Flare Gas Recovery Systems: Optimizing Natural Gas Usage in Refineries and Plants

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Flare Gas Recovery Systems

Efficient Handling of Flare Streams

Refineries and chemical plants generate flare gas streams as a byproduct of various processes. These gases are typically combusted through open flare stacks, resulting in emissions and wasted resources. Flare gas recovery (FGR) systems provide an effective solution for handling these streams in an environmentally-responsible manner. By capturing and reusing flare gases, facilities can optimize natural gas usage while reducing emissions.

Capturing Flare Streams for Reinjection

The first step in an FGR system is to install piping infrastructure to capture all potential flare gas streams before they reach the flare stack. Compressors are then used to re-inject the captured gases into the gas handling system or fuel gas network. Common sources tapped include flash tanks, coker units, desulfurization units, catalytic cracking units, and emergency relief valves. Separating water, hydrocarbon liquids, and particulate matter ensures only clean, dry gas enters the collection lines.

Continuous Monitoring Ensures Reliability

Sophisticated instrumentation continuously monitors conditions in the collection and reinjection systems. Pressure, temperature, and flow transmitters provide real-time data to control systems. Composition analyzers also check gas properties to confirm it meets fuel specifications before reinjection. Automatic control valves isolate any streams that could compromise operations. This level of monitoring guarantees reliable and safe handling of flare streams at all times.

Maximizing Gas Reuse Potential

With captured Flare Gas Recovery Systems conditioned and monitored, they can be effectively reused onsite. Common reuse methods include using the gas as supplemental fuel for heaters, boilers and gas turbines. It can also be blended into the fuel gas network supplying plant furnaces and reactors. In some cases, the Btu content is sufficient for external customers via gas sales. Proper sizing of equipment like compressors and pipelines maximizes the potential for flare gas reuse.

Addressing Unique System Challenges

While flare gas recovery systems delivers many benefits, each system faces unique design challenges depending on facility configuration. Ensuring compatibility with existing fuel gas infrastructure is important. Dealing with variable gas composition and intermittent flow also requires flexible system control. Special projects may be needed like installing new pipelines to access remote flare headers. Reliable power sources for instrumentation and compression are also critical to maintain uptime. Experienced engineers can develop customized solutions.

Continuous Emissions Reduction

By recovering previously flared gases, FGR systems provide immediate and ongoing reductions in emissions. Captured methane that would have been combusted is now put to higher value reuse. Emissions of nitrogen oxides, carbon monoxide, and other combustion byproducts are also eliminated. Many regions now mandate flare gas recovery targets as part of air quality regulations. Proper design and operation allows FGR systems to deliver continuous emissions savings year after year.

Minimizing Wasted Resources

In addition to environmental benefits, FGR reduces operational costs through optimized natural gas usage. Captured flare gas supplements the fuel supply, displacing higher cost fuel purchases. The Btu content of recovered gas can partially or fully meet fuel demands of various plant systems. Wasted flare gas is therefore put to productive use as an energy source. Proper reinjection also helps stabilize refinery fuel gas balance. Overall, FGR ensures resources are not wasted and fuel efficiency is increased.

Overall, flare gas recovery systems is a versatile solution that delivers emissions reductions and optimized natural gas usage for petrochemical refineries and plants. Through well-engineered collection, handling, and reinjection infrastructure, previously flared gases can be reliably captured and reused. This approach responsibly manages flare streams while minimizing emissions and reducing consumption of purchased fuels. With careful design addressing unique facility factors, FGR reliably meets operational and sustainability goals.

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About Author:

Money Singh is a seasoned content writer with over four years of experience in the market research sector. Her expertise spans various industries, including food and beverages, biotechnology, chemical and materials, defense and aerospace, consumer goods, etc. (https://www.linkedin.com/in/money-singh-590844163)

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