Single Stack Combustor for Low and High Pressure Vapor
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Solution Overview
Problem
Current combustor systems require separate stacks and incur high initial and maintenance costs for handling both low and high pressure hydrocarbon vapors, with inefficiencies in combustion and potential for smoke production, failing to meet stringent environmental and regulatory requirements for simultaneous combustion of low and high pressure gases.
Innovation Solution
A single stack combustor design featuring a primary burner at the base for low pressure vapor combustion and a flare at the top for high pressure vapor flaring, utilizing natural aspiration and additional air supply to optimize combustion efficiency and minimize smoke, with separate piping for each vapor type to prevent backflow and ensure complete combustion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate flare combustors are used to handle low pressure and high pressure vapors, then combustion efficiency for each pressure type is optimized, but initial capital cost and ongoing maintenance costs increase significantly
Solution Approach 1:
The patent merges separate flare combustors into a single integrated combustor that handles both low pressure and high pressure vapors. The combustor includes a primary burner at the base for low pressure vapor combustion and a flare at the top for high pressure vapor flaring, both within one stack structure. This consolidation reduces the number of stacks from two to one, thereby reducing initial capital cost and ongoing maintenance costs while maintaining combustion efficiency for both pressure types through properly designed burners and flares positioned at different locations.
Solution Approach 2:
The single combustor is designed with multi-functionality to perform both low pressure vapor combustion and high pressure vapor flaring operations. The combustor structure accommodates different types of combustion processes at different locations: the primary burner at the base handles low pressure vapors with natural aspiration, while the flare at the top handles high pressure vapors. This universal design allows one combustor to replace two separate combustors, reducing system complexity and operational costs.
2Device complexity
If low pressure hydrocarbon gases are combusted without smoke suppressant or additional air, then combustion process is simple, but smoke is produced due to incomplete combustion and free carbon formation
Solution Approach 1:
The patent introduces air as an intermediary substance to the combustion process of low pressure hydrocarbon gases. Additional air is supplied to the primary burner to provide turbulent mixing with the hydrocarbon vapors, which minimizes smoke production during combustion. This intermediary air facilitates more complete combustion by ensuring adequate oxygen supply and enhancing mixing between fuel and oxidizer, thereby reducing the formation of smoke and free carbon.
Solution Approach 2:
The patent changes the combustion parameters by introducing additional air to alter the air-to-fuel ratio and combustion atmosphere. By modifying these parameters, the combustion process transitions from incomplete combustion (which produces smoke) to more complete combustion. The natural aspiration system and additional air supply adjust the combustion parameters to achieve efficient burning with minimal smoke, transforming the harmful smoke production into a controlled combustion process.
3Device complexity
If high pressure gas flaring is conducted using simple open pipe discharge, then device complexity is minimized, but significant radiant heat is produced requiring elevation above ground
Solution Approach 1:
The patent addresses the radiant heat issue by positioning the flare in a vertical dimension above the ground level. The flare is located in the bore of the stack adjacent to the top, elevating the high pressure vapor discharge and combustion zone above ground-based equipment and personnel. This vertical placement reduces the radiant heat exposure to ground-level objects and people, while the simple open pipe discharge configuration maintains device complexity at minimal levels.
4Device complexity
If single stack combustor combines both low and high pressure vapor combustion, then capital and maintenance costs are reduced, but pressure differential may cause backflow along low pressure can triggering release valves
Solution Approach 1:
The patent segments the combustor into distinct functional zones: a primary burner at the base for low pressure vapor combustion and a flare at the top for high pressure vapor flaring. Separate piping systems are provided for low pressure and high pressure vapors, with the high pressure vapor line extending along the stack and entering the bore at the top. This segmentation physically separates the vapor delivery paths and combustion zones, reducing the risk of backflow along the low pressure can while maintaining the simplicity of a single stack structure.
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 solution enables efficient, cost-effective combustion of both low and high pressure vapors in a single stack, meeting or exceeding regulatory efficiency standards (98% in Canada and 95% in the USA) while reducing smoke production and eliminating the need for separate flare stacks, thereby reducing capital and maintenance costs.
Implementation Method 1
combustion of low pressure vapors
Implementation Method 2
air is introduced to provide turbulent mixing with the hydrocarbon for minimizing smoke during combustion
Implementation Method 3
combustion of high pressure vapors
Implementation Method 4
air is introduced to provide turbulent mixing with the hydrocarbon for minimizing smoke during combustion
Implementation Method 5
A primary burner positioned in the bore adjacent a base of the stack naturally aspirating combustion air through inlets below the primary burners
Data Source
AI summary
A stack is provided for combustion of low pressure hydrocarbon vapors from various equipment, the combustion being discrete from periodic flaring of high pressure vapors from a top of the stack. A primary burner is positioned adjacent a base of the stack and a flare is positioned in the stack's bore adjacent a top thereof. Combustion air is naturally aspirated through the stack through inlets in the stack below the primary burners, providing both primary air and secondary air for the primary burners and first combustion air for the flare. The flare aspirates further combustion air from about the top of the stack. The combustion air optimizes clean burning at the primary burner and for reducing smoke production from the flare. A controller provides an auto re-light igniters at the primary burner and a continuous igniter at the flare.