Combi-Flare Exhaust Stack Integration for OG and Engine Exhaust Burning

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Solution Overview

Problem

Existing hydrocarbon processing sites face inefficiencies due to separate treatment of organic gases (OGs) and engine exhaust, leading to increased costs and emissions, as well as the need for extensive piping and separate flare and exhaust stacks.

Innovation Solution

A combi-flare system that integrates an exhaust stack and flare section, combining engine exhaust gas and OGs for simultaneous combustion, reducing the need for separate systems and piping, and enhancing combustion efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate treatment systems are used for OGs and engine exhaust, then each system can be optimized independently, but the overall system complexity increases and more piping is required

Engineering Contradiction:

Improvesystem optimizationVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the OG flare system and engine exhaust system into a single integrated combi-flare system. The exhaust stack serves dual purposes: capturing engine exhaust gases and serving as the flare stack for OG combustion. This merging eliminates the need for separate stacks and reduces piping complexity while maintaining the ability to treat both OGs and exhaust gases effectively.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The exhaust stack is designed to perform multiple functions simultaneously: it captures engine exhaust, mixes with OGs, and serves as the combustion chamber for flaring. This multi-functional design reduces the number of separate components needed and simplifies the overall system architecture while maintaining treatment effectiveness.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If separate flare and exhaust stacks are used, then each function can be independently designed, but the footprint and manufacturing costs increase

Engineering Contradiction:

Improvefunctional independenceVSAvoidsite footprint

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The patent merges the flare stack and exhaust stack into a single combi-flare structure. The exhaust stack captures engine exhaust while simultaneously serving as the flare stack for OG combustion, eliminating the need for two separate stacks and reducing the overall site footprint.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The exhaust stack is nested within or integrated with the flare stack structure. The exhaust capture system is positioned to utilize the existing flare stack architecture, allowing one system to be contained within or alongside the other, thereby minimizing the total space required.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Reliability

If separate treatment systems are used, then each system can be optimized for its specific function, but emissions control efficiency decreases

Engineering Contradiction:

Improvefunctional optimizationVSAvoidemissions

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent converts the potentially harmful engine exhaust gases into a beneficial resource by mixing them with OGs for combined combustion. The exhaust gases, which would normally be emitted separately, are now utilized as part of the flaring process, improving overall emissions control efficiency and reducing total harmful emissions.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

By merging the treatment of OGs and engine exhaust into a single combustion process, the system achieves improved emissions control efficiency. The combined combustion allows for better mixing and more complete oxidation of hydrocarbons, reducing harmful emissions compared to separate treatment systems.

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The combi-flare system improves operational efficiency by reducing emissions, lowering manufacturing costs, and minimizing the footprint of hydrocarbon processing sites by integrating exhaust and flare functions, thereby enhancing the destruction efficiency of OGs and engine exhaust.

Implementation Method 1

The exhaust stack receives the second portion of the process fluid and the exhaust gas, and the second portion of the process fluid and the exhaust gas operationally mix within the exhaust stack

Methodology Applied

Scientific EffectMixing:

Implementation Method 2

the flare section generates a flame to burn the mixture of the second portion of the process fluid and the exhaust gas

Methodology Applied

Scientific EffectCombustion: Combustion

Data Source

PatentUS12590699B2Combination exhaust stack and flare systems and methods

Publication Date: 2026.03.31 INNIO WAUKESHA GAS ENGINES INC

AI summary

In certain embodiments, a hydrocarbon processing site may include an internal combustion engine that, during operation, generates an exhaust gas and one or more hydrocarbon processing components that receive a process fluid, output a first portion of the process fluid via a first outlet, and output a second portion of the process fluid via a second outlet. The hydrocarbon processing site may also include a combi-flare that includes an exhaust stack of the internal combustion engine and a flare section. The exhaust stack receives the second portion of the process fluid and the exhaust gas, and the second portion of the process fluid and the exhaust gas operationally mix within the exhaust stack. Additionally, the flare section generates a flame to burn the mixture of the second portion of the process fluid and the exhaust gas.