Flare Gas

ANALYTICAL SOLUTIONS FOR FLARE GAS compliance
Innovative Instrumentation, Gas Analysis and Process Control Solutions for Flare Gas Monitoring

Flare gas compliance has become a hot topic in recent years due to the environmental impact of flaring and venting gas. Flaring is the controlled burning of natural gas that cannot be processed or transported, while venting is the release of gas into the atmosphere during the production and processing of oil and gas.

New regulations of flare emissions require oil refineries and chemical plants to analyze the vent gas and quickly make adjustments to maintain sufficient destruction efficiency. And we can you with meet those emissions regulations. According to new requirements in the General Provisions, flares used as Air Pollution Control Devices (APCD) are expected to achieve 98% Hazardous Air Pollutant (HAP) destruction efficiencies. These updated requirements include monitoring of the pilot flame, visible emissions, flare tip velocity, net heating values, and dilution parameters, as well as maintaining a Flare Management Plan and a Continuous Parameter Monitoring System Plan.

Process Insights is your SINGLE SOURCE for complete flare gas analysis for total compliance – EMACT, MONMACT, RSR, Subpart Ja, HRVOC and more.

We know your process and how critical it is for you to protect precious and limited resources.

WE’RE HERE FOR YOU

We will work to match your needs and budget and provide the optimal, and most stable process analysis solution for your application.

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SOLUTIONS FOR FLARE GAS MONITORING

Meet EMACT Requirements with Process Insights Analytical Solutions

The EPA has recently introduced more stringent environmental regulations on flare emissions, which include the Ethylene MACT (EMACT) and Miscellaneous Organic Chemical Manufacturing NESHAP (MON) regulations. These regulations aim to reduce flare emissions from chemical and petrochemical plants, with the compliance deadline for many plants set for mid-2023. One of the crucial requirements of these regulations is to ensure that any organics in the flare gas undergo sufficient combustion. This necessitates the confirmation of a minimum BTU in the gas being burned by the flare, but measuring the BTU can be challenging due to the dynamic range of components involved.

The aim of these regulations is to decrease flare emissions in numerous chemical and petrochemical plants, and many plants must comply with them by mid-2023. A significant aspect of these regulations is to guarantee that there is adequate combustion of organics in the flare gas. Hence, a crucial compliance criterion for the affected flares is to verify that the gas being burned by the flare contains a minimum BTU. However, accurately and swiftly measuring the BTU can be challenging due to the wide range of components involved.

Process Insights Analytical Solutions Deliver

Tailored analytical compliance solutions designed to meet specific requirements
Rapid BTU analysis with the option of integrating a calorimeter
Hydrogen speciation to enhance the accuracy of BTU compliance calculations
Sulfur and Nitrogen speciation for updating the density of flare gas in ultrasonic flow meters
Well-established sample system designs for optimal measurement uptime

Efficient project expertise and execution is crucial for compliance monitoring measurements. Process Insights offers comprehensive project execution capabilities that cover every step of the process, from conception to commissioning, to ensure seamless project execution. By taking full responsibility for the project, Process Insights eliminates complexity, coordination and communication issues that may arise when dealing with multiple suppliers. We are your single source provider.

Process Insights: Your SINGLE SOURCE for complete flare gas COMPLIANCE

For total compliance – EMACT, MONMACT, RSR, Subpart Ja, HRVOC and more.

Flare gas analysis using Excimer UV Technology

The ATOM INSTRUMENT™ FGA-1000 Process Analyzer with UV Fluorescence Technology is a highly specialized instrument designed for Flare Gas Analysis. It offers several benefits over traditional methods including:

High sensitivity and selectivity: Uses advanced technology to accurately and precisely measure the concentration of different gases in the flare stack, even at very low concentrations. This means that it can detect even small changes in gas composition and provide highly accurate results.
Real-time monitoring: Designed for real-time monitoring, which means that it can quickly provide information on the gas composition and flow rate in the flare stack. This is essential for ensuring compliance with environmental regulations and identifying potential safety hazards.
Wide range of gas detection: Can detect a wide range of gases, including hydrocarbons, hydrogen sulfide, and carbon monoxide, which are commonly found in flare gas streams. This makes it a versatile tool for analyzing different types of flare gas and identifying potential issues.
Non-invasive measurement: Uses a non-invasive measurement technique that does not require any sampling or preparation of the flare gas. This means that it can provide accurate results without disturbing the flare stack operation, which is important for maintaining safety and avoiding downtime.

The FGA-1000 continuous process analyzer is a device used to analyze the composition and properties of flare gas emissions in various industries, including chemical and petrochemical plants. It is a continuous process analyzer that operates in real-time, providing continuous analysis of the flare gas emissions. The device is designed to operate in hazardous and harsh environments and can withstand extreme temperatures, pressures, and humidity.

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Flare gas analysis using a quadrupole mass spectrometer

The EXTREL™ MAX300-RTG 2.0 Process Mass Spectrometer is a highly specialized instrument designed for the analysis of flare gas streams. It offers several benefits over traditional methods of flare gas analysis, including:

High sensitivity and selectivity: Uses advanced technology to accurately and precisely measure the concentration of different gases in the flare gas stream, even at very low concentrations. This means that it can detect even small changes in gas composition and provide highly accurate results.
Real-time monitoring: Designed for real-time monitoring, which means that it can quickly provide information on the gas composition and flow rate in the flare gas stream. This is essential for ensuring compliance with environmental regulations and identifying potential safety hazards.
Wide range of gas detection: Can detect a wide range of gases, including hydrocarbons, hydrogen sulfide, and carbon monoxide, which are commonly found in flare gas streams. This makes it a versatile tool for analyzing different types of flare gas and identifying potential issues.
High sample throughput: Can analyze multiple gas streams simultaneously, which means that it can handle high sample throughput and provide rapid analysis of large volumes of gas.
Robust and reliable: Designed for use in harsh industrial environments and is built to withstand the demands of continuous operation. It is also easy to maintain and calibrate, which ensures reliable and accurate performance over time.

The MAX300-RTG 2.0 Process Mass Spectrometer is a device used for the analysis of flare gas emissions in various industrial applications, including chemical and petrochemical plants. The mass spectrometer can detect and measure a wide range of components, from light gases, such as hydrogen and helium, to heavier hydrocarbons, such as benzene and toluene.

Flare gas analysis using an injection style zero emissions calorimeter

Using our COSA XENTUAR™ 9800CXi™ injection-style zero emissions calorimeter in flare gas analysis offers several benefits:

Accuracy: This type of calorimeter offers highly accurate measurements of the heat content of the flare gas, which is crucial for compliance with environmental regulations.
Safety: An injection-style zero emissions calorimeter does not require any sample handling or disposal, which eliminates the potential safety hazards associated with handling combustible or hazardous materials.
Cost savings: This type of calorimeter has a low total cost of ownership as it requires minimal maintenance and does not require any consumables or calibration gases.
Environmentally friendly: As the name suggests, zero emissions calorimeters do not produce any emissions or waste, which is beneficial for the environment.
Time savings: Injection-style zero emissions calorimeters have a fast response time, which enables real-time monitoring of the flare gas composition, allowing for rapid identification and correction of any issues that may arise

The 9800CXi injection-style zero emissions calorimeter is a device used to measure the heat content (BTU) of flare gas emissions in various industries, including chemical and petrochemical plants. The device operates on the principle of a gas being injected into a combustion chamber where it is burned completely. The heat released during combustion is transferred to a fluid flowing through a coil in the combustion chamber. The temperature of the fluid is then measured to calculate the heat content of the gas.

The 9800CXi injection-style zero emissions calorimeter uses a unique injection-style design, which eliminates the need for any sample handling or disposal, making it a zero-emissions device. The device operates continuously and can take measurements every two minutes, providing real-time analysis of the flare gas.

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Flare gas analysis using a continuous direct calorimeter

Using our COSA XENTUAR™ 9610CXc™ continuous “direct” calorimeter in flare gas analysis offers several benefits:

Accuracy: Direct calorimeters offer highly accurate measurements of the heat content of the flare gas, which is critical for compliance with environmental regulations.
Real-time monitoring: Continuous measurement enables real-time monitoring of the flare gas composition, allowing for rapid identification and correction of any issues that may arise. This can prevent downtime and reduce the likelihood of non-compliance.
Minimal maintenance: Direct calorimeters require minimal maintenance, with no moving parts, which reduces downtime and maintenance costs.
High repeatability: The direct calorimeter offers excellent repeatability and precision in its measurements, resulting in increased confidence in the accuracy of the data.
Comprehensive analysis: Direct calorimeters can provide comprehensive analysis of the flare gas composition, including the heating value, Wobbe index, and the specific gravity of the gas, which can aid in troubleshooting and identifying potential issues.

The 9610CXc is a continuous, direct calorimeter used to measure the heat content (BTU) of flare gas emissions in various industries, including chemical and petrochemical plants. The device operates on the principle of calorimetry, which measures the heat released during the combustion of the flare gas. The 9610CXc calorimeter uses a combustion chamber where the gas is burned completely, and the heat released is transferred to a cooling fluid flowing through a coil in the combustion chamber. The cooling fluid temperature is measured, and the amount of heat released is calculated based on the temperature difference between the inlet and outlet of the cooling fluid.

The device is designed to operate continuously, providing real-time measurement of the heat content of the flare gas. It can measure the heating value, Wobbe index, and specific gravity of the gas and provides real-time data on these parameters.

HERE ARE SOME COMMON FLARE GAS COMPLIANCE ISSUES

Accurate measurement

Flare gas monitoring requires accurate measurement of the flow rate and composition of the gas being flared. However, the high temperature and pressure of the gas can make accurate measurement challenging, as can the variability in the gas flow and composition.

Environmental conditions

Flare gas monitoring equipment must be able to operate in a range of environmental conditions, including extreme temperatures, high winds, and heavy rain. This can be challenging, especially in remote locations where access to power and other infrastructure may be limited.

Regulatory compliance

Flare gas monitoring is subject to regulatory requirements in many jurisdictions, and companies must be able to demonstrate compliance with these requirements through regular monitoring and reporting. This can be challenging due to the complexity of the regulations and the need for accurate data and reporting systems.

Fines

Non-compliant companies may face fines or penalties that can be significant, especially for repeated or willful violations of regulations.

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Shutdowns

Regulators may require a company to shut down operations if they are found to be in violation of flare gas regulations. This can result in significant financial losses and reputational damage.

Reputational damage

Companies that are found to be non-compliant with flare gas regulations may face negative publicity and reputational damage, which can have long-term impacts on their business.