engineering with flare

Gasco – Combustion, Process and Thermal Engineering

INTRODUCTION

Gasco Pty Ltd has established a reputation asone of Australia’s leading combustion andprocess engineering companies.

Gasco was formed in 1991 and is anindependent, 100 per cent Australian ownedcompany. Its board and management is mainlycomprised of professional engineersacknowledged for their experience andexpertise.

Gasco offers a comprehensive range ofengineering, consulting and design,fabrication, installation, commissioning,project management, audit, maintenance andservice.

The purpose built equipment and systemsprovided by Gasco include thermal oxidizer,fired heaters, thermal oil heaters, flares,water bath heaters, burners, ovens and heattreatment furnaces, heat recovery systems,heat exchangers and burner managementsystems.

Gasco, with its staff of over 45 personnel,including professional design engineers, itsmanufacturing facility together with on-siteinstallation and commissioning, is able tooffer a comprehensive range of equipmentand services.

Gasco has a wide range of clients acrossvarious industries including oil and gas bothonshore and offshore, environmental, mining,mineral, chemical processing, refining andpetrochemical, food, automotive, water andwaste treatment, biogas and powergeneration.

Gasco clients include Shell, Mobil, ExxonMobil, BP, Chevron, Conoco Phillips, Toyota,Ford, Boeing, Australian DefenceDepartment, ORICA, ICI, Dulux, PPG, BHPBilliton, Bechtel, Fluor Daniel, ToyoEngineering, KBR, Worley Parsons, Clough,Shedden Udhe, Aker Kvaerner and manyothers.

Gasco has supplied Fired Heaters andThermal Oxidizers to Pakistan, SmelterBurners to China and India, Crude Oil Heatersto Russia, Hot Oil Heaters to Indonesia, SouthAfrica, Tanzania and the Philippines,Convective Condensate Heaters to Thailand,Flares to Vietnam, Gas Skid to Bahrain, andFlare Heat Shield to Malaysia.

Quality Assurance is a key aspect to all ourprojects with the majority being managed tomeet requirements of ISO 9001.

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Left to right: Alan Hovorka Project Director, Ian Matthews Sales & Marketing Director, John PeruzzoDirector/Chairman, Nick Grzegorczyn Managing Director/CEO,Ed Strauks Director/Chief Combustion Engineer.

Cover – Left to right:

Top:

Coal SeamMethane Flare.

Burner,RecuperativeThermal Oxidizer.

4MW Hot OilHeater, Indonesia.

Centre:

Water BathHeaters, PowerStation.

Vertical UpfiredFired Heater.

Convective FiredHeater, Thailand.

Bottom:

Paint Curing Oven.

Fired Heaters andThermal Oxidizers,Pakistan.

Gas ConditioningSkid.

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THERMAL OXIDIZERS

Gasco Thermal Oxidizers include:

• Straight Thermal Oxidizers with or without heatrecovery

• Recuperative• Catalytic• Regenerative

Gasco Thermal Oxidizers can handle a wide rangeof process parameters including variable waste flowrates, calorific values, temperature and oxygencontent.

Features of our Thermal Oxidizers are their robustperformance, ability to operate at high thermalefficiency and achieve >99.99 per cent destructionefficiency.

Gasco Thermal Oxidizers scope may include turnkeyprojects, designed to comply with our clientsspecifications and environmental authorityregulations.

We have supplied Thermal Oxidizers to the oil andgas, chemical, automotive, medical, food, mineralsand metals industries.

Heat from the exhaust of a Thermal Oxidizer can berecovered in a Waste Heat Recovery Unit, energycan be utilized in the form of heat transfer fluids –oil, water, air and to raise steam.

Thermal Oxidizers are a class of pollution controldevices that use the combustion process to destroyvolatile organic compounds (VOC) and HydrogenSulphide, hence they are sometimes calledafterburners, fume incinerators or tail gas incinerators.

Top: Thermal Oxidizer and Hot Oil HeatRecovery, BHP Billiton/KBR Minerva Gas Plant.

Centre: Recuperative Thermal Oxidizer at anAustralian LNG plant .

Bottom: Thermal Oxidizer and Hot Oil HeatRecovery OMV/Clough Sawan, Pakistan.

F IRED HEATERS

A typical Fired Heater would consist of a:

• Radiant Section• Convective Section• Stack• Burners• Fuel Skid• Control System

Gasco being both a combustion and heat transfercompany is uniquely placed to achieve the bestpossible outcomes with respect to high thermalefficiencies, low emission, reliable operation andstate-of-the-art Burner Management Systems (BMS)to NFPA, IEC and other codes.

Gasco can supply cylindrical or box cabin type directfired heaters, equipped with low NOx natural draftor forced draft burners.

To increase efficiency, preheating of combustion aircan be achieved by adding a variety of air preheaterexchangers.

With the demand for ever increasing safety andreliability levels Gasco can design and supply BMS toIEC 61508 Programmable Electronic Safety Systems.We can also provide a basic hard wired system upto SIL 3.

Gasco convective heaters rely on forced convectionheating only, are compact and can achieve thermalefficiency of 90per cent using convective heattransfer.

Gasco supplies Fired Heaters to API 560 andISO 13705 and proprietory Gasco forced draftconvective designs.

Top: Convective off-shore Condensate Heater – Chevron, Thailand.

Centre: Thermal Fluid and Regenerative Gas FiredHeaters, OMV/Clough – Sawan, Pakistan.

Bottom: Erection of a 43MW Pre-Insulated and TubedRadiant Section, Thermal Fluid Heater – Origin Energy,Australia.

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The majority of Gasco Flares are designed to meetthe requirements of API 530, which calculates theheight of the flare to achieve a predeterminedradiation level.

Gasco can provide the following:-

Flare Alternatives

Environmental concerns with global warming areleading to increased attention being paid to VapourRecovery and Zero Flaring.

Gasco with our many years experience in thecombustion and process field can engineer a zeroflaring system to suit your requirements.

FLARES

Top: Utility Flare and Ignition System – MelbourneWater/John Holland, Australia.

Centre: Air Assist, Self Supporting Flare – PetrochemicalIndustry.

Bottom: Enclosed Ground Flare complete with FlameArrestor and Control System – Biogas Industry, Australia.

Flare type• Utility (Pipe) • Steam Assist• Air Assist• Gas Assist• High Pressure Staged• Enclosed Ground• Pit/Ground

Flame support structures• Self Supporting• Guyed• Derrick

Purge seals• Dynamic• Molecular• Non Pulsating Liquid

Vessel

Ancillaries • Knock Out Drums• Staging control• Control systems:

hazardousnon hazardousarea rated

• Snuffing• Remote Flame

Monitoring• Flame and Detonation

Arrestors• Radiation Shields for

Offshore Platforms• Consulting

Gasco together with our technology partner hassupplied flares to the oil and gas, petrochemicals,terminals, landfill and sewage (biogas) industries.

WATER BATH HEATERS

Water Bath Heaters can also be used for heating:

• Crude Oil• Vaporizing and superheating LPG & LNG• Regeneration Gas Heating• Heat Transfer Fluids• Heat sensitive gas and fluids• Molten Salt Heaters

Direct Fired Reboilers• Amine Reboilers• TEG Reboilers

The main application for Indirect Fired Water BathHeaters is to heat high pressure gas prior topressure reduction, this prevents hydrate formationthat can occur because of the temperature dropdue to the Joule Thomson effect. The natural gascan also be post heated to suit the operation of gasturbines.

A typical water bath heater consists of an insulatedshell, removable process coil, removable fire tube,stack burner, gas train and control system.

Gasco options include:

• Natural Draft Burners• Forced Draft Burners• Pneumatic Gas Control• Electric (Electronic) Control• Remote Monitoring

Gasco can also supply complete gas conditioningskids consisting of Water Bath Heater, PressureReduction, Filter Coalescer and Metering.

Water Bath Heaters are Indirect Fired Typeusually designed to API 12K, these devices aretraditionally used to heat natural gas and oil.

Top: Crude Oil Heating – Sakhalin, Russian Federation.

Centre: City Gate Water Bath Heater – GCI Kenny/TruEnergy, Brooklyn, Victoria, Australia.

Bottom: Gas Turbine Water Bath Heater and GasConditioning Skids – Loy Yang, Victoria, Australia.

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The gas fired heaters consist of two concentric helicalcoils which has the advantage of:

• Compactness• High Efficiency• Low Thermal Mass

The dual helical coil design allows maximized heattransfer, minimises thermal stresses and preventsoverheating. The coil design has the advantage thatensures high fluid velocities, low film temperatures andno accumulation of gases.

The burner can be selected to suit the application, typeof fuel – gas, oil, heavy oil, timber and turndown. Theflame shape is carefully matched to the coilconfiguration. Typical efficiency with air preheating canrange up to 88 per cent depending on thermal fluidoutlet temperature, fuel, and atmospheric conditions.

Each heater has a pre wired control panel that ensuressafe and efficient operation of the heater.

As well as supplying heaters, we can provide skidmounted units that incorporate primary and secondarypumps, expansion tanks, stack and drain/fill tanks.

There are a myriad of applications that are suitable forhot oil heating.

• Tank Heating – Bitumen, Wax, Emulsions• Reactor Heating – Chemical Industry, BioTech• Platen Presses – Timber Industry, Moulding• Hollow Flight Screws – Mineral Processing• Pipe Tracing – Heavy Fuel Oil, Bitumen, Wax• Ovens – Printing, Automotive• Extruders – Plastic• Fryers – Food• Calendar Rolls – Plastic, Film• Autoclaves – Aerospace, Rubber, Brick• Dryers – Timber, Food• Kilns – Timber

Gasco can supply a stand-alone heater or a totalengineered package to suit any or all of the aboveapplications. Turnkey bitumen heating is a speciality.

HOT OIL HEATERS

Top: 1,000KW Gas Fired Hot Oil Heater for a Grease Plant –Brisbane, Queensland, Australia.

Centre: 500KW Oil Fired Hot Oil Heater and ElutriationHeating Skid – Gold Industry,Tanzania, Africa.

Bottom: 400KW Gas Fired Hot Oil Heater and PrimaryPumping Skid – Biotech Reactor Heating – Perth, WesternAustralia.

Gasco manufactures a range of Hot OilHeaters: 100KW to 7,500KW gas fired,25KW to 1500KW electric.

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PROCESS SKIDS

• Gas Turbines – ThermalOil, Hot Water, Glycol

• Thermal Oxidizers –Thermal Oil, Glycol

• Air Preheat /Recuperators

• Furnaces

For gas turbine heatrecovery systems Gasco,offers a complete turnkeyplant comprising:

• Inlet duct

• Divertor valve

• Divertor stack

• Supplementary burnerand controls

• Waste Heat RecoveryUnit

• Exhaust Stack

Gasco designs, fabricates, installs,commissions and services an extensiverange of Process Skids for GasConditioning and Oil Treatment.

WASTE HEAT RECOVERY

Gasco and our associated companies havesupplied waste heat recovery systems for:

Gasco supplies pressure reduction, metering, separators,filter coalescers, hot oil primary and secondary skids, burnerskids and waterbath heaters.

Gasco skids are engineered to meet the client’s specificationsand International Piping Codes ANSI B 31.3 etc.

Equipment and pipes are sized using inhouse computerprograms; pipe layouts are computer pipe stressed.Instrumentation and PLC controls, pre-piped and wired, aresupplied as a complete unit saving valuable time and costson site.

Gasco can supply a variety of Gas / Liquid Separators,Vertical or Horizontal.

Top: Gas Conditioning Skid – ALBA/Bechtal,Bahrain.

Bottom: Thermal Oil Heat Recovery from aThermal Oxidizer– BHP Billiton/KBR,Minerva, Victoria, Australia.

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S ITE WORKS

As well as installing Gasco supplied equipment andinstalling new plants, our site crew has also relocated ordemolished process plants and undertaken completefactory and equipment relocations.

We also contract for complete piping systems whichincludes installing pipe work, pumps, reactors, valves,instrumentation, pipe bridges, tanks and skids.

We have supplied services to the aerospace, chemical,petrochemical, gas, automotive, paper, paint, plastic, waterand waste water treatment and manufacturing, food andlaundry industries.

Gasco has a dedicated piping andsite installation team.

• Compliance Audits

• Design of Bitumen andBitumen Emulsion plants

• Thermal Oil (Hot Oil)Heating Systems

• Combustion & BurnerSystems

• BMS Upgrades to IEC61508 PES Systems

• Furnace Design andEfficiency Upgrades

• Oven Upgrades

• Flare SystemTroubleshooting

• Flare Radiation andDispersion

• Thermal OxidizerApplications

• Fired Heater and WasteHeat Recovery

• Upgrades andCommissioning

• Energy Audits

CONSULT ING

Gasco has supplied consulting and troubleshootingservices to a number of major corporations. We haveeight qualified combustion engineers on our staff.We have provided assistance to major Oil and Gascompanies, EPC Contractors and mineral processingcompanies.

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Top: Installation of tanks, vessels, pumps,process equipment and piping – Orica,Yarraville, Victoria, Australia.

Bottom: Low NOx Recirculated CombustionGas Burner System.

OVENS AND FURNACES

Ovens

Gasco has supplied Toyotaand Ford with major paintline ovens, air houses andmaterial handling equipment.

As well as car companies,Gasco has designed, suppliedand installed complete paintlines for automotive brakemanufacturer, comprisingcleaning, powdercoatapplication, curing andcooling.

Gasco has also suppliedbogie hearth and continuousovens for the glass, fibreglasscuring, automotivecomponents and paint andchemical drum heatingapplications.

FurnacesGasco has designed andsupplied stress relievingfurnaces, salt curing baths,heat treatment, andcremators.

Gasco has supplied numerous customdesigned ovens and furnaces for manyapplications.

BURNERS AND COMBUSTION

Gasco prides itself as a combustioncompany on its ability to creativelysolve your combustion problems.

Top: Disc Brake Pad Paint Curing Oven –FMP, Ballarat, Victoria, Australia

Bottom: 40GJ/h Smelter Start-Up Burnersupplied to India and China.

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Gasco can supply a solution to your combustion requirements.We design and manufacture specialized burners and systemssuch as 40 GJ /h smelter start-up burners. We also incorporateother leading proprietary brands of burners in combustionpackages to provide our clients with the most cost effectivesolution. Specifically, we can offer:

• Combustion SystemDesign

• Burners

• Gas Trains

• Skid Mounting

• Burner ManagementSystems (BMS)

• Instrumentation andControl Systems

• Hardwired, PLC, PES toIEC 61508

• Safety PLC with SILanalysis

• Scada Systems

SERVICE

If you have a combustion orhigh temperature heat transferproblem or need an upgrade,Gasco has supplied:

• Ladle Pre-Heaters

• Stub Heater for AluminiumSmelters

• Propellant DestructionFurnaces

• Fired Heaters for SimulatingGas Turbine OperatingConditions

• Fired Heaters for R&D in theMineral Industry

• Robots for AutomotiveIndustry

• Conversion of Carbon BakeBurners from Oil to Gas

• Spray Booths R&D PaintIndustry

• Hydrogen Fired Hot OilHeaters

• Hot Oil Heaters forCasino/Hotel Laundries

This is only a partial list ofspecial products. See GascoProducts by Industry listing –back page.

We can offer 24 hour, 7 days-per-week coverage.

As well as covering Victoria, we can also supply Australiawide as well as international coverage.

We have commissioned and serviced combustion equipmentin Papua New Guinea, Indonesia, Phillipines, China, India,Russia, Tanzania and Thailand.

We regularly service a range of combustion equipment notof Gasco’s manufacture.

Service maintenance contracts with Gasco providesconvenience and peace of mind for many of our clients.

Gasco has four fully equipped service vans withqualified Type B technicians and an additional eightengineers with Type B qualifications.

CUSTOM SOLUTIONS — ‘SPECIALS’

Over the years, Gasco has tackled manydifferent and unique problems that arenot easily categorised.

Top: Eight of Gasco’s twelve CombustionEngineers and Service Personnel

Below: Ladle Pre-Heater – Hi Smelt, PerthWestern Australia.

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ALUMINIUM Custom designedheaters or dryers for the following:ladles, crucibles, siphon tubes,cathode collector bars, aluminiumscrap, moulds, launders, anode stubs,anode blocks. Tar waste melt out andcollection. Tar Hot Oil Heaters, AirHeaters, Thermal Oxidizers, GasConditioning Skids, Carbon BakeFurnace Conversions.

AUTOMOTIVE Paint and CuringLines, Spray Booths, Ovens, CoreDrying, Air Houses, Heat Recovery,Washing Systems, Thermal Oxidizers.

CHEMICAL Combustion Systems, AirHeaters, Heat Exchangers, ThermalOxidation, Heat Recovery, Hot OilSystems, Resin Kettles.

ENVIRONMENTAL Afterburners,Incinerators, Thermal Oxidizers,Flares, Scrubbers, Landfill Gas Flares,Odour Incineration, Biogas Flares andBurners, Heat Recovery, SoilRemediation Systems, LiquidsIncineration.

FOOD Air heaters, Ovens, Burnersand Combustion Systems, ThermalOxidizers, Hot Oil Systems, HeatExchangers

GENERAL INDUSTRIAL Driers,Ovens, Kilns, Furnaces, Hot OilSystems, Heaters, Thermal Oxidizers.

MINERALS & METALS Air Heaters,Driers, Kilns, Hot Oil Systems, Heaters

for Launders, Ladles, Burners andCombustion Systems, Start UpBurners, Flares & Thermal Oxidizers.

OIL, GAS Fired Heaters, ThermalOxidizers, Flares, Waste HeatRecovery.

PETROCHEMICAL Hot Oil Heaters,Filter Coalescers, Acid Gas/Tail GasIncineration, Water Bath Heaters,Crude Oil Preheaters, CondensateHeaters, Pressure Reduction Skids,Heater Treaters, Radiation Shields,Metering Skids.

PHARMACEUTICAL Air Heaters,Driers, Thermal Oxidizers, Flares,Heating and Combustion, Hot OilSystems.

PIPELINE & TERMINAL City GateHeaters, Gas Conditioning, WaterBath Heaters, Let Down Skids,Filter/Coalescers, Metering Skids,Flares.

POWER GENERATIONGas Conditioning Skids, TurbineExhaust WHRU, Water Bath Heaters,Let Down and Filter/Coalescer Skids.

STEEL Heaters and Driers for Ladles,Tundish, Launders, Vessels, Start UpBurners, Combustion and ControlSystems, Thermal Oxidizers,Refurbishment of FurnaceCombustion Systems.

Represented by: Gasco Pty Ltd ABN: 55 869 575 588 ACN: 051 824 741

Factory 8, 981 Mountain Highway Boronia Victoria Australia 3155Ph: +61 3 9720 8577

24 hr service +61 3 9738 1773 Fax: +61 3 9720 4240

Email: gasco@gasco.net.au Internet: www.gasco.net.au

engineering with flare

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