Flare System

MEMBERS
1. Yutika Naik (U19CH002)
2. Vijay Pratap (U19CH005)
3. Bharvi Patel (U19CH021)
4. Mayushi Gamit (U19CH025)

MENTORS

1. Sagar Jariwala (U18CH062)

2. Riya Shah (U18CH064)
CONTENTS CONTENTS

Contents
1 Flare system 2
1.1 What is Flare? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 When do we Flare? . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Why do we flare? . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Gas flaring composition: . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Types of flare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.5.1 By the height of the flare tip . . . . . . . . . . . . . . . . 5
1.5.2 By the method of enhancing mixing at the flare tip . . 6
1.6 Parts and uses of Flare system . . . . . . . . . . . . . . . . . . . 10
1.7 Detailed information on parts of flare system . . . . . . . . . . 11
1.7.1 Knockout drum . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.7.2 Liquid Seal drum . . . . . . . . . . . . . . . . . . . . . . . . 13
1.7.3 Alternative gas recovery system . . . . . . . . . . . . . . 15
1.7.4 Steam injection system . . . . . . . . . . . . . . . . . . . . 15
1.7.5 Pilot and Ignition Systems . . . . . . . . . . . . . . . . . . 16
1.7.6 Manual Ignition Tube System . . . . . . . . . . . . . . . . 18
1.7.7 Retractable Ignition Systems . . . . . . . . . . . . . . . . 18
1.7.8 Flare stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.7.9 Flashback prevention system . . . . . . . . . . . . . . . . 19
1.8 Disadvantages of flaring . . . . . . . . . . . . . . . . . . . . . . . 20
1.8.1 Impact on health: . . . . . . . . . . . . . . . . . . . . . . . 20
1.8.2 Impact on environment: . . . . . . . . . . . . . . . . . . . 23
1.9 Government norms for flaring . . . . . . . . . . . . . . . . . . . . 24

2 Flare gas recovery system 26

2.1 Types of FGRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.2 Parts of FGRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.2.1 Liquid ring compressor . . . . . . . . . . . . . . . . . . . . 27
2.2.2 Three phase separator . . . . . . . . . . . . . . . . . . . . 29
2.3 How a FGRS unit Works . . . . . . . . . . . . . . . . . . . . . . . 31

3 Automatic flare ignition system 33

3.1 Benefits of the automatic ignition system: . . . . . . . . . . . . 33

4 Smokeless Flaring 34

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CONTENTS CONTENTS

5 Purge Reduction System 35

5.1 What is Purge Gas? . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.2 Purge Reduction Seals . . . . . . . . . . . . . . . . . . . . . . . . 35
5.2.1 Velocity seal . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.2.2 Molecular seal . . . . . . . . . . . . . . . . . . . . . . . . . 36

6 Aspen flare system analyser 37

6.1 Streamlined With Process Simulation . . . . . . . . . . . . . . 37
6.2 Rigorous and Flexible Solution . . . . . . . . . . . . . . . . . . . 37
6.3 Trusted Accuracy of FLARENET . . . . . . . . . . . . . . . . . 38

7 Flowsheets in Aspen flare system analyser 39

7.1 Flowsheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.2 Flowsheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

8 DWSIM 42
8.1 Thermodynamic models . . . . . . . . . . . . . . . . . . . . . . . 42
8.2 Unit operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.3 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.4 Process Analysis and Optimization . . . . . . . . . . . . . . . . 44
8.5 Extras . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

9 Flowsheet in DWSIM 45
9.1 Design 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

10 Basic defiitions 47

11 Conclusion 49

12 References 50

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CONTENTS CONTENTS

Acknowledgement

We are thankful to ChES for conducting ’Eureka!’ and for providing us such a
platform from which we gained knowledge about Flare system. We are very thankful
to our mentors Riya ma’am and Sagar sir for their constant guidance and support.

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CONTENTS CONTENTS

Abstract

During the oil and gas extraction and their refining processes, at petroleum industry;
a large amount of unused gases is sent to the flare system, so the flare system becomes
both a safety and environmental control device. Both carbon dioxide and methane
(the major components of natural gas) are known as greenhouse gases associated
with concerns about global warming.Using flare gas recovery system we can reduce
the flare gas emissions which mainly consists of natural gas and also cost of natural
gas can be reduced. Since the inception of flaring, technology advancements have
made flare system more environment-friendly. These include:
1. Reducing the fuel consumption of flare pilots
2. Implementing purge reduction devices to reduce the amount of supplemental fuel
gas burned
3. Using steam more efficiently to achieve smokeless flaring
4. The automatic ignition system and
5. Installing flare gas recovery systems to reduce the amount of gas flared. Our aim
is to make flare system more environment-friendly, safe and efficient using flare gas
recovery system by preparing a simulation model in Aspen HYSYS.

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 1 FLARE SYSTEM

1 Flare system

1.1 What is Flare?

A gas flare, alternatively known as a flare stack is a gas combustion device used
in industrial plants such as petroleum refineries, chemical plants, and natural gas
processing plants, and at oil or gas production sites with oil wells, gas wells, offshore
oil and gas rigs, and landfills.

1.2 When do we Flare?

Flare systems provide for the safe disposal of gaseous wastes. Depending on local
environmental constraints, these systems can be used for:
1.Extensive venting during start up or shut down.
2.Venting of excess process plant gas.
3.Handling emergency releases from safety valves, blow-down and depressuring sys-
tems.

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1.3 Why do we flare? 1 FLARE SYSTEM

1.3 Why do we flare?

In general, flaring is for pressure relief without simply venting dangerous chemicals
to the environment. Flaring often occurs during discovery and testing of an oil well.
During operation of a well, it can be that there are gases which are not economical to
transport or capture, and so are flared. It can also occur during chemical processing.
In chemical processing, flaring is usually to remove waste products or for emergency
pressure relief. Start-up and shutdown of plants are also common sources of flaring;
the list of possible examples is long.
Products of flaring are often water and carbon dioxide with usually greater than
98% combustion of volatile organic compounds. This is excellent from a toxicity
standpoint. Depending on the inlet gasses, other products such as sulfur dioxide are
possible, which can be locally restricted. Flaring can be used in place of venting
waste streams to reduce the load of toxic or greenhouse gasses, such as methane,
which is more than 20 times as deleterious as carbon dioxide towards global warm-
ing, where carbon dioxide is a direct combustion product. In this way, flaring is far
more acceptable than venting, or simply releasing chemicals into the atmosphere.

1.4 Gas flaring composition:

Generally the flare gas consists of a mixture of different gases. The composition de-
pends upon the source of the gas going to the flare system. Associated gases released
during oil-gas production mainly contain natural gas. Natural gas is more than 90
percent methane (CH4) with ethane and a small amount of other hydrocarbons; in-
ert gases such as N2 and CO2 may also be present. Gas flaring from refineries and
other process operations will commonly contain a mixture of hydrocarbons and in
some cases H2. However, landfill gas, biogas or digester gas is a mixture of CH4 and
CO2 along with small amounts of other inert gases. There is in fact no standard
composition and it is therefore necessary to define some group of gas flaring accord-
ing to the actual parameters of the gas. Changing gas composition will affect the
heat transfer capabilities of the gas and affect the performance of the measurement
by flow meter. An example of waste gas compositions at a typical plant is listed in
Table below. This is Waste gas compositions at a typical plant
The value of the gas is based primarily on its heating value. Composition of flared
gas is important for assessing its economic value and for matching it with suitable

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1.4 Gas flaring composition: 1 FLARE SYSTEM

process or disposal. For example, for transport in the upstream pipeline network, the
key consideration is the H2S content of the gas. Gas is considered sour if it contains
10 mol/kmol H2S or more.

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1.5 Types of flare 1 FLARE SYSTEM

1.5 Types of flare

1.5.1 By the height of the flare tip
1.Elevated Flare

2.Ground Flare:
1)Enclosed flare

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1.5 Types of flare 1 FLARE SYSTEM

2)Open flare

1.5.2 By the method of enhancing mixing at the flare tip

1.Steam-assisted flares

Steam assisted flares are designed to dispose of heavier waste gases which have a
greater tendency to smoke. In order to prevent incomplete combustion, steam is
injected into the waste stream using peripheral steam rings, center steam spargers,
and/or inner induction tubes. The injection of steam has two principal effects:
High-pressure steam flow causes turbulence in the waste stream which improves mix-
ing and therefore improves combustion efficiency.
Additional air is induced into the waste gas providing the oxygen necessary for aug-
mented smokeless capacity. Steam flares are typically used in applications where the
customer has high-pressure steam available on site.

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1.5 Types of flare 1 FLARE SYSTEM

Advantages:
Low maintenance costs High smokeless capacity due to steam injection Stable, reli-
able combustion due to flame retention ring High smokeless flow rate Longer tip life
due to steam cooling effect.
SA MODEL:
External steam injection stabilizes the flame and entrains air, ensuring efficient com-
bustion
SAI MODEL:
Internal induction tubes with venturi inlets for improved air inspiration Higher
smokeless capacity Reduced noise at a given capacity

2.Air-assisted flares

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1.5 Types of flare 1 FLARE SYSTEM

Air-assisted flares are comprised of two risers (waste gas and air) and a blower sys-
tem that provides supplemental combustion air. Air is fed by the blower into the air
riser, to combine with the process gas, which passes through its own secondary riser
to the flare tip.. Upon mixing, the auxilliary air flow causes turbulence in the waste
gas stream, improving mixing, and ultimately combustion efficiency. These flares
generally dispose of heavier waste gases which have a greater tendency to smoke.

3.Non-assisted flares

The non-assisted flare is just a flare tip without any auxiliary provision for enhanc-
ing the mixing of air into its flame. Its use is limited essentially to gas streams that
have a low heat contentand a low carbon/hydrogen ratio that burn readily without
producing smoke. These streams require less air for complete combustion, have lower
combustion temperatures that minimize cracking reactions, and are more resistant
to cracking.

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1.5 Types of flare 1 FLARE SYSTEM

4.Pressure-assisted flares

Pressure-assisted flares use the vent stream pressure to promote mixing at the burner
tip. Several vendors now market proprietary, high pressure drop burner tip designs.
If sufficient vent stream pressure is available, these flares can be applied to streams
previously requiring steam or air assist for smokeless operation. Pressure-assisted
flares generally (but not necessarily) have the burner arrangement at ground level,
and consequently, must be located in a remote area of the plant where there is plenty
of space available. They have multiple burner heads that are staged to operate based
on the quantity of gas being released. The size, design, number, and group arrange-
ment of the burner heads depend on the vent gas characteristics.

5.Gas-assisted flares

Gas-assisted flares are comprised of two risers (waste gas and assist gas) and an
assist gas distribution ring at the tip that provides turbulence with combustion air
and waste gas at the flare tip. Upon mixing, the increased turbulence in the waste
gas stream, improves combustion efficiency and smokeless performance. These flares
generally dispose of heavier waste gases which have a greater tendency to smoke and
are favored in applications where electrical utilities are limited. For upstream Oil
and Gas production sites, we have developed a suite of standard INFERNO series
Gas Assist Flares that provide great performance at an attractive price point

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1.6 Parts and uses of Flare system 1 FLARE SYSTEM

1.6 Parts and uses of Flare system

Parts of flare system and their uses:

1. A knockout drum to remove any oil or water from the relieved gases.
2. A water seal drum to prevent any flashback of the flame from the top of the flare
stack.
3. An alternative gas recovery system for use during partial plant startups and shut-
downs as well as other times when required.The recovered gas is routed into the fuel
gas system of the overall industrial plant.
4. A steam injection system to provide an external momentum force used for efficient
mixing of air with the relieved gas, which promotes smokeless burning.
5. A pilot flame (with its ignition system) that burns all the time so that it is avail-
able to ignite relieved gases when needed.
6. The flare stack, including a flashback prevention section at the upper part of the
stack.

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1.7 Detailed information on parts of flare system 1 FLARE SYSTEM

1.7 Detailed information on parts of flare system

1.7.1 Knockout drum
A flare knockout drum is a vessel primarily used to remove any liquids or liquid
droplets from the flare gas. It is also known as a flash drum or a knockout pot.
The knockout drums are designed and sized according to a specific length-to-
diameter ratio between 2 to 4 to maintain the vapour velocity low enough so that
the liquids drop out or settle out. We dramatically reduce the speed of the gas so that
the liquid droplets settle out. We manually drain or pump the liquids out regularly
to ensure the flare KO is always empty of fluid.
Most knockout drums are horizontal. A horizontal knockout drum must have a
diameter large enough to keep the vapour velocity low enough to allow entrained liq-
uids to settle or drop out. All flare systems are designed to include a liquid knockout
drum. As per the safety and industry standards, the particle size should be between
400 to 500 micrometer which is why most flares are crafted to allow liquids with a
particle size less than 300 micrometer. They are operated at an atmospheric pres-
sure that allows the greatest liquid volume anticipated at the maximum rate of liquid
pump out and build up. For onshore operations, it is advised to allow a 10-minute
liquid holdup and take 20 percent of the maximum liquid stream. For offshore activ-
ities, a separation-retention time of 1 – 3 minutes with regards to API gravity must
be provided, and an emergency dump design without valves is recommended to han-
dle the maximum liquid flow. The maximum allowable working pressure (MAWP)
of the knockout drum is typically kept at 50 pounds per square inch gauge (psig) to
maintain an explosion.

Horizontal Drums

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1.7 Detailed information on parts of flare system 1 FLARE SYSTEM

This is a preferred design when a large quantity of liquid is required to be stored.

The standard length-to-diameter ratio of the horizontal drums ranges from 2 to 4,
and it should be large enough to contain the liquids and allow them to settle. They
are either designed to let vapours inside from one end and exit at the opposite top
side or enter from the center and leave at each end of the vessel.

Vertical Drums

They have vapour inlet nozzles placed radially, and the top of the drum’s verti-
cal axis has the outlet nozzle. They are also available with a tangential spout. Here
gravity causes the liquid to settle down at the bottom of the vessel, and the vapour
travels upwards.

Tangential Knockout Drums

These are vertical vessels with tangential nozzles. They are designed in a way to al-
low gases to enter and spin around a center tube that extends below the liquid inlet
nozzle. The gases and liquids flow downwards, which causes droplets of liquid to fly

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1.7 Detailed information on parts of flare system 1 FLARE SYSTEM

off and gather on the sides of the drum and gather at the bottom. Once the vapours
reach the bottom of the center tube, they change direction and flow upward and out
of the nozzle. Common Features All knockout drums include the vapour-liquid inlet
line, the vapour area, and the liquid zone. They also have a liquid level gauge or
an indicator, a control valve, a de-entrainment pad, and an intel distributor in some
cases.

Functions of flare knockout drum:

The primary aim is to remove any water or oil from the relieved gases. To knock out
free liquid gas or water that enters a compressor when it is at the point of suction.
When it is at the fuel stack’s bottom, its function is to knock out the free liquid.
It also works to entrain crude oil into the furnace or the burner.

1.7.2 Liquid Seal drum

The purpose of a liquid (commonly water) seal drums in a flare gas system in three-
fold:
Performance Features:
1.It operates as a non-return device preventing interaction from the outlet to the
inlet of the drum.

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1.7 Detailed information on parts of flare system 1 FLARE SYSTEM

2.It operates as an upstream pressure relief valve preventing gas flow from the inlet to
the outlet until a particular upstream pressure, frequently predetermined, is reached.
3.It acts as a diversionary unit for:- Ground flare to elevated flare systems; ground
flare to ground flare systems; Elevated flare to elevated flare systems; Fuel gas re-
covery systems to elevated flare.

Advantages:
1.Designed to prevent pulsing of the gas flow to the flare.
2.Ensures totally safe flare operation.
3.Can be designed to accommodate a future fuel gas recovery scheme.
4.Cost saving for fuel gas recovery installations.

Mode of Operation:
Part of the gas supply line dips below the surface of a reservoir of liquid contained
in the drum. The depth to which this dip tube is covered by liquid controls the gas
pressure required to cause flow. The pressure of the incoming gas displaces sustain
the flow and maintains the liquid displacement. When the flow or pressure falls the
liquid regains its original level and the flow ceases.
Water is normally used as the sealing medium but other liquids may be used for low
temperature applications or to prevent the gas being absorbed.

Design Characteristics:
Many variations of seal drum are available to suit requirements but all serve the
same basic function. In all cases the inlet tube forms the dip leg and the gas, having
displaced all liquid from the tube, bubbles through the liquid to the riser. The level
of liquid controls the back pressure.
The basic concept is simple but if the liquid seal is not correctly designed, bubbling
of gas through the liquid at low flows, or a surging motion of the liquid, can result
in a pulsating flow of gas.
A pulsating flow is a serious problem when the seal is used in conjunction with a
smokeless flare tip. The smoke suppressing effect of the tip remains constant whilst
the gas flow pulsates and this produces changes in the flame pattern creating smoke
and excessive noise.
An AFG Combustion designed liquid seal eliminates pulsating flows as well as ensur-
ing that sufficient water is retained to seal the flare header as soon as flaring ceases.
The liquid seal can be supplied as an integral part of a flare stack or as a remote
unit. It is designed to pressure vessel codes as required, and can be horizontally or

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1.7 Detailed information on parts of flare system 1 FLARE SYSTEM

vertically positioned.

1.7.3 Alternative gas recovery system

Flare Gas Recovery Systems (FGRS) are specialized compression packages, which
aim to recover and repurpose gasses and emissions, such as methane/LPGs and sulfur
dioxide, that would normally be burned during the flaring process. Key to the safe
operation of refineries and petrochemical facilities, the process involves capturing the
gas from the flare knock-out vessel and compressing it using liquid ring compressors.
The so-recovered gases can be reused within the facility’s fuel gas system, as a refinery
feedstock or for re-injection.
This topic has been discussed in a detailed manner later in the documentation.

1.7.4 Steam injection system

Basic requirements for steam injection system:
1. High pressure steam must be available
2. High alloy material construction in the heat affected zone prevents induction
tubes, rings, and spargers from warping and cracking
Primary or secondary steam injection through:
1. Peripheral ring (SA Model)
2. Center sparger (SA and SAI Models)
3. Internal induction tubes (SAI Model)
4. Flame Retention Ring to stabilize combustion
5. Low noise design with the use of external noise muffler (SAI Model)

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1.7 Detailed information on parts of flare system 1 FLARE SYSTEM

1.7.5 Pilot and Ignition Systems

What’s the difference between a Pilot and an Ignitor?

Simply put that a pilot is continuous, it’s always on. The pilot flame serves to
light the waste gas stream exiting the flare, or inside an incinerator, or any other
combustion unit. You need to have an available fuel gas supply in order to install a
continuous pilot.

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1.7 Detailed information on parts of flare system 1 FLARE SYSTEM

An ignitor (or ignition system) is an intermittent spark or flame front that is re-
sponsible for keeping the pilot lit. On systems where there is no on site fuel supply
available, and therefore no pilot, the ignitor may be used to light the waste gas
stream directly.

1. Standing Pilot
Tornado pilots are made from Silica Carbide. They are wind-proof up to 200 mph,
fuel-efficient, and resistant to the most corrosive conditions. Tornado pilots offer the
following benefits over competitive units:
1. Low fuel consumption 25 SCFH
2. Short intense blue flame
3. Tested to wind speeds of 200mph
4. Suitable for H2S
In Alberta, as per AER Directive 060, if a waste gas stream being flared has more
than 1 percent H2S then a standing pilot or electronic sparking ignition system is
required (excluding gas plants)

2. Standing Pilot with Monitor and Auto-Relight System

The ultimate in fail-safe reliability, the Tornado Pilot Monitor and Auto Relight
(TPMR) is used to relight the pilot in the rare case where flame failure may occur.
The TPMR system operates a continuous standing pilot made of silica carbide.
An enclosed thermocouple sits within the nozzle monitoring its temperature to detect

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1.7 Detailed information on parts of flare system 1 FLARE SYSTEM

flame failure. Should the pilot flame go out, the TPMR will activate an auto-relight
process by opening a solenoid valve and igniting a stoichiometric fuel-air mixture.
This sends a flame front to relight the pilot and the flare remains fully functional. If
the system encounters a problem it cannot correct itself, the Tornado unit initiates
an auto-shutdown to close the fuel gas supply to the pilot and activates an alarm.
In Alberta as per AER Directive 060, a standing pilot with automatic ignition
is required for gas plants flaring waste gas streams with greater than 0.001 percent
H2S
3. Electronic Ignition System The Tornado Electronic Ignition System (TEIS)
is used in low flow, high heat value and high flammability gas streams. It is designed
to arc every 30 to 45 seconds to directly light the waste gas stream where no fuel gas
supply (therefore no continuous pilot) is available.
In Alberta, as per AER Directive 060, if a waste gas stream being flared has more
than 1 percent H2S then a standing pilot or electronic sparking ignition system is
required (excluding gas plants)

1.7.6 Manual Ignition Tube System

A Tornado torpedo tube is a manual ignition system used to ignite both standing
pilots (as used on a TPMR system) or for igniting a flare via a shot tube running the
length of the flare. The most rudimentary of all systems, the torpedo tube carries a
shot from a flare gun to the top of a flare stack to ignite the waste gas stream. These
systems are not recommended for stacks over 100-feet tall.

1.7.7 Retractable Ignition Systems

Tornado standing pilots and TEIS ignition systems can be mounted on the side of
a flare stack retractably. This enables any maintenance operation to these pilot sys-
tems to be done easily from the ground, without the need for cranes or ladders to
remove them from the flare’s tip.

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1.7 Detailed information on parts of flare system 1 FLARE SYSTEM

1.7.8 Flare stack

Combustion of relief gases at elevation to minimize radiation exposure to personnel/
equipment/ structure.

Types of stacks:

1. Self-Supported
2. Derrick
3. Guyed- supported
4. Tripod

1.7.9 Flashback prevention system

The flashback prevention section at the top of the flare stack also prevents atmo-
spheric oxygen ingress into the flare stack and thus prevents the formation of an
explosive mixture.

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1.8 Disadvantages of flaring 1 FLARE SYSTEM

1.8 Disadvantages of flaring

1.8.1 Impact on health:
Impact of Gas flaring on Man

The investigations made are based on some selected wastes (gases) common to most
production fields during flaring; these are CO, H2S, and NOX gases. The detailed
investigations are elaborated below.

1. Carbon monoxide: This is one of the harmful gases released during flaring; it
is normally referred to as smoke. This gas causes reproduction problems to man
which is normally identified as Reproductive toxicity of Carbon monoxide. Carbon
monoxide is therefore a suspected and primary cause of reproductive toxicity. The
exposure to it has the potential to negatively affect the human reproductive system.
However, the gas has a wide range of applications in the food, chemical and oil indus-
tries. The severity and nature of the adverse effect is variable and can be influenced
by factors such as sex, level of exposure and individual sensitivity to the chemical.
There is evidence which indicate that some women exposed to carbon monoxide may
suffer adverse effects as a result. Carbon monoxide effects on the female reproductive
systems can include such things as:

1) Menstrual Problems, which include; Dysmenorrhoea, a medical term which means

painful period, Menorrhagia which also means heavy periods.

2) Altered Sexual Behaviour; in this effect the hormones for sex drives are low-
ered.

3) Infertility; this is the inability of an individual to be reproductive.

4) Altered Puberty Onset; the normal puberty onset for female (girls) is between
the ages of 9 and 14, but the effect of the CO gas lowers the age range thereby
causing girls to reach puberty prematurely.

5) Altered Length of Pregnancy; the normal length of pregnancy in human (women)

is 9 months, but the effect of CO on a pregnant woman causes her to deliver prema-
turely from 6 to 8 months.

6) Lactation Problems; this is where the nursing mother lacks breast milk to nurse

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1.8 Disadvantages of flaring 1 FLARE SYSTEM

her baby due to the exposure of the gas.

7) Altered Menopause Onset and pregnancy outcome; Menopause is the stage in

which there is a declination in the production of hormones responsible for sex drives
in women. The normal age is between 45 and 50. The exposure of CO causes women
to approach their menopause earlier before the actual age.

8)Spontaneous abortion (miscarriage) and low birth weight are also possible ad-
verse effects. The birth weight of a life born infant of less than 2, 500 grams can
be described as Low Birth Rate. Regardless of the gestation age. These adverse ef-
fects are generally only likely to occur in cases involving chronic exposure to carbon
monoxide.Effects on the male reproductive system can include such things as altered
sexual behavior, altered fertility and problems with sperm shape or count. These
adverse effects are also likely to occur in cases where chronic exposure is observed
though low concentrations of carbon monoxide (CO) also have adverse effects which
include; fatigue in healthy people and chest pain in people with heart diseases.
At higher concentrations, exposure can also cause impaired vision and coordination,
headaches, dizziness, confusion and nausea just to mention a few. Acute effects are
as a result of the formulation of carboxyhemoglobin in the blood, which inhibits
oxygen intake. Exposure to CO at moderate concentrations may result in angina
attacks, impaired vision, and reduced brain function. CO exposure can be fatal at
higher concentrations.

2. Hydrogen Sulphide (H2S) Hydrogen Sulphide is a poisonous gas that has an

adverse effect on humans as well as the environment. Exposure to low concentra-
tion of this gas causes irritation of the eyes, nose, or throat. In some cases it may
also cause difficulty in breathing for someone suffering from asthma. Brief exposure
to high concentration of hydrogen sulphide often (greater than 500 ppm) can cause
a loss of consciousness and possibly, death. In most cases, the person appears to
regain consciousness without any other effects. However in many individuals, there
may be permanent or long term effects such as headaches, poor attention span, poor
memory, and poor motor function.

3. Nitrogen Oxides (NOX)

Nitrogen Oxides (NO and N are a mixture or family of gases that can cause a
number of serious health effects. Nitrogen dioxide (NO2) is unhealthy to breathe
due to its complex health effects, especially for the under aged (children), the el-

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1.8 Disadvantages of flaring 1 FLARE SYSTEM

derly, asthmatics and people suffering from chronic obstructive pulmonary diseases.
However, NOx is also a key component to the formation of Ozone and Photochemical
oxidants. Breathing low levels of ozone, for instance, can trigger asthma attacks and
other problems for people with pre-existing respiratory problems. NOx also reacts
with ammonia, and other compounds to form nitric acid and related particles. These
tiny particles cause effects on breathing and the respiratory system, damage to lung
tissues, and even premature death.

22
1.8 Disadvantages of flaring 1 FLARE SYSTEM

1.8.2 Impact on environment:

Emissions as a result of flaring contribute to a severe environmental impact due to
the chemicals in the emissions; one of the effects is the cause of acid rain. Acid rain
is any form of precipitation with high levels of nitric and sulphuric acids. It can also
occur in the form of snow, fog, and tiny bits of dry material that settle on Earth.
Nevertheless rotting vegetation and erupting volcanoes also release some chemicals
that can cause acid rain, but most acid rainfall is attributed to human activities. The
biggest culprit is the burning of fossil fuels typically flaring and also by coal-burning
power plants, factories, and automobiles.
During flaring, Sulphur dioxide (SO2) and nitrogen oxides (NOx) are released into
the atmosphere.These chemical gases react with water, oxygen, and other substances
to form mild solutions of sulphuric and nitric acid. These acidic solutions may be
spread across the atmosphere and over hundreds of miles by winds. When acid rain
reaches Earth, it flows across the surface in runoff water,thereby entering water bod-
ies, and sinks into the soil. This rain (Acid rain) has many ecological effects, but none
is considered greater than its impact on streams, wetlands, lakes, and other aquatic
environments. Acid rain acidifies waters and causes them to absorb the aluminium
that makes its way from soil into water bodies such as lakes and streams. This ef-
fect makes water bodies toxic to aquatic life, organisms such as crayfish, clams, fish,
and other aquatic animals are greatly affected. It is noted that some species can
tolerate acidic waters better than others. However, in an interconnected ecosystem,
some species eventually impacts many more of the absorbed acids to other organisms
throughout the food chain including non-aquatic species such as birds.
Forests with much more exposure to acid rain can be destroyed, especially those
at higher altitudes. This rain leaches off essential nutrients in the soil and releases
aluminium into the soil, which makes it difficult for trees to absorb water. Leaves
and shrubs of trees and plants are also harmed by the acids. The effects of acid
rain, combined with other environmental impacts, leave trees and plants less able to
withstand cold temperatures, insects, and disease. The pollutants may also inhibit
trees’ ability to reproduce.
Some soils are better and able to neutralize acids than others, this is usually found
in areas where the soil’s ability to withstand rapid pH fluctuation is low. The severe
impact of acid rain are much greater, the only way to fight acid rain is by controlling
the release of the pollutants that causes it. This means burning fewer fossil fuels
(Flaring). Many governments are trying to find solutions to control emissions, these
include the cleaning up of industry smokestacks and promoting an alternative fuel
sources. The issue of acid rain cannot be dealt with today for an immediate responds,
it would take decades for this problem to be solved.

23
1.9 Government norms for flaring 1 FLARE SYSTEM

1.9 Government norms for flaring

The Environment Protection Rules 1989 provide that all gaseous emissions must be
flared. Elevated flares must be used except where it might affect crop production,
in which case ground flares can be used. In addition, the Environment Protection
Rules provide requirements with respect to flares, including minimum stack freight,
height of stack and green belt.
Under the Oil Mines Regulations 2017, the gas produced at any installation must be
discharged into the atmosphere from a flare line. The Oil Mines Regulations 2017
prescribe flare-stack height, anchoring requirement for flare-line and provision of re-
mote controlled electrical ignition device to ensure continuous ignition of any gases.
Elevated/ground flares:
1. Cold venting of gases never be resorted to and all the gaseous emissions are to be
flared.
2. All flaring shall be done by elevated flares except where there is any effect on crop
production in adjoining areas due to glaring. In such cases, one should adopt ground
flaring.
3. In case of ground flare, to minimise effects of flaring, the flare pit at GGS/OCS
should be made of RCC surrounded by a permanent wall (made of refractory brick)
of minimum 5 m height, to reduce the radiation and glaring effects in the adjoining
areas.
4. A green belt of 100 m width may be developed around the flare after the refractory
wall in case of ground flaring.
5. If the ground flaring with provision of gree belt is not feasible, enclosed ground
flare system should be adopted, and should be designed with proper enclosure height
to meet the ground level concentration (GLC) requirement.
6. In case of elevated flaring, the minimum stack height shall be 30 m, Height of
the stack shall be such that the max. GLC never exceeds the prescribed ambient air
quality limit.

24
1.9 Government norms for flaring 1 FLARE SYSTEM

25
 2 FLARE GAS RECOVERY SYSTEM

2 Flare gas recovery system

Flare Gas Recovery Systems (FGRS) are specialized compression packages, which
aim to recover and repurpose gasses and emissions, such as methane/LPGs and sul-
fur dioxide, that would normally be burned during the flaring process. Key to the
safe operation of refineries and petrochemical facilities, the process involves capturing
the gas from the flare knock-out vessel and compressing it using liquid ring compres-
sors. The so-recovered gases can be reused within the facility’s fuel gas system, as a
refinery feedstock or for re-injection.

2.1 Types of FGRS

There are many types of Flare Gas Recovery Systems(FGRS) in the industry:
1. Collection, compression, and injection/reinjection
Applications:
a. into oil fields for enhanced oil recovery;
b. into wet gas fields for maximal recovery of liquids;

26
2.2 Parts of FGRS 2 FLARE GAS RECOVERY SYSTEM

c. into of gas into an aquifer;

d. into the refinery pipelines
e. collection and delivery to a nearby gas-gathering system;
f. shipping the collecting flared gas to treatment plants before subsequent use;
g. using as an onsite fuel source;
h. using as a feedstock for petrochemicals production;

2.Generating electricity by generation and co-generation of steam and electricty

Applications:
a. burning flared gas in incinerators and recovering exhaust heat for further use

2.2 Parts of FGRS

2.2.1 Liquid ring compressor

A liquid ring compressor or vacuum pump is a rotating positive displacement com-

pressor and vacuum pump. As you review the list of the most significant pros and
cons, you will have an easier time determining if liquid ring compressor or vacuum
applications are right for your needs.

Advantages:
1.Simple and compact structure
2.Operating speeds are mostly designed to match electric motors synchronous speeds,

27
2.2 Parts of FGRS 2 FLARE GAS RECOVERY SYSTEM

making it possible to directly connect the compressor to the motor, eliminating the
need for a gearbox device. Relatively steady flow of gas without pulsation.
3.No pressure fluctuations.
4.With no metal friction on the cavity surface of the pump, it requires no internal
lubrication. As a result, the pump experiences less wear and tear.
5.Simple and reliable operation, and easy maintenance.
6.Low operating temperatures, Low vibration, Low noise level, no need for expensive
silencers.
7.On a rotating displacement pump, partial and full-load performance is reasonably
good.
8.Most importantly, when using a liquid compressor, the gas compression is isother-
mal, making it possible to pump flammable and explosive gas. Also, with no friction
surface or exhaust valve, pumping gas with dust or a mixture of vapours and non-
condensable gas becomes possible.
9.Discharged gas can be 100 percent oil free.

Disadvantages:
1.Efficiency in the range of 30 to 45 percent is often lower than dry type or oil lubri-
cated machines.
2.Water is required for service liquid or cooling.

As you can see, a liquid ring compressor has far more advantages than disadvan-
tages. Although this rotating positive displacement device has some similarities to a
rotary vane compressor, there are also distinct differences. Primarily, the liquid ring
compressor utilizes a centrifugal rotor instead of sliding vanes. Rotary slide vane
machines require lubricants such as oil therefore discharged gas is oil contaminated.
Water consumption can also be recovered or recycled with liquid ring compressors.

Liquid Ring Compressor Principle:

Induction motors usually drives the compressor rotor which is eccentrically mounted
inside of a cylindrical casing for compressing the gas. In this case a liquid, typically
water, gets fed into the compressor. With centrifugal force from the rotor, a moving
cylindrical liquid ring forms against the interior wall of the casing. This ring creates
multiple seals, filling the space between the vanes of the impeller. With that, com-
pression chambers form.
Between the axis of rotation by the impeller and geometric axis of the casing drawn
into the compressor through the inlet port, the gas becomes trapped inside of the

28
2.2 Parts of FGRS 2 FLARE GAS RECOVERY SYSTEM

compression chambers. With the rotation of the impeller liquid ring applies pressure
to the trapped gas thus reducing the volume of gas. Once compressed, the gas exits
the discharge port.

2.2.2 Three phase separator

Three phase separators are used to separate gas and two liquids of different den-
sities typically oil and water.They are a combination of Liquid - Liquid and Vapor
Liquid separators.They are typically employed in oil and gas fields in downstream of
wells.

Three Phase Separators Zones Regardless of the internal configuration. All liquid /
liquid and gas / liquid / liquid separators consist of three basic zones:
1. Inlet section
2. Liquid-liquid settling section
3. Gas- Liquid Separation zone

Factors Affecting Separator Efficiency :

1. Flow Pattern at Separator Inlet
2. Feed Pipe Geometry

29
2.2 Parts of FGRS 2 FLARE GAS RECOVERY SYSTEM

3. Inlet Device
4. Entrainment
5. Other Internals

How does a horizontal three phase separator work?

In a horizontal three-phase separator, fluid enters the vessel through an inlet, and
immediately hits an inlet diverter. This sudden impact provides the initial separa-
tion of liquid and vapor and begins the gas-oil separation process.
In the liquid collection section of the vessel, the oil and and emulsion separate, form-
ing a layer (or “pad”) above the free water. A weir maintains the oil level, while an
interface liquid level controller maintains the water level.
The oil spills over the top of the weir, and then a level controller, which operates the
oil dump valve, controls its level.
An interface level controller also senses the height of the oil-water interface. This
controller signals another dump valve to release as much water from the vessel as is
needed to maintain the oil-water interface at the pre-determined height.
Meanwhile, gas rises to the top of the separator. It flows horizontally and exits thru
a mist extractor to a pressure control valve, which maintains constant vessel pressure.

How does a vertical three phase separator work?

In a vertical three-phase separator, flow enters the vessel thru a side inlet as well, and
is immediately met by an inlet diverter. This impact begins the separation process.
A down-comer transmits the liquid through the oil-gas interface. A chimney equal-
izes gas pressure between the lower section and the gas section.
The “spreader,” or down-comer outlet, is located at the oil-water interface. As the
oil rises from this point, any free water separates out from the oil phase. The wa-
ter droplets flow down through the oil. As the water flows downward, oil droplets
trapped in the water phase rise up through the water flow.

30
2.3 How a FGRS unit Works 2 FLARE GAS RECOVERY SYSTEM

2.3 How a FGRS unit Works

1) First, the flare gas is sent to Knockout Drum which in the flare header is designed
to remove and accumulate condensed and entrained liquids from the relief gases.
There may be several knock out drums: high pressure and low-pressure drums tak-
ing relief flow from high pressure and low pressure equipment. A cold relief drum
which is segregated from wet relief system because of the risk of freezing.

2)Now, after passing through the flare header, a part of the relief gases reach liq-
uid/water seal drum vessel which is used to separate the relief gases and the flare
stack or any other ignition source by a layer of liquid. Water or any other liquid,
selected as per the application, is normally the sealing fluid. The flare gas is forced
to bubble through a layer of water before it reaches the flare stack. This prevents air
or gas from flowing backward beyond the water seal. It is also used for maintaining
the back pressure in the gas lines, for certain applications.

3) The other part reaches liquid ring compressor which uses a double-shaft seal
design, which creates a safer environment for the compression of flammable mixtures
as well as toxic and environmentally hazardous materials. Liquid ring compressors
use an impeller located within a cylindrical casing, which is filled with operating
liquid (typically water). As the impeller rotates, the resulting centrifugal force forms
a moving cylindrical ring against the inside wall of the casing. This results in a
volumetric expansion in the section of the outflowing liquid ring, which causes the
medium to be drawn in via the inlet port in the guide plate. In the area of the
inflowing liquid ring, the volume is reduced, causing the medium to be compressed.
After compression, the medium is discharged via the outlet port in the guide plate.

4) The compressed gas is then discharged into a mixed phase separator (Here three-
phase). In a horizontal three-phase separator, fluid enters the vessel through an inlet,
and immediately hits an inlet diverter. This sudden impact provides the initial sep-
aration of liquid and vapor and begins the gas-oil separation process. In the liquid
collection section of the vessel, the oil and and emulsion separate, forming a layer
above the free water. A weir maintains the oil level, while an interface liquid level
controller maintains the water level.The oil spills over the top of the weir, and then
a level controller, which operates the oil dump valve, controls its level.An interface
level controller also senses the height of the oil-water interface. This controller sig-
nals another dump valve to release as much water from the vessel as is needed to
maintain the oil-water interface at the pre-determined height.Meanwhile, gas rises to
the top of the separator. It flows horizontally and exits through a mist extractor to

31
2.3 How a FGRS unit Works 2 FLARE GAS RECOVERY SYSTEM

a pressure control valve, which maintains constant vessel pressure.

5) The liquid is pumped through a heat exchanger and back to the service liquid
inlet on the compressor.

6) The compressed gas is separated from the liquid and is piped to the plant fuel gas
header, or other appropriate location.

7) The compressor recycle valve is regulated with control signals based on the inlet
flare gas pressure. This ensures that the flare header is under positive pressure at all
times. In the event that the flow capacity of the FGRS is exceeded, the liquid seal
vessel will allow the excess waste gas to go to the flare where it is safely burned.

An FGRS provides a number of environmental and economic benefits to refiner-

ies, such as:
Lower Emissions: Recovering waste hydrocarbons allows refineries to reduce the
amount of toxic gasses, such as hydrogen sulfide (H2S), which are burned and re-
leased into the environment during the flaring process. Reduced Operating Costs:
Refineries can re-use recovered gasses, composed mainly of low molecular weight hy-
drocarbons (LPGs), resulting in a reduction in fuel gas cost for the facility. This
is in addition to saving that could be made as a result of reduced Greenhouse Gas
emissions, or through the sale of recovered gasses. Social and Environmental Respon-
sibility: Lowering CO2 emissions generated by facilities not only help organizations
meet environmental regulations, but also demonstrate an awareness and commitment
to social responsibility, and build goodwill within the surrounding community.

32
 3 AUTOMATIC FLARE IGNITION SYSTEM

3 Automatic flare ignition system

An important feature of every flare system is its ignition system. With more and
more facilities operating flare gas recovery systems with “zero flaring”, there is in-
creased pressure on the reliability of the flare ignition system to be functional when
called upon during a plant upset, blowdown or emergency shutdown.
Automatic Flare Ignition System is a spark ignition system, which features a spark
electrode installed on the igniter’s head, which is energised by an installed high-
tension transformer. This design provides a very high-density spark generation at the
ignition chamber, located inside the flare ignition pilot line.The spark is discharged
at intervals of five seconds, via a low tension, high energy spark plug. Ignition gas
is injected into the pilot line via an installed pilot venturi, using a natural draft self-
aspirated mechanism, this ensures instant and dependable ignition of the induced
air/gas mixture.
Optional flame sensing device may be installed on the pilot ignition line to automat-
ically shut down the ignition panel, once the flare-stack flame has been established,
and automatically re-ignite the flare-stack, if the flame is accidentally extinguished.
High temperature, stainless steel materials are chosen for the fabrication of the ig-
niter head (ignition tube), in order to guarantee durability, reliability, and optimum
stability even at extreme temperatures.

3.1 Benefits of the automatic ignition system:

1. Low Cost
2. Easy To Install and Operate
3. Compactness of Design
4. Long Warrantee Period (12 Months)
5. Automatic Flare Re-Ignition Guarantees a Dependable Ignition
6. System Needs No Gas Pressure Adjustment Before Operation
7. System Can Be Operated From A Remote Location (Over 1000ft)
8. Integral Ignition Hood and Windscreen Secures Reliability
9. System Adaptable To DC Power Supply, and Solar Energy Source
10. The Ignition Unit Can Be Retrofitted Into an Existing Flare Stack.

33
 4 SMOKELESS FLARING

4 Smokeless Flaring
Flares are generally used to control environment pollution by burning waste haz-
ardous gases, therefore, the burning of gases. The flaring must be smokeless in order
to reduce pollution and is usually a fraction of maximum gas flows, but some envi-
ronmentally sensitive areas require 100 percent smokeless.

The need for smokeless burning has become essential and should be explicitly de-
fined. Smoke consists of gas and small bits of solid material that are sent into the air
when something burns and which happen when there is an incomplete combustion
(not enough oxygen to burn the fuel completely).

Smokeless means to suppress the smoke formed while flaring using some techniques,
which are based on the premise that smoke is the result of a fuel-rich condition and
is eliminated by promoting uniform air distribution throughout the flames.

To promote even air distribution throughout the flames, energy is required for cre-
ating turbulence and mixing assisted fluid in the flame so as to prevent smoke. This
energy can be created in the form of pressure and velocity, or it can be exerted on the
system through another medium, such as injecting high pressure steam, compressed
air or low pressure blower air into gases as they exit the flare tip.

To assess the degree of smokelessness, Ringlemann scale is used.

Many state and countries regulation state the smokeless requirements in the form
‘No operator shall allow the flare emissions to exceed 20 percent opacity or Ringle-
mann 1 for more than 5min any consecutive 2 hour period’. Other regulations may
be different which depends on local regulatory authority. Therefore, the smokeless
operation is normally the overriding requirement while designing the flare system.

Smoking tendency is a function of the gas calorific value and of the bonding structure
of the hydrocarbons. The paraffinic series of hydrocarbons has the lowest tendency
to produce smoke, whereas olefinic, diolefinic and aromatic series of hydrocarbons
have a much higher tendency to produce smoke.

Smokeless combustion is achieved by utilizing air, steam, pressure energy of flare

gas or other means to create turbulence and entrain air within the flared gas steam.

34
 5 PURGE REDUCTION SYSTEM

5 Purge Reduction System

5.1 What is Purge Gas?
Purge gas (or ”purge flow”) is required to prevent air impingement in the process
header where there is little or no process flow going to the flare (as in the case of
a dedicated intermittent or ESD flare). If air should enter the flare stack, a release
of process gas could result in a combustible mixture present within the flare in a
restricted zone. The ignition of this air/gas mixture can result in an explosion and
cause severe equipment damage.

Purge gas is used to prevent two possible situations:

Flame ingress into the flare stack in low flow applications.
Oxygen concentrations in the stack from exceeding approximately 6 percent, which
could allow the ingress of the flame front.

5.2 Purge Reduction Seals

5.2.1 Velocity seal
A velocity seal works by increasing the velocity of the waste gas inside the flare tem-
porarily to push the air flowing down along the sides of the stack out.

99 percentage of Tornado Customers prefer to use velocity seals over molecular seals
to avoid the following problems:
1. Freezing in the Stack.
2. Large Pressure Drops Associated with Molecular Seals.
3. Possible Damage that can be done to Molecular Seals due to too high a pressure
from an emergency flaring application.

35
5.2 Purge Reduction Seals 5 PURGE REDUCTION SYSTEM

5.2.2 Molecular seal

The molecular seal works by using the lighter than air waste gas/purge gas to force
the air out at the middle of the seal or heavier than air waste gas/purge gas to force
the air out at the bottom of the seal.

36
 6 ASPEN FLARE SYSTEM ANALYSER

6 Aspen flare system analyser

Reduces overdesign and lower CapEx (Capital expenditures (CapEx) are funds used
by a company to acquire, upgrade, and maintain physical assets such as property,
plants, buildings, technology, or equipment. CapEx is often used to undertake new
projects or investments by a company.) by optimizing flare system networks and
process design simultaneously with a fast, trusted, integrated solution.

6.1 Streamlined With Process Simulation

Automatically import data from Aspen Plus and Aspen HYSYS (e.g., PSV, BDV,
streams). Map individual relief scenarios to flare global scenarios to complete flare
analysis faster and with fewer mistakes.

6.2 Rigorous and Flexible Solution

Complete flare system design, rating and debottlenecking analyses. Model both
single and multiphase flare or vent systems, including convergent, divergent and
complex looped systems.

37
6.3 Trusted Accuracy of FLARENET
6 ASPEN FLARE SYSTEM ANALYSER

6.3 Trusted Accuracy of FLARENET

Rely on the accuracy of the most trusted flare system design and rating solution to
evaluate the flare system capacity and identify any deficiencies.

38
 7 FLOWSHEETS IN ASPEN FLARE SYSTEM ANALYSER

7 Flowsheets in Aspen flare system analyser

Note:All the files of simulation have been uploaded on the google drive: Files

7.1 Flowsheet 1

This is practice flow sheet 1 which we made in Aspen Flare system analyzer. The
fluid from two sources (1 and 2) go to header 3 from tailpipe 1 and 2 respectively
via tee1. Header3 is connected to stack by a connector. From stack the fluid will be
burnt at the flare tip. The rated mass flow at each point is also mentioned here.

39
7.1 Flowsheet
7 FLOWSHEETS
1 IN ASPEN FLARE SYSTEM ANALYSER

Here in the graph, pressure across the system is given. As we can see pressure
decreases from sources to the flare tip due to friction loses.

40
7.2 Flowsheet
7 FLOWSHEETS
2 IN ASPEN FLARE SYSTEM ANALYSER

7.2 Flowsheet 2

This simulation contains four sources from which the fluid will come according to the
scenario. In the default scenario fluid will come from all four sources. Other details
resembles to the previous flow sheet.

41
 8 DWSIM

8 DWSIM

DWSIM is an open-source CAPE-OPEN compliant chemical process simulator for

Windows, Linux and macOS. DWSIM is built on top of the Microsoft .NET and Mono
Platforms and features a Graphical User Interface (GUI), advanced thermodynamics
calculations, reactions support and petroleum characterization / hypothetical com-
ponent generation tools.

DWSIM is able to simulate steady-state, vapor–liquid, vapor–liquid-liquid, solid–liquid

and aqueous electrolyte equilibrium processes with the following Thermodynamic
Models and Unit Operations:
8.1 Thermodynamic models
CoolProp
Peng–Robinson equation of state
Peng–Robinson-Strÿjek-Vera (PRSV2)
Soave–Redlich–Kwong
Lee-Kesler
Lee-Kesler-Plöcker
UNIFAC(-LL)
Modified UNIFAC (Dortmund)
Modified UNIFAC (NIST)
UNIQUAC
NRTL
Chao-Seader
Grayson-Streed
Extended UNIQUAC,
Raoult’s Law

42
8.2 Unit operations 8 DWSIM

IAPWS-IF97 Steam Tables

IAPWS-08 Seawater
Black-Oil and Sour Water.

8.2 Unit operations

CAPE-OPEN Socket
Spreadsheet
Custom (IronPython Script)
Mixer
Splitter
Separator
Pump
Compressor
Expander
Heater
Cooler
Valve
Pipe Segment
Shortcut Column
Heat exchanger
Reactors (Conversion, PFR, CSTR, Equilibrium and Gibbs)
Distillation column, Simple, Refluxed and Reboiled
Absorbers
Component Separator
Solids Separator
Continuous Cake Filter and Orifice plate.

Utilities:
Binary Data Regression
Phase Envelope
Natural Gas Hydrates,
Pure Component Properties
True Critical Point
PSV Sizing
Vessel Sizing
Spreadsheet and Petroleum Cold Flow Properties.

43
8.3 Tools 8 DWSIM

8.3 Tools
Hypothetical Component Generator
Bulk C7+/Distillation Curves Petroleum Characterization
Petroleum Assay Manager
Reactions Manager and Compound Creator.

8.4 Process Analysis and Optimization

Sensitivity Analysis Utility, Multivariate Optimizer with bound constraints.
8.5 Extras
Support for Runtime Python Scripts, Plugins and CAPE-OPEN Flowsheet Monitor-
ing Objects.

44
 9 FLOWSHEET IN DWSIM

9 Flowsheet in DWSIM
Note:All the files of simulation have been uploaded on the google drive: Files

The team tried to find as many as possible research papers to get sufficient data
for the simulation but every research paper the team could find had insufficient data
for simulation in Aspen HYSYS. So the team simulated FGRS in DWSIM software
as it requires less data. Due to this reason some parameters and compositions are
assumed on the basis of general condition. (For example composition of flare gas
varies for different plants and conditions. The team referred to the general compo-
sition of flare gas (mentioned in the documentation(found in a research paper)) for
simulation.)
9.1 Design 1
Here is the flowsheet.

In this flowsheet, flare gas first goes to splitter where it is separated into two streams.
First stream is a flare gas which goes for flaring. [When we have more gas for flaring
at that time we may not be able to take all of it for recovery as recovery unit has ca-
pacity constraints.In conditions like startup and shutdown when there is more gas for
flaring, splitters are useful.] From splitter another stream goes for recovery.A flare
knockout drum is a vessel primarily used to remove any liquids or liquid droplets

45
9.1 Design 1 9 FLOWSHEET IN DWSIM

from the flare gas. This stream goes to knockout drum where vapour and liquid
phases are separated.The gas outlet goes to compressor where it is compressed. The
compressed gas then goes to the three phase separator where it is separated into
three parts: 1. Recovered gas, water, condensed hydrocarbon.

46
 10 BASIC DEFIITIONS

10 Basic defiitions
Adiabatic Flow
Adiabatic flow is the constant enthalpy flow of a fluid in a pipe.

Choked Flow:
The velocity of a fluid in a pipe of the constant cross-sectional area cannot exceed
the sonic velocity of the fluid. If the flow of fluid in a pipe is great enough that the
sonic velocity is reached, then a pressure discontinuity is seen at the exit end of the
pipe.

Critical Pressure:
The critical pressure is the pressure at which the vapor density and liquid density of
a substance may be the same.

Critical Temperature:
The critical temperature is the temperature at which the vapor density and liquid
density of a substance may be the same.

Equivalent Length:
The equivalent length of a pipe is the straight length of pipe which would create the
same pressure drop as the actual pipe length plus losses due to bends and fittings.

Isothermal Flow:
Isothermal flow is the constant temperature flow of a fluid in a pipe. In general, when
the pressure of gas reduces, there is a small change in temperature. This assumption
leads to a small error in the calculated pressure profile. In practice, for pipes of
length at least 1000 diameters, this difference does not exceed 5% and in fact, never
exceeds 20%.

MABP:
The Maximum Allowable Back Pressure on a relief device is the maximum pressure
that can exist at the outlet of the device without affecting the capacity of the device.
In general, the MABP for a conventional pressure relief valve should not exceed 10%
of the set pressure at 10% overpressure.
In general, the MABP for a balanced pressure relief valve should not exceed 40% of
the set pressure at 10% overpressure.

Mach Number:

47
 10 BASIC DEFIITIONS

Mach number is the ratio of the fluid velocity to the sonic velocity in the fluid.

Node:
Nodes define the connection points between pipes, and pipes with sources. Each
node must have a unique name.

Reduced Pressure:
Reduced pressure is the ratio of the absolute pressure to the critical pressure of the
fluid.

Reduced Temperature:
Reduced temperature is the ratio of the absolute temperature to the critical temper-
ature of the fluid.

Scenario:
A scenario represents a set of flow and compositional data for all sources in the sys-
tem. It may also represent a particular set of limiting operating conditions.

Schedule:
The schedule of a pipe defines a standard thickness for a given nominal pipe size. In
general, flare and vent systems are constructed from schedule 40 or 80 pipes.

Source:
A source refers to a fluid entering the piping network regardless of the type of pipe
fitting from which it enters. the fluid is defined in terms of its composition, mass
flow rate, pressure, and temperature.

Static Pressure:
The pressure acting equally in all directions at a point in the fluid. Physical proper-
ties are calculated at the static pressure condition.

Tailpipe:
The section of pipe between the discharge flange of the source valve and the main
collection header is generally referred to as a tailpipe.

Total Pressure:
The sum of the static and velocity pressures.

48
 11 CONCLUSION

11 Conclusion
Globally, final product costs of refinery operations are becoming more dependent on
processing fuel costs. Flaring of the precious natural gas should be avoided. In this
situation Flare gas recovery system is a good option. The focus should be on making
recovery system more efficient, environment friendly and cost effective. By achieving
this we can take a step ahead for a better environment. .

49
 12 REFERENCES

12 References
1.Flare gas recovery system
2.Flare system
3.Parts of flare system
4.Purge Reduction
5.Animation of Flare system along with FGRS
6.Flare system handbook
7.Simulation Files

50