emissions testing of sonic velocity...
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ZEECO, INC. ZEECO, INC.
2010 ZEECO, INC. ZEECO, INC.
Emissions Testing of Sonic Velocity Flares
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2010 ZEECO, INC. ZEECO, INC.
Flare Product DivisionJohn Ehlig
ZEECO, INC.
Multipoint Ground Flare History
Developed Early 1970’s
Zeeco founder was one of the original inventors and listed on Original Patent
Original Installation In 1972
Many Improvements over past 43 years in Burner technology
Basic Overall Concept Today is Same as Original
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ZEECO, INC.
Original Multipoint Flare Drawings
ZEECO, INC.
Burner Development in Past Years
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Use Jet action of gas to entrain air for smokeless burning
Smokeless Burning over Wide pressure ranges
Low Radiation
Stable Operation at Sonic Velocity
Multiple burners for unobstructed air access
Wind is less of a factor due to significant momentum
Common Burner Characteristics
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Variable Arm Area
Investment Cast
Pressure Tested at Factory
310 SS Cast Material
Inherently Stable on Wide Range of Gases
Modern Sonic Velocity Burners
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Many small burners – each able to pull in air
Staging system to Ensure Operation in Optimum Pressure Band – leading to smokeless operation
Burners in Service are Proportional to Gas Flow
Typically Used for High Pressure, Heavy Hydrocarbon Service
Allows for Controlled Flame Length from Burners
Common MPGF Design Concept
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Typical Staging Curve
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Typical Installations
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Typical Installations
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1983 CMA Testing
Air assisted flare
Un-assisted flare
Steam assisted flare
Extractive Sampling
EPA Involvement
Basis for Current Flare Regulations, 40 CFR 60.18
ZEECO, INC.
1983 CMA Testing
Subsequent to all of the CMA sponsored testing of flare systems, there was a separate test using the same equipment on a pressure assisted flare tip.
Results of that test were submitted to the EPA.
Results showed very high destruction efficiency.
No specific conclusion, but the concept of if a stable flame exist, high CE exists.
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1983 CMA TEST DATA ON PRESSURE ASSISTED TIP TESTING, CRUDE PROPYLENE FIRING
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1986 EER Testing for EPA
Further EPA sponsored testing on different type of flare tips.
Testing was intended to analyze further gas mixtures, alternative gas types, etc.
3 inch nominal flare tip size for most tests.
Also, testing was performed on Pressure Assisted commercially available high velocity flare tips, Commercial tips “E” and “F”.
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1986 EER TESTING ON PRESSURE ASSISTED FLARE TIPS, PROPANE IN NITROGEN
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ZEECO, INC.
Testing by DOW for Two Installations
Sonic velocity multipoint ground flares
Two different applications, 2007 and 2014
Nominal 4 inch spider type sonic burners.
General Test results presents at AFRC Meetings.
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DOW PRESSURE ASSISTED TIP TESTING, AFRC PRESENTATION, 2007, PROPYLENE / N2 MIX.
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DOW PRESSURE ASSISTED TIP TESTING, AFRC PRESENTATION, 2014.
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Sonic Flare Full Scale Testing for Smokeless / Flame Length / Cross Lighting
Xylene Testing Ethylene Testing28
ZEECO, INC.
Multipoint Flare Burner Testing
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Sonic Flare Testing at Zeeco for DRE
Natural Gas
Propylene
Propane
Inert / H2 Mixtures
Consistently over 99.5% DE
Summer 2013, Fall 2013, Fall 2014, Spring 2015
ZEECO, INC.
Testing Methods Used
Extractive Sampling
Sample Hood with Venturi Suction
Same Design and TCEQ / TU Tests 2010
Temperature and FLIR Camera for Positioning
PFTIR Analysis
Providence FEMS Optical Efficiency Monitor Device
Wind and weather monitoring
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Multipoint Sonic Flare Testing at Zeeco
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Test Area Video
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Details for Recent Sonic Testing
Flare Gas Fuel TypeFlare Gas Lower Heating Value
(Btu/SCF)Max Allowable Exit Velocity per 40
CFR 60.18 Regulation (ft/s)Flare Gas Exit Velocity in Zeeco Test
Facility (ft/s)
Destruction Efficiency % from Extractive Sampling of Zeeco
FlaresCombustion Efficiency % from Extractive Sampling
Combustion Efficiency % from IMACC PFTIR Measurement
Operating Pressure (psig)
Propane 2316 400 800 99.99 99.99 99.6 16
54mol% Propane/46mol% N2 1251 400 903 99.99 99.99 99.9 10.3
Propylene 2183 400 823 99.99 99.96 99.6 16.9
Tulsa Natural Gas 937 400 1378 99.99 99.99 99.5 15
Propane 2316 400 820 99.99 99.99 15.1
55mol% Propane/ 45mol% N2 1274 400 913 99.99 99.99 10.2
Propylene 2183 400 859 99.99 99.99 15.4
Tulsa Natural Gas 937 400 1403 99.99 99.98 15.3
TNG 937 1443 99.997 99.9955 20
TNG 937 1440 99.9949 99.9943 20
87TNG/13N2 800 1411 99.9988 99.9976 20
65TNG/35N2 600 1323 99.9983 99.9971 20
76TNG/24N2 700 1387 99.9972 99.9887 20
54TNG/46N2 500 1307 99.9964 99.9882 20
30TNG/70H2 465 2500 99.9985 99.9964 20
30TNG/70H2 465 2450 99.9951 99.9923 20
30TNG/70H2 465 2495 99.9941 99.9925 20
Propane 2316 840 99.9977 99.9947 20
Propylene 2183 870 99.9991 99.9968 20
63Propylene/37N2 1375 954 99.9992 99.9971 20
37Propylene/63N2 808 1030 99.9979 99.9957 20
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Destruction Efficiency, Sonic Velocity
95.0
96.0
97.0
98.0
99.0
100.0
101.0
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500
Des
truct
ion
Effic
ienc
y (%
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Flare Gas Exit Velocity (ft/s)
Destruction Efficiency versus Flare Gas Exit Velocity
Assumed Destruction Efficiency per 40 CFR 60.18
Measured Destruction Efficiency from Extractive Sampling
Maximum Allowable Exit Velocity per 40 CFR 60.18
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ZEECO, INC.
Combustion Efficiency, Sonic Velocity
95.0
96.0
97.0
98.0
99.0
100.0
101.0
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500
Com
bust
ion
Effic
ienc
y (%
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Flare Gas Exit Velocity (ft/s)
Combustion Efficiency versus Flare Gas Exit Velocity
Maximum Allowable Exit Velocity per 40 CFR 60.18
Measured Combustion Efficiency from Extractive Sampling
Measured Combustion Efficiency from IMACC PFTIR technology
ZEECO, INC.
PFTIR versus Extractive Sampling Data
CE/DRE Testing Points - IMACC Testing Air Hygiene Data
Test Date Start TimeTest Facility Notation -
Test Point # Flare Fuel Actual Fuel Rate lb/hIMAAC Notation - Test
Point # IMACC CE% DRE % CE%
11/11/2014 9:25:00 AM 11A MPGF Propane 5159 15 99.6 99.99 99.99
11/11/2014 9:35:00 AM 13A MPGF Propane/ N2 2474/1347 16 99.9 99.99 99.99
11/11/2014 8:57:00 AM 12A MPGF Propylene 5053 17 99.6 99.99 99.96
11/11/2014 9:57:00 AM 14A MPGF Tulsa NG 3300 18 99.5 99.99 99.99
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Past Zeeco Sonic Testing Results
ZEECO, INC.
CFD Analysis
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CFD Analysis
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CFD Analysis
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General Benefits for MPGF High Destruction Efficiencies
Maximum Smokeless Capacity Possible
Low Utility Usage and Cost
Minimizes Impact to your Neighbors
Radiation Fence
Smoke Production
Easy Access for Maintenance
Small Plot Space
2010 ZEECO, INC. ZEECO, INC.
Questions?