REFINERY FLARE

SYSTEM
AMJAD MAHMOOD ( CH-001)
ABDUL HASEEB
(CH-014)
MUHAMMAD ZUBAIR (CH-038)
AHSAN KHURRAM
(CH-046)

ADVISOR : MR. RIZWAN AHMED

QAMAR

PROJECT
OBJECTIVES
I) SIMULATION OF REFINERY FLARE SYSTEM:
Simulation of Flare system of refinery complex of BYCO (ORC

II)using Aspen Flare System Analyzer

Study of Flare system for worst contingency of power failure
Rating of existing Flare system through Aspen Flare
Modification of system In Accordance to API standards

PROJECT
OBJECTIVES
II) STUDY OF CARBON CAPTURE TECHNIQUES FOR
GROUND FLARE SYSTEM
Carbon Capture through Chemical Treatment techniques
Carbon capture through membrane separation technique
Comparative Analysis of Above techniques

INTRODUCTION
WHAT IS FLARING?
Flaring is a standard operation aimed at converting flammable , toxic
and corrosive vapors in to environmentally acceptable discharges by
means of combustion.

FLARE
A pilot igniter
A large burner
With exhaust stack below burner
PSVs and headers
Used to burn combustible exhaust gases from vent

PURPOSE OF FLARE
SYSTEM

To prevent the failure of equipment from overpressure,

To ensure the safe and efficient disposal of relieved gases or

liquids.

It is extremely important in event of worst contingencies like

power failure, fire scenarios, blocked cases etc.
Operating at extreme turndown ratio

TYPES OF FLARE
1. ELEVATED FLARE
In an elevated flare system, combustion reactions are carried out at
the top of stack where burner igniter are located.

TYPES OF FLARE
2. GROUND FLARE
Enclosed or Ground Flare are constructed so as to conceal the
flame from direct contact. An enclosed flare has number of
component.

Combustion chamber
Burners
Piping system
Wind fence

TYPES OF FLARE
3. COMBINED FLARE SYSTEM
A Common combination is an enclosed flare of limited capacity paired
with an elevated flare.

COMPONENTS OF A
FLARE SYSTEM

COMPONENTS OF A FLARE
SYSTEM
RELIEF,SAFETY AND DEPRESSURIZING
VALVES
These valves are used to release vapors in case of over

pressurization of the equipment. Three types of valves are

used namely conventional, balanced and pilot type
pressure relief valves.

PRESSURE RELIEVING HEADERS

They convey discharges from safety valves and pressure
control valves in the process unit to the flare.

FLARE BURNER
The flare burner mixes fuel and air at velocities , turbulence and
concentration required to establish and maintain proper ignition and
stable combustion.

PILOT IGNITER
They are small ,independently controlled burners used to ignite the
larger burner
A pilot flame (with its ignition system) that burns all the time so that it
is available to ignite relieved gases when needed.

MOLECULAR SEAL
To prevent Air infiltration to enter in into flare stack, knock out drum
vent network and used to reduce the amount of purge gas used. Two
types of molecular are commonly used.
Velocity Seals
Buoyancy Seal

KNOCK OUT DRUM

Separates liquid from a gas in a flare system
usually located before flare stack or liquid seal
Three basic types of knockout drums are : 1) Horizontal Drum 2)
Vertical drum
Reducing potential for incomplete combustion or soot formation

PRESSURE SAFETY
VALVES
CONVENTIONAL PSV
A conventional pressure safety valve is a self actuated
spring loaded pressure safety valve which is designed
to open at a predetermined pressure and protect a
vessel or system from excess pressure by removing
or relieving fluid from that vessel or system.

BALANCED BELLOWS PSV

A balanced bellow pressure safety valve is a spring loaded
pressure safety valve which incorporates a bellow or other
means of balancing the valve disc to minimize the effects of
back pressure on the performance characteristics of the valve.

PILOT OPERATED PSV

A pilot operated pressure safety valve consists of the main
valve which normally encloses a floating unbalanced piston
assembly and an external pilot. At the set pressure the pilot
vents the pressure from the top of the piston

BACK PRESSURE
Pressure existing at the outlet of relief valve is known as
back pressure. Back pressure is the sum of super imposed
back pressure and built-up back pressure

BACK PRESSURE
1) SUPERIMPOSED BACK PRESSURE
Back pressure which is present at the outlet of relief valve
when it is closed

BACK PRESSURE
2) BUILT UP BACK PRESSURE
Back pressure develops when the safety valve opens and
fluid start flowing.

EFFECT OF BACK
PRESSURE
Reduce the lifting force of PSVs
Flutter and chatter
Reduction in flow capacity

PROGRESS

ASPEN FLARE
SYSTEM ANALYZER
1) DESIGNING
Designing of Flare Network
Sizing of header & Sub header
PSV Sizing
Stack Diameter and Height

ASPEN FLARE
SYSTEM ANALYZER
2) RATING
Analysis of Existing System
Identification of noise , back pressure and Mach

number
Modification of Exceeding parameters

COLLECTION OF
DATA
PFDs
Source Relieve Data
Knockout Drum size
Stack Height and diameter

SIMULATION

SIMULATION
Fluid Package : Peng Robinson

SIMULATION
PALLET BOX :

ASPEN FLARE ANALYZER

SHEET

RESULTS
After running the simulation model for power failure contingency we
get the following results:

We locate the PSVs where backpressure exceed the limit.

We locate the headers in which noise and mach number exceeds

the limit.

Aspen Flare System Analyzer Process

summary

RESLUTS

Aspen flare analyzer process summary

RESULTS
SUMMARY OF A RELIEF VALVE

WHAT NEXT ?

RESIZING
Identified PSVs using Pentair PRV sizing software that

satisfy the backpressure.

Modifications in network to keep noise and mach

number under the limits.

CARBON CAPTURING
TECHNIQUES
CO2 is the major green house gas, the recent research techniques for minimizing CO2 emissions at oil
and gas industry include chemical treatment and membrane separation of combustion products.
There are three main steps to carbon capture and storage (CCS) -- trapping and separating the CO2 from
other gases, transporting this captured
CO2 to a storage location, and storing
that CO2 far away from the atmosphere
(underground or deep in the ocean).

CHEMICAL TREATMENT
The Post-Combustion CO2 Capture process is by itself quite
simple. It comprises an absorber where CO2 is captured using a
chemical solvent like an amine and a regenerator where the
captured CO2 is released from the solvent.

MEMBRANE SEPERATION TECHNIQUES

Gas separation membranes allow one component in a gas
stream to pass through faster than the others. There are many
different types of gas separation membrane, including porous
inorganic membranes, palladium membranes, polymeric
membranes and zeolites.

REFRENCES
1) API 537
2) API 521
3) API 520
4) DATA SHEET , PFDS ( Provided by BYCO)
5) ASPEN FLARE SYSTEM ANALYZER GUIDE V7.3