Flare Combustion Control Using Sound Speed for Real-Time Heating Value

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Solution Overview

Problem

Existing flare control systems face challenges in continuously measuring the heating value of flare gases due to the slow response time of gas chromatographs and calorimeters, which limits their ability to handle fast fluctuations in flare vent gas composition.

Innovation Solution

A flare combustion control system that utilizes a sound speed measurement device to determine the molecular weight and net heating value of flare vent gases, allowing for real-time adjustments of supplemental fuel gas to maintain optimal combustion conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a gas chromatograph is used to determine heating value, then measurement accuracy is improved, but response time increases significantly

Engineering Contradiction:

Improveheating value measurement accuracyVSAvoidresponse time

Core Design Contradiction:

Measurement precisionVSSpeed

Solution Approach 1:

The patent replaces the mechanical gas chromatograph system with an acoustic measurement system that uses sound velocity measurements to determine molecular weight and heating value. This substitution eliminates the slow mechanical separation and detection processes of GC while maintaining measurement accuracy through the physical relationship between sound velocity, molecular weight, and heating value.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the measurement parameter from direct thermal measurement (calorimetry) or compositional analysis (chromatography) to acoustic parameter measurement (sound velocity). By measuring sound velocity in the gas stream and correlating it to molecular weight and heating value, the system achieves both fast response and accurate measurement.

Inventive Principle:

Principle #35Parameter changes

2Measurement precision

If a calorimeter is used to calculate BTU value, then heating value measurement is achieved, but response time remains slow and gas speciation is lost

Engineering Contradiction:

Improveheating value calculationVSAvoidmeasurement time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent replaces the calorimeter's thermal measurement process with an acoustic measurement system. Instead of measuring heat release through temperature changes, the system measures sound velocity, which provides instantaneous data without the time delays inherent in thermal equilibrium measurements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces molecular weight as an intermediary parameter that links sound velocity measurement to heating value determination. By measuring sound velocity to determine molecular weight, and then using molecular weight to calculate heating value, the system achieves accurate heating value measurement with fast response time.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Speed

If real-time measurement is implemented, then response to composition fluctuations is improved, but measurement system complexity increases

Engineering Contradiction:

Improveresponse speed to composition changesVSAvoidmeasurement system complexity

Core Design Contradiction:

SpeedVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical measurement systems (GC or calorimeter) with a simpler acoustic measurement system. The sound velocity measurement apparatus is inherently simpler in structure and operation, requiring no complex separation columns, detectors, or thermal equilibrium chambers, thus reducing device complexity while enabling real-time measurement.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 system enables continuous, efficient, and smokeless combustion of flare vent gases by providing accurate, real-time measurements of molecular weight and net heating value, thereby optimizing flare operation and ensuring compliance with regulatory requirements.

Implementation Method 1

a sound speed measurement device for measuring sound speed in a flare vent gas

Methodology Applied

Scientific EffectSpeed of sound: Speed of Sound

Implementation Method 2

regulating a flow of the assist gas for mixing with the flare vent gas to produce smokeless combustion of the flare vent gas

Methodology Applied

Scientific EffectCombustion: Combustion

Data Source

PatentUS12305853B2Integrated flare combustion control

Publication Date: 2025.05.20 BAKER HUGHES CO

AI summary

A system for flare combustion control includes a sound speed measurement device for measuring sound speed in a flare vent gas, and a flare combustion controller including a memory and a processor. The processor is configured to receive the measured sound speed and determine, based on the measured sound speed, a molecular weight of the flare vent gas. The processor is further configured to determine, based on the determined molecular weight, a net heating value of the flare vent gas, and adjust the net heating value of the flare vent gas by regulating an amount of a supplemental fuel gas in the flare vent gas.