Flare Gas Recovery (FGR) is the process of recovering the waste gases that would normally be flared, so they can be used as fuel gas elsewhere in the facility. This results in reduced emissions and cost savings.
Flare Gas Recovery Systems (FGRS) perform the following processes:
A facility’s safety depends on properly integrating the Flare Gas Recovery System into the relief header and the flare system. The compressor skid is only one piece of the package – all components must be properly designed and built to ensure safe and reliable operation of the entire package. This is why it is so important to utilize the expertise of a company like Zeeco with Flare Gas Recovery and Flare System experience.
Typical FGR Sizing:
Services Offered:
Zeeco’s staff members have extensive experience in design, fabrication, and installation of Flare Gas Recovery Systems, along with a full range of vapor control, vapor combustors, and vapor recovery units (VRU). We can evaluate the existing flare system, including the normal flow to the flare, size the Flare Gas Recovery system, design the liquid seal drum, and recommend proper integration of all the equipment and controls for your specific application.
Zeeco's fully automated Vapor Combustor Units (VCU) are primarily used to control the VOC laden vapors generated during the loading of crude oil and refined petroleum products into trucks, railcars and marine vessels. They are also used to control the vapors generated by the venting of petroleum storage tanks. Zeeco's vapor combustors are fully enclosed, have automated temperature control, and can achieve VOC destruction efficiencies of up to 99.9%. These high-efficiency vapor combustors can operate on a wide range of vapors without smoke or visible flames. Units can be sized to fit the smallest truck rack to the largest marine loading systems. Flow rates up to 80,000 BPH or higher by combining multiple VCUs in parallel.
Biogas flare systems are used to dispose of gases that are produced from decomposition of organic matter or biomass. Typical examples are gases produced from landfills, wastewater treatment (anaerobic digesters), or other biomass sources. Gases are typically mixtures of methane, carbon dioxide, small amounts of nitrogen, oxygen, hydrogen sulfide, and others. Biogas must be handled in a specific manner to ensure combustion to a high degree of efficiency. In addition, the possibility of oxygen in the gas mixture coming to the flare means flame arrestors and special flame arresting burners must be employed. Biogas can be burned to a high degree of efficiency in either an elevated flare or an enclosed ground flare system.
If your facility is an environmentally sensitive area where NOx emissions are tightly regulated, such as one of the EPA’s 8-hour ozone Nonattainment areas, then you will also need an ultra-NOx VCU. Zeeco has developed the TriClean VCU, which is an ultra-low emission VCU that can achieve NOx emission of less than or equal to 15 ppm (0.018 MMBTU/hr.) and CO emissions of less than 10 ppm (0.01 MMBTU/hr.).
Wherever liquids are loaded into trucks, ships, or rail cars, a vapor stream, laden with Volatile Organic Compounds (VOCs), is generated and must be controlled to prevent it from escaping into the atmosphere and creating both harmful emissions and lost product.
There are two primary methods for controlling these vapors, burning them in a vapor combustor unit (VCU) or recovering them in an activated carbon vapor recovery unit (VRU). Typically, a VCU requires less capital and can achieve very high VOC destruction efficiencies, but it will also generate other emissions, such as NOx, CO, and CO2. A VRU, on the other hand, requires more capital, can achieve similar equivalent VOC destruction efficiencies, but does NOT generate any other emissions and will recover approximately one to two gallons of product for every 1,000 gallons of product loaded. It is one of the few vapor control technologies with a payback.
Zeeco offers the industry's most advanced vapor recovery units (VRUs) that are tailored to meet your precise needs, which ensures maximum recovery of hydrocarbon vapors. We custom engineer our VRU’s for crude oil and refined products, at any flow rate and ambient conditions.
Standard systems for crude and refined products, including:
Key Features include: