Flare Systems

unassisted

Zeeco's non-assisted flares and utility flares are used in applications that don't require smokeless operation, or where smokeless operation can be achieved without the assistance of external steam, air or pressure.

Utility flare tips are used for combustion of gases that do not produce smoke, gases with a low heating value, or for installations where smokeless combustion of heavy hydrocarbons is not required. Utility flare tips are one of the lower capital cost options for safe disposal of waste gases.

Zeeco’s UF style flare tip assembly utilizes a unique arrangement of proprietary flame stabilization tabs to ensure stable and high efficiency flaring through the entire design range of flows, from maximum emergency flaring to purge gas flow rates. The flame stabilization tabs work in conjunction with constantly burning pilot assemblies to ensure ignition of the waste gas. The flame stabilization tabs create a low pressure zone at the perimeter of the flare tip gas exit point, providing an area of slow moving gases that can be easily ignited by the pilot assembly. Zeeco flame stabilization tabs are unique, fully investment cast assemblies, mounted to the flare barrel using plug welds, to avoid stress risers and to eliminate cracking associated with linear welding in high heat zones.

Zeeco offers complete skid-mounted and trailer-mounted flare assemblies, as well as aftermarket products, services and engineered solutions.

smokeless

Zeeco offers both single-point and multi-point gas-assisted flares for smokeless burning of low- pressure, heavy hydrocarbons. Our patented designs deliver stable burning, high-destruction efficiency and low radiation levels wherever steam or air is unavailable.

Ground / Enclosed

Zeeco offers a comprehensive range of multi-point and enclosed ground flares for applications where at-grade levels achieve higher combustion efficiency for fully smokeless performance, or where government compliance requires flame concealment.

zero routine flaring

Flares are a necessary safety system in processing facilities across many industries. Although the need for flaring systems isn’t likely to be eliminated, Zeeco continues to bring innovative solutions to the market to reduce the impact of continuous flaring worldwide.

Vapor control

Flare Gas Recovery (FGR) is the process of recovering the waste gases that would normally be flared, so they can be used as fuel gas elsewhere in the facility. This results in reduced emissions and cost savings.

Flare Structures

Guyed

Guy-supported (guyed) type stacks are one type of support system for an elevated flare. The elevated flare tip is mounted on top of a riser supported through a system of cables (guy-wires), typically arranged with a set of three (3) cables at 120 degree angles. Guyed flares require multiple deadman foundation anchors to anchor the cables to the ground, and therefore this support system necessitates a larger plot space than other support systems. The design of guy-supported flares requires special attention to process temperature conditions in conjunction with multiple levels of guy-wires.

Guyed Derrick

Guyed derrick type stacks are one type of support system for an elevated flare. The elevated flare tip is mounted on top of a riser supported by both a steel trussed derrick structure and through a system of cables (guy-wires), typically arranged with a set of three (3) cables at 120 degree angles. Similar to a guyed flare, a guy derrick flare requires multiple deadman foundation anchors to anchor the cables to the ground, and therefore this support system necessitates a larger plot space than other support systems. It also requires a smaller, more economical derrick structure compared to a conventional type of derrick supported flare. Guyed derrick flares eliminate concerns associated with process temperature designs.

Derrick

Derrick type stacks are one type of support system for an elevated flare. The elevated flare tip is mounted on top of a riser supported by a steel trussed (derrick) structure. Derrick supported flares require three or four additional foundations for the derrick legs, but this is a relatively smaller plot space when compared to a guyed flare of the same height. Derrick flares eliminate process temperature design concerns. Additionally, a single common derrick structure can support multiple flare risers.

Demountable Derrick

Demountable derrick type stacks are one type of support system for an elevated flare. The elevated flare tip is mounted on top of a riser supported by a steel trussed (derrick) structure. Similar to a conventional derrick supported flare system, demountable derricks require three or four additional foundations for the derrick legs. Due to the economic impact of shutting a flare down and the requirement for large cranes, users welcome a means to be able to lower the flare tip to grade for maintenance, inspection, or repair activities without ever having to shut the flare down. A demountable derrick allows a user the ability to lower the flare tip and pilots to grade through the use of a winch system (typically three different winches), guide rails, tilting tables, and flanged riser sections. Demountable derricks eliminate concerns associated with process temperature designs. Additionally, a single common demountable derrick structure can support multiple flare risers.

Self-Supported

Self supported type stacks are one type of support system for an elevated flare. The elevated flare tip is mounted on top of a free-standing riser consisting typically of multiple diameter cylinder sections. Self supported flares require only one foundation and therefore a relatively small plot space. Riser is maintenance free, and no concerns for process temperature conditions are required. Self supported stacks can be designed to lift in multiple sections or as a single piece (fully dressed with ladders, platforms and utility piping). This type of support system is generally limited in height due to the base diameter section (whether by shipping constraints or economic feasibility of fabricating at the jobsite).

Flare Control Systems

Flare systems require many different types of controls. Controls are required for the ignition and monitoring of flare system pilots, control of fluid levels in knockout and liquid seal drums, for the control of steam or air or water or gas injection for control of smoke, measurement of oxygen, measurement of lower heating value, adjustment of assist gas injection, adjustment of blower speed for control of smoke, snuffing system controls, purging systems, staging controls, pump packages, solar power systems, etc. 

Auxiliary Equipment 

Purge Reduction Devices

Velocity Seals

• Integral Piece of Equipment Within the Flare Tip
• Does NOT Require a Dedicated Drain Line
• Ensures O₂ Level Does Not Reach Over 6-8% Below the Velocity Seal Device

Gas (Buoyancy) Seals

• Separate Piece of Equipment Below Flare Tip
• Requires a Dedicated Drain Line
• Ensures O₂ Level stays near 0.1% for the Gas Seal Device (for most compositions)

Liquid Seal Drum

Liquid seal drum is a safety device usually located in the stack base to prevent a flashback from entering the piping upstream of the flare.

Knockout Drum

Knockout drums are used to collect any liquid entrained in a waste gas stream.

KnockOut drum types include:

• Separate / Stand-Alone (Horizontal or Vertical)
• Integral in Stack Base (Vertical)

Combination Liquid Seal / Knockout Drum

The ZEECO combination liquid seal/knockout drum protects the flare header from air infiltration or flashback from entering the piping upstream of the flare (liquid seal) and is also used to remove and store condensed and entrained liquid (knockout drum).

Blowers

Zeeco can supply many different types of blowers including Engine Driven, Vaneaxial and Centrifugal.