Flares System

Design & Operation

By
Shahsawar
 Introduction

• Flare systems are designed primarily to

o Destroy uncontrolled or un-burnt vapors produced during
process upsets & emergency releases.
o Destroy flammable, toxic & corrosive vapors.
• A variety of flare styles & operating modes are
available for such applications.
• Flares may be designed for elevated, ground-level
or enclosed operation.
• Sizing & safety in designing a flare involve
consideration of
o Flare size or capacity
o Thermal & Solar Radiation
o Explosion hazards
o Liquid carry over
o Noise Level
o Ground level concentration of toxic material
Types
• Flares can be classified as :
1. Pipe Flares
2. Smokeless Flares
3. Endothermic Flares
1. Pipe Flares:
– Vertical or Horizontal pipes with external ignition pilot
– Used for HC vapor stream such as Methane, Hydrogen
& Carbon mono-oxide which produce limited smoke
when burnt
– Heavier HC may be burnt but with smoke.
– Velocity for open-pipe flares should be limited to Mach 0.4 to
minimize flame lift-off
2. Smokeless Flares:
– Vertical, single or multiple burners designed to properly mix
adequate oxygen from the air with relieved vapors for
complete combustion
 – Used for smokeless disposal of HC vapor streams.
– use a variety of methods such as steam, high pressure
fuel gas, water spray, an air blower or high velocity vortex
action to mix air with gas.
3. Fired Or Endothermic Flares:
– Elevated incinerators for low heat content waste streams
– When heat content of waste stream is below 4280KJ/m3
(~ 28 Btu/Scf) fired flare with a high energy assist gas
may be required for complete combustion.
Thermal Radiation:

• In flare design, thermal radiation is a prime concern.

• Thermal radiation calculations must be done to avoid
dangerous exposure to personnel, equipment and the
surrounding area.
• For safe operation, flare height must be selected based on
potential radiations level and should not exceed the allowable
levels on the ground.
• Length of flame & its angle in relation to stack is necessary to
calculate radiation levels at different locations.
Thermal Radiation (cont’d):

• The radiation level commonly used for designs

are attached. Typical design value is 1500-
2000 btu/hr-ft2.
• Geometric dimensions are needed to calculate
radiation level at a particular distance.
Solar Radiation:
• Solar radiation adds to the calculated flame
radiation and is dependent upon specific
atmospheric conditions & site locations but its
impact is minor on acceptable exposure time.
• Regardless of impact, solar radiation should
be considered in total radiation computation.
• Intensity of solar radiation is typically in the
range of 250-330 btu/hr-ft2.
Sizing :
• Sizing of a flare stack can be done either by
process engineer or vendor. In case of vender
design, following data is to be supplied to the
vendor.
 Type & sp. gr. of gas
 Site conditions i.e. elevation, ambient temp.& wind speed
 Design flow rate
 Design temperature
 Radiation Level (solar & thermal)
 Maximum Mach No. in stack
• Sizing of a flare stack at Accutech can be done by
using following:
 Excel Spreadsheets
Sizing steps:
1. Flare size or capacity:
Flare be sized properly for safety purpose because
– In an oversized flare flame may easily be extinguished by the
wind
– In undersize case, excessive flow rate may cause flame to lift off
the flare tip or blow out and result is escape of un-burnt
compounds
Flare diameter is generally sized on a velocity basis with a velocity
of upto 0.5 mach for a peak, short term, infrequent flow with 0.2
mach for normal conditions. Mach No. is calculated by eq.
M=1.702X10-5X(W/P2D2)X(ZT/KMw)0.5
where W =Flare gas flow,lb/hr
P2 =Press. at flare tip, psia
D =Flare ID, ft
T =Temp.,R
K =Ratip of specific heats
z =compressibility factor
MW= Mol. Wt.
Sizing steps (Cont’d):
2. Flame Length:
The heat liberated, Q (Btu/Hr) is calculated by the

eq.
Q=Flow rate (lb/hr) X Gas Heating Value (Btu/lb)
From API RP-521 fig.8 &9, flame length is
determined.
3. Flame Distortion caused by wind velocity:
Flame distortion caused by wind velocity is calculated by eq.
U∞/Uj= Wind velocity/Flare tip velocity
Flare tip velocity Uj may be determined as
Uj = 4* Q(Acf/sec) /πd2(ft ) 2

From API RP-521 fig.10,flame distortion due to

lateral wind i.e. ∑∆y/L & ∑∆x/L on jet velocity from
flare stack is determined which further entail ∑∆y &
∑∆x
Sizing steps:
4. Flare Stack Height:
The distance D, from the flame center to the object being
considered is calculated by the eq.
D =(TFQ/4 π K)1/2
Where T = Fraction of heat intensity transmitted~1.0
F = Fraction of heat radiated ~0.15-0.3
K = Radiation Level ,Btu/h-ft2

Flare stack height is calculated as follows:

H’=H+1/2∑∆y
R’=R-1/2 ∑∆y
at a distance of 150m,
R’=150-1/2 ∑∆y
As R’2=H’2+D2
By solving , H is worked out.
Stack Support:
To support stack, three common stack support methods are
used.
1. Self-supported:
2. Guy-wire supported
3. Derrick supported.
1. Self-supported:
• These are normally the most desirable.
• Most expensive because of greater material requirements
for structural integrity over conditions like wind, siesmic,
etc.
• Require less land area, limited to a height of 200-300ft.
2. Guy-wire supported:
• These are the least expensive, require largest land area due
to guy-wire radius requirements typically one-half the stack
height.
• Guyed stacks heights are of 600 to 800ft.
3. Derrick supported:
• Used only on larger stacks where self support is not practical
• Available land area is not available for a guy wire design.
Pilots & ignition:
• Reliable pilot operation under all wind & weather conditions
are essential.
• Flaring options are mostly intermittent & non scheduled. The
flare must be for full emergency duty to prevent hazardous
discharge to atmosphere.
• Wind shields & flame retention devices may be used to
ensure continuous piloting.
• Most pilots are designed to operate at wind velocity of 100
miles/hr & higher.
Seals:
• Seal is required to prevent air ingress and forming explosive
mixture and also to keep flame traveling back into plant
piping.
• Flare should be purged continuously with an oxygen free gas
if liq. seal is not provided.
Guidelines for Heat Intensities BTU/hr-ft² (W/m²)

Equipment Protection Required : 3000 (9465)

Working Safe Limit: 1250-1500 (3945-4735)
Tree.. Safe Limit: 950 (3000)
Personnel Safe Limit: 650 (2053)
Public Safe Limit: 440 (1390)

Liquid Carryover distance @ 2.5 x Stack height