The ZEECO® Contour is an Automatic Flare Control System created by Zeeco flare engineers for the specific purpose of optimizing flare control to prevent non-compliance with environmental regulations, reduce utility consumption, prolong equipment life, and enhance Destruction Efficiency (DE). When implemented, this turnkey combustion control solution costs a fraction of indirect measurement systems. The ZEECO Contour requires no contact with the flare header and is maintainable from grade.
Over-applying steam or air to achieve smokeless flaring is a chronic practice at many plants, which can negatively impact the environment. The application of too much smokeless injection media at minimum or normal flare rates dilutes the combustion zone, thus greatly reducing the flare’s Destruction Efficiency (DE). Over-aeration (whether the assist medium is air or steam) and the resultant lowering of DE can increase the chance of venting unburned purge and flare waste gases to the atmosphere rather than destroying them through high DE combustion. To prevent the negative effects associated with low DE, government regulations are mandating new control parameters for steam and air injection to ensure proper Net Heating Values of the combustion zone (NHVcz) are achieved. These new regulations require the aggregate of all components entering the combustion zone (i.e. purge gas, enriching gas, steam injection, combustion air injection, etc.) to have a combined lower heating value of 270 BTU/SCF or greater. Failure to properly control steam or air injection and over-aerating the flare can mean:
Past methods for control of air or steam have been indirect, such as measuring the flare release flow and characteristics, then calculating the steam or air injection requirement. The ZEECO Contour is an automated, real-time, direct monitoring and flare control package using Infrared (IR) technology to assess the flare combustion zone and inject the correct amount of assist media to ensure proper (High DE) combustion – independent of the waste gas composition and flow.
At Zeeco, we understand flare systems, regulations, and technology must work together to ensure the safety of the plant, nearby people, and environment. The ZEECO Contour™ requires no contact with the flare header, and is maintainable from grade. Users gain immediate utility savings by optimizing smokeless media injection rates based on real-time feedback rather than the lag time inherent with indirect monitoring methods. Zeeco combustion professionals oversee the commissioning of the system, tuning it on-site to your equipment to enable a quick, simple transition and startup.