Flare Tip Assembly Dynamic Cone for High Turndown Ratio
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Solution Overview
Problem
Existing flare systems struggle to efficiently combust both low-pressure and high-pressure vapors in a single stack without smoking, failing to meet regulatory standards and requiring multiple flare assemblies for different pressure conditions.
Innovation Solution
A flare tip assembly with a machined cone and tubular firing orifices that adjusts open area based on pressure, using a spring assembly to maintain stable fuel and air mixing across a wide range of pressures, eliminating the need for multiple flare assemblies by achieving a high turndown ratio and preventing backflow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single flare assembly is used for both low-pressure and high-pressure vapors, then device complexity is reduced, but combustion efficiency deteriorates due to inability to maintain stable fuel-air mixing across wide pressure ranges
Solution Approach 1:
The flare tip assembly employs a movable cone that dynamically adjusts the open area based on inlet pressure conditions. At low pressures, the cone remains retracted to maintain proper fuel-air mixing; at high pressures, the cone extends to increase the open area and accommodate higher flow rates. This dynamic adjustment enables a single assembly to efficiently handle both low-pressure and high-pressure vapors without requiring multiple static configurations.
Solution Approach 2:
The invention changes the geometric parameter of the open area by moving the cone along the central axis. The cone's position varies the effective opening area of the flare tip, allowing the system to adapt to different pressure conditions. This parameter change enables the single flare assembly to maintain optimal combustion efficiency across a turndown ratio exceeding 200:1, from 0 to 30 psig.
2Quantity of substance
If the open area is increased to handle high-pressure vapors, then处理能力 for high-pressure flows is improved, but fuel-air mixing stability deteriorates at low-pressure conditions
Solution Approach 1:
The movable cone creates a dynamic system where the open area automatically adjusts to pressure conditions. A spring mechanism provides the restoring force that returns the cone to its retracted position at low pressures, ensuring stable fuel-air mixing. When high-pressure vapors enter, the pressure differential overcomes the spring force, extending the cone to increase the open area and accommodate higher vapor quantities without disrupting mixing stability at lower pressures.
Solution Approach 2:
The flare tip assembly uses the inlet pressure itself to drive the cone movement. The high-pressure vapor flow directly pushes the cone outward to increase the open area, while at low pressures, the spring mechanism automatically returns the cone to its original position. This self-regulating mechanism eliminates the need for external control systems to maintain proper fuel-air mixing across different operating conditions.
3Adaptability or versatility
If a movable cone is added to adjust open area, then adaptability to different pressures is improved, but device complexity increases
Solution Approach 1:
The cone movement mechanism is entirely self-actuating, using the inlet pressure differential to drive the cone outward and a spring mechanism to return it to the retracted position. No external actuators, sensors, or control systems are required. This self-service approach provides adaptability across a turndown ratio exceeding 200:1 while minimizing the addition of complex control infrastructure.
Solution Approach 2:
The invention uses pneumatic principles where the inlet vapor pressure directly acts on the cone surface to generate the force necessary for movement. The spring mechanism provides a mechanical counterbalance that works in conjunction with the pressure differential. This pneumatic-mechanical system achieves wide pressure range adaptability through simple, reliable physical principles rather than complex electronic or hydraulic control systems.
4Adaptability or versatility
If the flare tip operates at high turndown ratio, then versatility for different applications is improved, but risk of backflow and smoking increases
Solution Approach 1:
The dynamic cone position maintains optimal fuel-air mixing ratios across the entire pressure range. At low pressures, the retracted cone ensures proper mixing to prevent smoking and incomplete combustion. At high pressures, the extended cone accommodates higher flow rates while maintaining mixing stability. This dynamic adjustment prevents backflow by ensuring that the combustion process remains stable and controlled under all operating conditions, eliminating the harmful effects associated with high turndown ratio operation.
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 flare tip assembly ensures efficient combustion of vapors with greater than 98% destruction efficiency and no visible smoke, operating from 0 to 30 psig with a turndown ratio of over 200:1, meeting emission requirements and handling both subsonic and sonic flows.
Implementation Method 1
a spring assembly to maintain stable fuel and air mixing across a wide range of pressures
Implementation Method 2
ensures efficient combustion of vapors with greater than 98% destruction efficiency and no visible smoke
Data Source
AI summary
A high turn down ratio flare tip assembly, that allows for both low and high flowrate and pressure flows using a single flare. The flare assembly comprising a nozzle tube connected to the waste stream fuel inlet at one end. The other end of the flare tip assembly providing a seat for a conical structure with flow through orifices/ports that allow the waste stream to flow therethrough during low pressure operation. The conical structure connected to one end of a connecting rod, the connecting rod extending longitudinally downward through the nozzle tube and connected to a spring assembly. The flare tip assembly is designed to allow low flow and pressure to pass through the cone orifices, and during high flow and pressure operation, the cone is unseated from the nozzle tube, allowing the waste stream to flow therethrough. The flare tip assembly also includes a slotted/holed shroud that allows for smokeless combustion of the waste stream during high flow and pressure conditions.