Integrated Flare Gas Assemblies for High- and Low-Pressure Combustion
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Solution Overview
Problem
High and low pressure flare gases from oil and gas well sites cannot be accumulated due to safety and environmental hazards, and existing flaring systems are inadequate for safely and efficiently burning these gases.
Innovation Solution
A flare gas system with integrated low and high pressure flare gas assemblies, utilizing a mixing chamber and pressure-operated valve assembly to mix and ignite gases, and a flow restrictor to increase gas velocity, allowing a single igniter to burn both pressures effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate flaring systems are used for high and low pressure gases, then each gas type can be flared independently, but the device complexity increases
Solution Approach 1:
The patent combines separate high pressure and low pressure flaring systems into a single integrated flare stack. The common flare stack receives both high pressure flare gas from separators and low pressure flare gas from tank batteries through a manifold system, eliminating the need for separate flaring infrastructure and reducing overall system complexity while maintaining reliable flaring capability for both gas types
Solution Approach 2:
The flare stack is designed with multi-functionality to handle both high pressure and low pressure gases simultaneously. The system includes pressure-operated valves that automatically route appropriate amounts of each gas type to the common flare stack, allowing a single flaring device to perform multiple functions that previously required separate specialized systems
2Device complexity
If a single igniter is used for both high and low pressure gases, then the device complexity is reduced, but the reliability of complete combustion decreases
Solution Approach 1:
The system incorporates a diffuser at the base of the flare stack that creates localized turbulence and mixing zones. This local modification ensures that both high pressure and low pressure gases are thoroughly mixed and pre-heated before reaching the single igniter, creating optimal combustion conditions that enable complete burning of both gas types despite using only one ignition device
Solution Approach 2:
The patent introduces air injection as an intermediary mechanism between the gas input and the igniter. Compressed air is injected through the diffuser to create turbulence and mix the high and low pressure gases thoroughly, acting as a mediator that prepares the gas mixture for reliable ignition and complete combustion by a single igniter
3Device complexity
If high pressure gas is used to drive low pressure gas through a flow restrictor, then the flow control is simplified, but the pressure stability of low pressure gas decreases
Solution Approach 1:
The system employs dynamic pressure-operated valves that automatically adjust their opening based on real-time pressure conditions. These valves respond to pressure changes in both high and low pressure lines, dynamically balancing the flow to maintain stable low pressure gas delivery to the flare stack while using the high pressure gas to drive the flow restrictor mechanism
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 safely and efficiently burns high and low pressure flare gases, reducing safety hazards and environmental impact by ensuring complete combustion.
Implementation Method 1
a flow restrictor to increase gas velocity
Implementation Method 2
utilizing a mixing chamber and pressure-operated valve assembly to mix and ignite gases
Implementation Method 3
a single igniter to burn both pressures effectively
Data Source
AI summary
A flare gas system for flaring high and low pressure flare gases, the system including a first flare gas assembly that has a central air pipe and first and second conduits in surrounding relationship to the air pipe. There is a first annulus formed between the air pipe and the first conduit, and a second annulus formed between the first conduit and the second conduit. A flow restrictor is disposed in the second annulus. A first gas handler conveys a first flare gas to the first flare gas assembly. A second flare gas assembly is connected to the first flare gas assembly and has a tubular housing in which is disposed a pressure operated valve assembly. A second flare gas handler distributes a second flare gas between the second annulus and the tubular housing. A single igniter can be used to ignite the gas from the first flare gas assembly and multiple second flare gas assemblies.