Industrial Flares

Shivshakti is a reputed manufacture of Flare Stack Burner suitable for Oil and Gas, and Petrochemical Industries.

The Flare Stacks safely burn excess hydrocarbon gases which cannot be recovered or recycled. Excess hydrocarbon gases are burnt in the flare systems in an environmentally-sound manner, as an alternative to releasing the vapour directly into the atmosphere. During flaring, excess gases are combined with steam and/or air and burnt off in the flare system to produce water vapour and carbon dioxide. The process of burning these excess gases is similar to the burning of liquefied petroleum gases (LPG).

Flare design

A flare is a device used to safely dispose of unwanted or excess gases and liquids from normal, unplanned or upset conditions during process operations in Shivshakti sites. Flaring is done by burning off the gas or liquid into the atmosphere. The gases or liquids to be combusted are usually rich in heat content, enabling them to self-sustain the combustion without the need for additional external combustion gas.

A typical flare consists of a gas inlet connected to a flare header. Combustion is achieved through an ignition device located at the ground level and a pilot burner tip located at the top of the flare header. The gas to the pilot is usually provided from a utility source. A water seal or purge-gas arrangement is used to prevent any flashback into the process stream. A flare usually generates water vapor and CO 2, which are discharged into the atmosphere.

Flare types

Flares are classified into two common types: elevated and ground flares. Elevated flares are the most widely used flare type. In elevated flares, the gases are combusted using flare headers that are located at a considerable height above the ground. Elevated flares are again classified into several types, depending on the type of gas, the incoming gas pressures, smoking or non-smoking requirements, heat radiation levels and location. Elevated flares have an open flare associated with them. An open flare consists of a visible flame that generates heat and some noise.

Ground flares are systems where the combustion of the gases takes place at the ground level. Since these flames are close to the ground, they have to be enclosed in a refractory-lined chamber or enclosure. As combustion takes place at the ground level, gases are released close to the ground, resulting in poor gas dispersion. Due to these limitations, enclosed ground flares are commonly used in situations where the gases to be burned are relatively clean and when reducing noise pollution is critical.

Elevated and ground flares used which can be further classified into two types: single-point and multi-point flares. Single-point flares are typically oriented to fire upwards. Single-point flares can be smokeless or non-smokeless using air-assisted or steam-assisted designs, and are suitable for low-pressure applications. Multi-point flares are designed for higher-pressure applications and where smokeless burning is required. Multi-point flares are used to improve the burning by applying multiple burning points. These can be located on the ground level or at an altitude using boom supports.

Key features

• Flame holders fitted on the periphery of the flare tip ensure stable operation These flame holders provide a zone of recirculated flue gases/air, which prevent flame lift off, from the flare tip

• Wind deflectors to prevent flame impingement, due to flame lick in the low pressure zone, downwind of the tip

• Pilot burner arrangement to further stabilise the flame

• Use of high grade alloys to enhance lifetime of the flare tip

• Use of dynamic seal to reduce purge gas requirements and prevent flash back.

For Flare Stack Burner we supply flare tips, flare pilot ignition systems, elevated flare structures and associated flare equipment. Flare Stack Burner systems we supply are used at chemical plants, producer gas production facilities and power stations; in fact, anywhere there is a need to flare off large volumes of flammable gases quickly and safely.