Modular Flare System with Stirling Engines for Residue Gas Energy Recovery
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Solution Overview
Problem
Conventional flare systems for industrial processes are inefficient in recovering energy from residue gases, as they consume all energy content without conversion, cause noise and pollution, and require extensive infrastructure and maintenance, making them unsuitable for fluctuating gas flows and hazardous environments.
Innovation Solution
A modular flare system incorporating Stirling engines connected in parallel with a conventional flare stack, allowing for energy recovery from residue gases with flexible and dynamic control, easy installation, and reduced maintenance needs, using standardized modules for efficient energy conversion and power generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional flare stack is used to combust residue gas, then the gas can be safely eliminated and explosive/poisonous gases removed, but all energy content is consumed and evaporated without useful conversion
Solution Approach 1:
The system segments the residue gas flow into two parallel paths: one leading to the flare stack for safety disposal and another leading to energy conversion modules for useful energy recovery. This allows simultaneous achievement of safe gas elimination and energy recovery without compromising either function.
Solution Approach 2:
Energy conversion modules act as intermediary devices between the residue gas source and the flare stack. These modules first capture and convert energy from the residue gas, then pass the remaining gas to the flare stack for safe disposal, thereby mediating between energy recovery and safety requirements.
2Loss of energy
If a turbine power station is installed to generate electrical power from residue gas, then energy can be recovered, but massive expensive infrastructure with large footprint and maintenance personnel is required
Solution Approach 1:
The system replaces expensive, complex turbine infrastructure with simpler, modular energy conversion units that have lower installation costs, smaller footprints, and reduced maintenance requirements. These modular units can be deployed without massive infrastructure construction.
Solution Approach 2:
The energy recovery system is divided into multiple independent modular units rather than a single large turbine. Each module can operate independently, simplifying installation and maintenance while collectively achieving the required energy recovery capacity.
3Device complexity
If combustion engines are used to recover energy from residue gas, then smaller footprint is achieved, but significant variation of H2 content and contaminations cause ignition control difficulties and costly maintenance
Solution Approach 1:
A gas conditioning unit serves as an intermediary between the residue gas source and the energy conversion modules. This unit pre-treats the gas by removing contaminants and stabilizing composition, thereby protecting the energy conversion modules from damage and ignition control issues while maintaining compact design.
4Use of energy by moving object
If residue gas is used in heating applications within the smelting plant, then some energy is recovered, but a large portion (40% or more) cannot be recovered and must be burned in flare stack
Solution Approach 1:
The energy conversion modules are designed to handle multiple types of residue gas compositions and can operate in parallel with both internal heating applications and external energy generation. This multi-functionality maximizes energy recovery from all residue gas streams regardless of their ultimate destination.
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 modular flare system effectively recovers energy from fluctuating residue gas flows, reduces installation and maintenance costs, and provides a flexible, reliable, and cost-optimized solution for industrial processes, even in hazardous environments, by utilizing Stirling engines for efficient energy conversion and power generation.
Implementation Method 1
a Stirling engine configured to convert heat from the combustion chamber into mechanical energy, the Stirling engine having a heat engine heat exchanger including a set of tubes conducting a compressible working fluid
Implementation Method 2
the combustion chamber configured to receive a flow of residue gas through the fuel inlet for combustion in the chamber at near atmospheric pressure
Implementation Method 3
The electric generator is connected to the output shaft and is configured to generate electric power from the mechanical energy
Data Source
AI summary
A flare system including a flare stack and a modular flare unit connected in parallel with the flare stack. The modular flare unit includes a frame, at least two energy conversion modules detachably supported by the frame, a fuel manifold, an air manifold, an exhaust manifold, and an electric generator. Each energy conversion module includes a combustion chamber configured to receive a flow of residue gas through the fuel inlet for combustion in the chamber at (or close to) atmospheric pressure, and a Stirling engine configured to convert heat from the combustion chamber into mechanical energy. The electric generator is connected to generate electric power from the mechanical energy.