Flare Stack Smokeless Burner www.plantprocessenergy.com
Building Better Products Through Technology 41 HC Pioneer Parkway | Sulphur Springs, TX 75482 | Phone 903.689.5060 | Fax 903.689.5059
Flare Stack Smokeless Burner Advantages Plant Process offers Flare-Tip Burners capable of combustion completion when operated within design parameters set forth by Plant Process. Plant Process Smokeless Flare Burners include necessary internal components for efficiency, stability, and will meet or exceed current regulation requirements. Design parameters have been developed by Plant Process in order to operate the Smokeless Flare Burners. The burners have been designed with calculations for sizing two stages of air to mix with the waste gas to complete combustion. Plant Process has designed eight of these unique combustion burners for eight different site ranges. Plant Process can custom design burners for specific site conditions as needed. Plant Process has designed several variable smokeless flare burner tips using Jerry Lang’s Patented Technology, ranging from 1MSCFD to 6MMSCFD. These tips are available on new stationary and mobile flare stacks. Our flares are truly smokeless based on your site conditions including flow rates, waste gas composition, and pressure available. We design each burner to mix proper air with the gas coming off of your facility without blowers or steam. While you can buy similar systems from others, Emission control is our advantage and what we have been doing for many years.
EPA Requirements Flare Systems Meet All EPA Requirements Plant Process open flare systems are guaranteed to meet EPA requirements for 40 CFR 60.18 and have destruction removal efficiency (DRE) of 98%. If higher destruction is required, an enclosed flare system may be utilized if it is economically practical. Our designs are based on experience with flare installations and flow medium analysis supplied by customer. Plant Process is a leader in flare system innovation and design, having supplied and installed successful, proven systems nationwide. From our use of modern structural and control techniques, to our proven flare tip and seal designs, Plant Process is committed to manufacturing the best flares built. We are able to accomplish this goal in part due to the following: Plant Process believes in safety first. Our flare system designs adhere to the strictest of safety standards. Flares are of the highest quality. Flare Pilots are designed for years of reliable, continuous operation. Plant Process Flame Retention Rings promote stable combustion and prevent lift-off at high exit velocities. Plant Process Purge Seals are designed for maximum efficiency and low operating cost. Prompt and reliable pilot ignition/monitoring systems allow for optimum performance of the flare systems. Our experience and relentless pursuit to keep our customers happy are unmatched in the combustion and flare industries.
Building Better Products Through Technology 41 HC Pioneer Parkway | Sulphur Springs, TX 75482 | Phone 903.689.5060 | Fax 903.689.5059
Flare Stack Smokeless Tip Specifications Tip Specifications
H2S FLARING
1. GAS & SITE ANALYSIS TO COMPLY WITH • MSCF/d - Minimum/Maximum • PSI - Minimum Available/Maximum Available • BTU/ft3 / Specific Gravity
Hydrogen sulfide is a toxic gas and is most commonly obtained by its separation from sour gas, which is natural gas with high content of H2S. In most cases, this gas must be flared for the protection of people as well as environment. Many flares around shale areas are only flaring 40-50% of the hydrocarbons, leaving unburned hydrocarbons going into the atmosphere. H2S is slightly heavier than air so typical flares are not safe for combusting this molecular weight of gas while Plant Process’ flare burners combust this gas and burn it off first.
2. OTHER CONSIDERATIONS • Tip Velocity is calculated at less than 400 ft/sec • Ideal pressure on standard Plant Process burners is 30 PSI except when higher BTU gas is being burned than what the tip is designed for • Explanation: Heavier gasses (2,300 BTU/ft3 would use lower pressure than what the tip is for if it is designed for (1,400 BTU/ft3) 3. BURNER TIP CAPACITY FLOW RATE • 0 - 1,000,000 MSCF/d • 1,000,000 - 2,000,000 MSCF/d • 2,000,000 - 4,000,000 MSCF/d • 4,000,000 - 6,000,000 MSCF/d
Guarantee Plant Process can guarantee that when the smokeless burners are operated within their designed parameters, they will burn smokeless.
Uses • • • • • • • • •
Gas Well Facilities Flowback & H2S Flaring Centrifugal and Reciprocating Compressor Facilities Pneumatic Controller Facilities Storage Vessels & Tank Battery Facilities Equipment Leaks Facilities Sweetening Unit Facilities Natural Gas Processing Plants Crude Oil Tanker Vents and L.A.C.T.
Building Better Products Through Technology 41 HC Pioneer Parkway | Sulphur Springs, TX 75482 | Phone 903.689.5060 | Fax 903.689.5059
Flare Stack Specifications
4 x 40
4 x 60
6 x 60
Flare Tube Length ........................................................................................................................... 25’ - 78’ Flare Tube Diameter ....................................................................................................................... 4” - 10” Trailer Capacity ................................................................................................................. 2 - 8000lb axles Outriggers ...................................................................................................... 20 feet w/ Stabilizing Struts Liquid Collector .................................................................. 18” x 8’ S/S 75 PSI KOD (ASME code optional) Electrical ......................................................................................................................................... 12 VDC Hydraulic .................................................................................... 30” stroke (2500 PSI UP/500 PSI DOWN) Ignitors ........................................................................................................................................... DBI/ACL Service ............................................................................................................................... Sweet/Sour Gas Crew Size ...................................................................................................................................... 2-Person
Building Better Products Through Technology 41 HC Pioneer Parkway | Sulphur Springs, TX 75482 | Phone 903.689.5060 | Fax 903.689.5059
Flare Stack Pilot Igniter
Plant Process’ SP8 Series Spark Ignited Pilots are designed to provide an ignition source for small to medium size flares. Ignition of the pilot gas is assured by an intermittent spark in the pilot nozzle every two seconds regardless of the pilot flame temperature. Control for the SP8 Series Pilots includes a Spark Oscillator Module, thermocouple controller (with alarm contacts and an analog temperature retransmission signal), battery and battery charger in a Nema 4 fiberglass enclosure. The standard controls for the SP8 Series Pilots are designed to operate on 120 VAC and will provide 10 hours of operation during power disruption. Minimum methane requirement for this pilot is 70scfh@ 5 psi. As with all of our equipment, custom pilots and controls are offered to meet field requirements. • • • •
Burner fabrication material 306 SS Pilot fabrication material 306 SS Stack fabrication material A-106 NACE Wind loading analysis for 80 MPH
Building Better Products Through Technology 41 HC Pioneer Parkway | Sulphur Springs, TX 75482 | Phone 903.689.5060 | Fax 903.689.5059
Flare Stack Warranty
Warranty applies to fabrication, defective workmanship or materials, assembly and manufactured components. Plant Process Energy warrants all fabrication and assembly for one (1) year from the date that each flare is commissioned successfully. Warranty does not cover the removal, re-installation or modification of equipment. All manufacturers’ warranties for third party components installed are passed on and these items are not underwritten by Plant Process Energy. Any defective component must be returned to Plant Process for replacement under warranty. Shipping costs and labor to replace the items are not covered by warranty. Plant Process Energy guarantees and warrants that the environmental control equipment supplied will effectively thermally oxidize the waste gas for the process conditions specified herein. Plant Process Energy does not provided any performance guarantee if the operating conditions differ from the client specified design conditions as detailed in this proposal or if the sizing and design of the equipment has been provided to Plant Process by others. Plant Process Energy liability hereunder shall be limited to the obligation to repair or replace only those products proven to have been defective in material or workmanship at the time of delivery. Warranty does not cover the removal, reinstallation or modification of equipment. Plant Process Energy total cumulative liability in any way arising from or pertaining to any product sold or required to be sold under this contract shall not in any case exceed the purchase price paid by Buyer for such products. In no event shall Plant Process Energy have any liability for commercial loss, lost profits, claims for labor, or consequential or incidental damages of any type, whether buyer’s claim be based in contract, tort, warranty, strict liability, negligence, or otherwise. It is expressly agreed that buyer’s remedies expressed herein are buyer’s sole and exclusive remedies. The above stated warranty, which is given expressly in lieu of all other warranties, expressed or implied by the customer, trade usage or law, including warranties of merchantability and fitness for particular purpose, constitutes the only warranty made by the seller.
Building Better Products Through Technology 41 HC Pioneer Parkway | Sulphur Springs, TX 75482 | Phone 903.689.5060 | Fax 903.689.5059
Contact Request a Quote
To Learn more about our products or Request a Custom Quote Contact Us: Plant Process Energy 41 HC Pioneer Parkway Sulphur Springs, TX 75482 Phone 903.689.5060 Fax 903.689.5059 sales@plantprocessenergy.com www.plantprocessenergy.com
Building Better Products Through Technology 41 HC Pioneer Parkway | Sulphur Springs, TX 75482 | Phone 903.689.5060 | Fax 903.689.5059