging: Nitrogen is used to purge the flare header and associated piping during startup or
shutdown to prevent the formation of explosive mixtures.

- Inerting: Nitrogen ensures that no oxygen remains in the flare header during operation,
preventing the risk of combustion within the piping.

9. Safety Systems in Flare Distribution

A. Flame Detection Systems:

Flame detectors (typically UV or IR sensors) are used to continuously monitor the flame in
the flare stack. If the pilot flame or flare flame is extinguished, the system sends an alert,
allowing operators to take corrective action.

B. Emergency Shutdown (ESD) System:

In the event of an abnormal condition, such as high pressure in the flare header or failure of
the pilot flame, the ESD system activates to isolate the flare system and prevent gas
release.

C. Pressure Relief Systems:

Pressure relief valves (PRVs) connected to the flare system ensure that over-pressurized
equipment can safely vent excess gases to the flare for combustion, protecting the process
units from damage.

D. Knockout Drum Overflow Protection:

Liquid level sensors in the KOD ensure that the vessel does not overflow, preventing liquids
from reaching the flare stack.

E. Noise and Radiation Shields:

In cases where the flare system operates at high flow rates, noise and radiation shields are
installed to protect personnel and equipment from excessive heat and noise generated
during flaring.
Conclusion

The flare distribution system is a critical safety component in the petrochemical industry,
designed to manage excess gases safely. Through a combination of knockout drums, flame
arrestors, pilot burners, water seals, and the use of steam and nitrogen, flare systems
ensure the safe combustion of volatile gases while protecting the plant from overpressure
and explosion risks. Adhering to best practices and incorporating advanced safety systems
ensures that flaring operations are both efficient and environmentally responsible.