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ESL-IE-97-04-09

DESIGN ENHANCEMENTS TO Il\fPROVE FLARE EFF1CIENCY Kenneth A Dooley Senior Chemical Engineer G. Michael McLeod Assistant Department Superintendent Eastman Chemical Company Longview, Texas Mark D. Lorenz Principal Chemical Engineer

ABSTRACf Two flare systems used at separate Wlits within a larger chemical complex were modified to improve overall performance and efficiency. One system was a standard enclosed ground flare; the other was a less-conventional horizontal ground flare system. In both cases, restaging resulted in significant reductions in energy usage and continuing or improved compliance with regulatory requirements while maintaining the flexibility to manage gases having variable tlowrates and heat contents. OVERVIEW The continuing importance of maintaining a high level of energy efficiency, the more recent emphasis placed on the generation of greenhouse gases, and the ever-tightening regulatory requirements for emissions sources provided a chemical company with opportunities to assess the performance of two flare systems. The flare systems, an enclosed ground flare at a plastics production facility and a horizontal groWld flare at an olefin cracker, were modified to decrease the energy required for operation of each unit while insming compliance with applicable environmental regulations. Other benefits were realized as well. THE ENCLOSED GROUND FLARE

design. As a result, natural gas make-up to the flare was excessive and costly. Modifications The flare system was reconfigured to accommodate the lower heat content via the addition of an alternate first stage. The new stage was comprised of three new burners designed for lower flowrates and for gases with lower heating values than the original fin-plate burners.

An existing on-line analyzer was respanned so the range of heating values measured by the analyzer matched the capabilities of the new burners. The minimum measurable value was decreased to 200

BTU/SCF.
Finally, the control logic was reconfigured to take advantage of the combustion capabilities of the alternate first stage. Results Natural gas usage by the flare system was reduced by 47% between 1994 and 1995 amounting to savings of 264,000 MMBTU per year while maintaining smokeless operation and the required combustion efficiency of the unit THE HORIZONTAL GROUND FLARE

Original Design The enclosed ground flare system was designed for use at a plastics production facility, to burn routine vent and purge gases. It was configured as a two-stage system with each stage consisting of multiple burners. The original burners were of a fin plate design. The flare system was designed to operate at low pressure due to venting constraints imposed by plant equipment. Vent gases were enriched with natural gas to maintain a minimlDll heat content of 600 BTU/SCF, required for stable combustion and complete destruction of volatile organic compounds (VOC's). Actual Operations As the plant was brought on line, the actual heat content of the vent gases was found to be significantly lower than that used in the original

Original Design The flare system was designed for use at an olefin cracker and was used for both routine vent gases and those generated as a result of shutdowns, maintenance activities. and plant upsets. The flare system consisted of horizontal 12" and 42" open ended pipes with water spray racks at the ends to suppress smoking. Actual Operations A continuous and significant methane purge from the plant was routed through the flare lines to prevent air ingress. Due to the variability in flows to the flare system, smokeless operation was difficult to maintain.

Proceedings from the Nineteenth Industrial Energy Technology Conference, Houston, TX, April 23-24, 1997

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ESL-IE-97-04-09

Modifications Several changes were made to the flare system. Routine vent gases in the 42" flare line were diverted to the 12" line via a new 12" crossover. A steam assisted flare tip was installed on the 12" flare line to minimize air ingress and to ensure smokeless combustion of routine vent gases. Rupture pin devices (specialized relief devices) were installed on the 42" flare line downstream of the crossover that would automatically open when the flare pressure exceeded predetermined limits such as would occur during emergency venting; the main 42" flare line was used only as required by venting conditions. Finally, the water spray rack on the 42" flare line was rebuilt and the control logic was redefined to ensure smokeless operation of the flare during emergency venting. Results The required methane purge to the flare was reduced by 75%, a reduction of 80,000 MMBTU per

year for the one installation. The flare operates without smoke during routine venting and flaring. Capital expenditures were only 20% of those required for a replacement vertical flare system. Similar modifications were completed on other existing flare systems with similar reSUlts. CONCLUSIONS Venting requirements are unique to each production facility and are likely to change over the life of the facility. The operation of flare systems associated with the production facility should be reviewed periodically. Flare systems should be designed (or retrofitted) to match the venting requirements; proper staging is vital to ensure efficient operation and proper performance of the flare system. For the subject flare systems, criteria used in their redesign include energy requirements, environmental concerns, capital constraints, and applicability to other systems.

Proceedings from the Nineteenth Industrial Energy Technology Conference, Houston, TX, April 23-24, 1997

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