Flare Technology (Presented By Scot Smith of Zeeco)

Transcription

••Burners
Burners
••Flares
Flares
••Incinerators
Incinerators
••Vapor
Vapor Combustion
Combustion
Company Profile
• Incorporated in 1979 by John S. Zink
• Specialty machining, Close tolerance
aircraft parts
• Resumed the design and manufacture
of Combustion equipment in 1983
Click here to:
View a message from John S. Zink
John Smith (Jack) Zink
Is the founder of Zeeco Inc. He
holds a Bachelor of Science
Degree from Oklahoma State
University and began his career as
an engineer with the John Zink
Company in 1951. After serving in
numerous capacities throughout
the company,
Mr. Zink assumed the Presidency in 1967, a position he
held until leaving the firm in 1980. Mr. Zink has been
responsible for inventions that have led to more than 35
patents for burners, flares, incinerators and related
combustion equipment including the flame front generator
for flare ignition, steam assisted flares for smokeless
flaring, and energy efficient burners for reduced plant
operating costs.
Company Statistics

193 acre (78 hectare) facility in Broken
Arrow, OK
• 24,500 sq. ft. (2276 m2) office space
• 56,500 sq. ft. (5250 m2) manufacturing
• 160,000 sq. ft. (14864 m2) outside
manufacturing and storage
• 5 acre (2 hectare) research and
development facility
2,000 acre (810 hectare)remote test
facility northwest of Tulsa
View Aerial Photo
Zeeco Inc.
Combustion
Engineering Experience
• Zeeco engineers have over 300 years of
combined combustion design experience.
• Zeeco takes full advantage of computer
simulation methods for designing our equipment
to achieve the best combustion characteristics
and to meet the process specifications.
• Zeeco uses combustion data generated from our
combustion test facility to prepare computer
simulation programs to accurately predict
product performance.
Engineering and Sales
Offices
Complete Machining and
Manufacturing Facility
Quality Control
• ISO 9001 Accredited Engineering,
Manufacturing and Testing facility
• ASME Section VIII Code Shop; U, R & S
Stamps
• UL Certified
• An absence of warranty cases
demonstrates the effectiveness of our
quality program
Zeeco Worldwide
Installations in over 43 Countries
22 International Locations
10 Domestic Locations
Zeeco Clients
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ABB Lummus
Air Products
Amoco
Arco
British Petroleum
BASF Corp.
Bechtel
Bherat Petrochemical
Brown & Root
Caltex
Chevron
Citgo
Coastal
Conoco
Chinese Petroleum
Daelim
DOW
DuPont
Essar
Exxon
Engineers India Ltd.
Ecopetrol
Fluor Daniel
Formosa Plastics
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Foster Wheeler
Glitsch
Haliburton
Hess Oil
Howe-Baker
Hindustan Petrochemical
Hyundai
Hydro-Chem
Indian Oil Corp.
Jacobs Engineering
JGC Corp.
Kerr-McGee
KTI
Kuwait Oil
Kvaerner
LG Engineering
Lyondell/Citgo
MAPCO
Marathon
McDermott/Hudson
Mitsui
Mobil
Monsanto
Oderbrecht
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Olin Chemicals
PDVSA
PEMEX
Petro-Chem
Petrobras
Phillips
Quantum Chemical
Reliance Industries
Samsung
Schlumberger
Shell
Sinclair
Star Enterprise
Stone & Webster
Sun Oil
Sunkyong
Taekwang Industrial
Texaco
Total Petroleum
Toyo
Unocal
UOP
Williams
Witco
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Utility
Steam Assisted
Air Assisted
Multi
-Point Staged
Multi-Point
Enclosed
Liquids
Guy Supported Flares
• Heights to 600
feet plus
• Low Capital
Cost
• Low Install
Cost
• Large Plot
Space
• Maintenance
Requirements
• Process Temp
Limits
Self Supported Flares
• Heights to 300
feet
• Moderate
Installation Cost
• Moderate Capital
Cost
• Small Plot
• No Process Temp
Limits
• No Unusual
Maintenance
Derrick Supported Flares
• Heights to 600
feet plus
• High Capital
Cost
• Small Plot
• High Install
Cost
• No Process
Temp Limits
• Multiple Risers
Possible
De-mountable Flares
• Heights to
600 Feet
Plus
• Flare Tip
Maintenance
Without
Cranes
• High Capital
Cost
• Small Plot
• High Install
Cost
Lifting Tackle and Cables
Grade
Mounted
Lifting and
Tilting
Winches
Platform
Access for
Lifting,
Assembly,
Disassembly
Access Stair Tower,
Radiation Shields at
Top
Each Riser has
All Piping and
Wiring
Attached
Steam
Control
Skid and
Piping
Demountable Air
Assisted Unit with
Separate Air and
Gas Risers
Flare Pilots
Model CFP
Model HSLF
• 250,000 Btu/hr
• High Stability
• Flame front
generator or
Electric
ignition
• 1 or 2
Thermocouple
• Retractable
Thermocouple
• 65,000 Btu/hr
• High Stability
• Flame front
generator or
Electric
ignition
• 1 or 2
Thermocouple
• Retractable
Thermocouple
Pilot Systems
Pilot Stability Testing
• 125 mph winds
• 6 inch per hour rain
• Wind at 90 degrees to pilot
• Wind into FACE of pilot
• HEI and FFG Ignition
• Thermocouple Flame Proving
• Flame Ionization Rod Proving
Pilot
Lowering
System
Ignition Systems
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Flame Front
Generators
– Manual
– Automatic
– Combination
Electric Ignition
– Reliable
– Direct ignition
– Non-fouling
Click here for video
Video Clip
HEI
Electronic
Ignition
System
Purge Reduction
Velocity Seals
Reduces amount of air
infiltrating flare system
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Reduce purge gas
requirements
• nozzle-like restriction in
flare stack
• increased velocity in throat
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Flare Tip
Purge gas is any gas that will not go to dew point under flare conditions
Purge Reduction
Gas Seals
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Only device which provides
for 0% O2 in stack
Reduces purge gas
consumption by 75% over
Velocity seal
Continues to function even if
purge is lost
Designed for internal
pressure of 50 psig
Purge gas is any gas that will not go to dew point under flare conditions
Recommended Purge
Gases
• Natural Gas or any other hydrocarbon
gas
• Nitrogen or any inert gas that does not
condense
• Steam can be used, however, steam
injection rate is usually very high to
ensure steam does not condense prior
to reaching the flare tip. Also steam
can cause increased corrosion in flare
system. Therefore, steam is not
recommended
Supplemental Purge Injection,
Zeeco Tempurge System
• For Very Hot Relief Gas Cases,
supplemental purge gas injection
is required. Additional purge gas
is needed, after any hot gas flare
relief, to compensate for
shrinkage and condensation of
flare gas in the flare header.
Standard purge is not sufficient
to protect the system against
vacuum.
Series UF
Utility Flares
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Low Capital Cost
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Minimal Utility Consumption
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High Flame Stability
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High Reliability
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Low or High pressure gases
Pilot
Burner
Wind
Shield
Ignition
Inlet
Pilot
Gas Inlet
Velocity
Seal
Smokeless Capacity
• Steam injection for smoke
control
• Two types of single point
steam tips available
• Different levels of noise
generation
• Different steam injection
efficiency
Series QFS
Steam Assisted
Steam
Injector
Pilot
Burner
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High Smokeless range
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Smokeless combustion of
Wind
Shield
a wide variety of waste
streams
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Maximum Flame Stability
Ignition
Inlet
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Lower Capital Cost than
other assist methods
Center
Steam
Pilot
Gas Inlet
Steam
Inlet
Velocity
Seal
Series QFSC
Steam Assisted
Steam
Injector
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Steam injection from external
manifold at perimeter of flare
Wind
Shield
tip exit point
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Steam must penetrate gas
bundle
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Lowest cost steam flare tip
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Center steam injection to
improve flare tip life
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For Xylene, 1.0 kg steam per kg
smokeless flare gas
Center
Steam
Velocity
Seal
Series HCS
Steam Assisted
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Reduced Noise
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Wide Smokeless range
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Smokeless combustion of
Steam
Injector
Pilot
Burner
a wide variety of waste
Ignition
Inlet
streams
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Lower Capital Cost than
other assist methods
Pilot
Gas Inlet
Upper
Steam Inlet
Lower
Steam Inlet
Series HCSX
Steam Assisted
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Reduced Noise from Steam
using muffler assembly
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Higher Steam Efficiency
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Injects Air Mixture Directly in
Gas Bundle
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Higher Cost Steam Flare Tip
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Center Steam Injection to
Improve Flare Tip Life
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For Xylene, 0.70 kg steam per
kg smokeless flare gas
Flare System Grade
Level Noise Example
• QFSC Flare Tip, Smokeless Flare Rate, 25.2
t/hr Steam Injection, grade noise is 86 dba
• QFSC Flare Tip, Maximum Flare Rate, 25.2
t/hr steam injection, grade noise is 90 dba
• HCSX Flare Tip, Smokeless Flare rate, 17.7
t/hr steam Injection, Grade noise is 75 dba
• HCSX Flare Tip, Maximum Flare Rate, 17.7
t/hr steam injection, Grade Noise is 88 dba
• 250 Ft. Overall Height Flare, 65 t/hr
Smokeless Capacity, 300 t/hr max. Flow
Severe Duty Flare Tips
• Refractory
Lined
• Refractory
Exterior
• Hex Mesh
Anchor System
Series MJ
Single Point Sonic Flare
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Low Pressure
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High Pressure
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Liquids,
Condensates or
Gases
Low Radiation
Single and Multistage
Series HPEF
Sonic Flaring
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High Pressure
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High Capacity
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Smokeless Flaring
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Low Radiation
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Combustion occurs
away from the tip
providing long tip
life
Sonic Flaring
Summary
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Proprietary Jet
Nozzles
Jet Action entrains air
for smokeless
combustion
Recommended pressures
>14 PSIG
High Capacity
MJ Sonic Flare
HP / LP
CombinatioN
Tip
Series UFA
Air Assisted
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Lower Utility Costs
Smokeless Capacity
where steam is
unavailable
Wide Smokeless range
May be used for low
pressure gases
Video Clip
Air Assisted
Flare Technology
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Gas in center riser
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Air in outer riser
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Mixes at tip exit
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Variable speed fans
may be used for
staging
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May be used for low
pressure gases
Air
Assisted
Smokeless
with Engine
Driven
Blowers
KOC Kuwait
Gathering Center
Flares
Staged Flare Systems
• Useful for Flare Gas
Recovery Systems
• Used to Achieve Smokeless
Flaring without Utilities
• Used to Prolong Flare Tip Life
• Used to Facilitate
Maintenance of Flares
Examples of Staged Flare Systems
CUSTOMER
Flare TYPE
Staging
method
JOBSITE
Pluspetrol
Multipoint Ground Flare
Valves
Peru
El Paso Natural
Gas
Valves
Texas, USA
Mobil
Valves
Nigeria
BP
Enclosed Ground Flare
Valves
Scotland
FPC
elevated multipoint
Valves
Texas, USA
Marathon
Multipoint ground flare
Valves
Equatorial Guinea
Pemex
Multitip burn pit flare
Liquid seals
Mexico
FPC
Enclosed Ground flare
Valves
Taiwan
FPC
Elevated steam flare
Liquid seals
taiwan
Reliance
Elevated utility flares
Liquid seals
india
Conoco
Elevated steam flare
Liquid seal
Oklahoma, usa
Qatar petroleum
Elevated multitip flare
Valves
qatar
Typical Types of Staged
Flare Systems
• Multistage High Pressure Smokeless Ground
Flares
• Flare Gas Recovery Unit Staged to Emergency
Elevated Flare
• Enclosed Ground Flare staged to Emergency
elevated Flare
• Air Assisted Flare Staged to Emergency
Elevated Flare
• Steam Assisted Flare Staged to Emergency
Elevated Flare
• Multistage High Pressure Smokeless Elevated
Flare
Multipoint Flare History
• Developed Early 1970’s
• John S. Zink, President of Zeeco,
one of the original inventors
• Original Installation Initially
Failed
• Many Improvements over past 30
years in technology
• Basic Concept Same as Original
Key Factors in Design
• Composition of
Gases
• Inclusion of
Liquids
• Burner Pressure
Range
• Temperature of
Gases
• Radiation Fence
Design
• Piping Flexibility
Analysis
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Burner Design
Burner Drilling
Burner Spacing
Row Spacing
Row to Fence
Spacing
• Burner Height
• Runner Radiation
Shielding Type
• CFD Modeling
Burner Development
Series MJ
Jet Assisted Smokeless Flaring
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Uses Jet action of gas
to entrain air for
smokeless burning
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Wide pressure ranges
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Low Radiation
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Stainless steel sand
Casting
Multijet Flare Tip
• Zeeco
Design
• Variable
Arm Area
• Investment
Cast
• Pressure
Tested at
Factory
• 310 SS
Cast
Material
Series MJ
Elevated Staged
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Wide Pressure Ranges
High turndown
May be used in
combination with Utility,
Air or Steam assisted
flares
Wide variety of waste
streams
Series MJ
Ground Flares
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Wide Pressure
Ranges
Low Radiation
High turndown
May be used in
combination with
Utility, Air or Steam
assisted flares
Wide variety of waste
streams
Exxon Mobil Nigeria
Multipoint
Without
Steam Assist
MTBE Malaysia
Multipoint
with Steam
Assist
El Paso Farmington
Multipoint Shipment Options
• Runners
with
Burners
Installed
Staging Valve Bypass
Device’s
• Rupture Disc
• Spring Type Relief Valves
• Liquid Seal Drum
• Rupture Pin Valve
• Bursting Pin Relief Valve
• Piloted Rupture Pin Valve
• Pilot Operated Relief Valve
Rupture Pin Type Valve
Suppliers
• Rupture Pin Technologies Inc.
• Oklahoma Pressure Relief
Systems Inc.
• BS+B
• Fike
• Pressure Wise
Series MJ
Enclosed Flares
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Very low thermal radiation
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No visible flame
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High destruction
efficiency
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High reliability
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Low noise
Totally Enclosed Ground flare
Enclosed Flare: No Smoke, No
Flame, Low Noise
Series ZLF
Liquid Flaring
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Smokeless Capacity
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Variety of atomizing
media
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High flow rates
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No detectable fallout
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Onshore and Offshore
Burn Pit Flares
Enclosed Ground Flare
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Provide Emissions Levels of
35 mg/l or less
Low installation cost
Skid Assembly
– Anti-Flashback burner
– Combustion air blower
– Hydroseal
– Detonation/Flame
arrestor
– PLC based control
system
Hydroseal
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Fabricated to ASME Section VIII Code
Specifically designed to reduce surging
Instrumentation
– Liquid level control
– High/Low shutdown alarm
– Pressure Indicator
– Liquid addition control
– Visible level gauge
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Testing Capabilities
• Real-Time Data
Acquisition
• Continuous Emissions
Monitoring
• Burner Performance
• Flame quality and
pattern
• Ambient, Preheat and
GTE combustion air
• Emission levels of NO, NO2, CO, CO2 and
SOx.
Fuel Capabilities
• Gaseous Fuels
– Natural Gas (approx. 95% Methane), Hydrogen,
Propane, Propene, Butane, Butene, Pentane, Ammonia
– Specific fuel blends with inert gases including CO2 &
N2 with above gases
• Liquid Fuels
– Kerosene, Diesel, #2 Oil, Heavy Oil (#6), Naphtha,
Styrene, PFO, Special Blends of Liquid
Flare Demonstration/Development
This scale model,
which is one tenth the
size of the finished
plant flare, was used
to develop air
assisted flare
technology with flow
rates greater than
200,000 lb/hr
(90,800 kg/hr) of 60
m.w. waste gas.
Video Clip
Test Flare No. 2
• Enclosed ground flare
• Designed for low
pressure smokeless
operation
• No visible flame
• Virtually no radiation
• Low noise
• Natural draft ambient
air
• 8.5’ OD x 40’
• 2.6m OD x 12.2m
• Burner Orientation
– Vertical
Test Flare No. 3
• Steam Assisted
• Standard Utility
• Capable of testing
flare tips from 4” to
30”
• Riser 30’ x 24” I.D.
• Capability for blended
waste gases
Test Flare Area No. 4
• High
Pressure
Sonic
• Free Jet
Design
• High Flow
Rates
• Test multiple
tips
• Capability
for blended
waste gases
Large Scale Remote Testing
For testing applications requiring large fuel capacities
or where large visible flames or combustion noise might
be objectionable, Zeeco utilizes our remote testing site.
This private site is located northwest of Tulsa on
32,000 acres (12,950 hectares). the site is equipped
with water and high volume fuel storage capacity.