FLARE

GAS
RECOVERY
SYSTEM
SENIOR YEAR DESIGN
PROJECT
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(FMCE)
GROUP MEMBERS
• Haider Ali Reg:2015122
• Hasnain Fakhruddin Reg:2015145
• Muhammad Haroon Reg:2015264
• Azhar Ayub Khan Reg:2015087

SUPERVISORS
Advisor: Dr. Khurrum Imran Khan
Co-Advisor: Dr. Sajjad Hussain
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 INTRODUCTION

• Over 150 billion cubic meters of gas is flared annually worldwide, worth
approximately $30 billion.
• It is estimated that flaring results in some 400 million tones of greenhouse gas
emissions per year (World Bank, 2014).
• 1994 to 2012 GHG emissions in Pakistan have increased at an annual growth
rate of 4.1%.

The Effective Solution: Flare Gas Recovery System (FGRS)

• Economic benefits
• Environmental benefits
• Pakistan: Only in Byco Refinery Karachi.
• Other countries: Iran, Australia, USA, Italy, Netherlands, and Switzerland.
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 OBJECTIVES

1. Design a new system comprising of compressor, pre-treatment and post-

treatment system to utilize the flare gases in the furnaces.
• Evaluate flare gas composition (MB and EB)
• Flare gas flow rates
• Design of FGR system will be on the basis of average properties of flare
gas
Pre- treatment:
• Flare Gas Conditioning
Post- treatment:
• Amine Sweetening unit
• Glycol Dehydration unit
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Reliability considerations (API 521 Pressure-relieving and DE pressuring
Systems)
PROCESS FLOW DIAGRAM

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 OBJECTIVES

2. Effects of the new system in the existing flare system and PSV’s.
• No modification in existing flare gas system
• Liquid seal drums to prevent the ingression of air to flare stack
• PSV as shutdown valve when compressor is not working or excessive flow
• PSV as spillback valve to re-open the suction zone of compressor

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 OBJECTIVES

3. Perform cost analysis as compared to the existing flare system.

Existing flare system:
• Maintenance cost
• Energy cost

Flare gas recovery system cost:

• Capital costs
• Operating costs
• Maintenance costs

Cost analysis basis :

• $0.11-------- 1m3 fuel gas from FGR unit
• $6------------0.42m3 steam 7
• $0.5----------1 unit of electricity
DATA REQUIRED

We need to know the composition, distribution and flow rates of flares

and how it changes over space and time
Existing Flare system of NRL:
• Process and Instrumentation diagram of NRL.
• Material and Energy Balance of all process streams.
• Flare and Relief load summary.
Simulation Software
ASPEN Plus V8.8

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GANTT CHART

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 REFERENCES

• International Conference on Chemical, Food and Environment Engineering

(ICCFEE'15) Jan. 11-12, 2015 Dubai (UAE)

• Oil & Gas Science and Technology – Rev. IFP, Vol. 63 (2008), No. 6, pp. 705-711
Copyright c 2008, Institut français du pétrole DOI: 10.2516/ogst:2008023

• American Petroleum Institute (API) and International Petroleum Industry

Environmental Conservation Association (IPIECA). Oil and Natural Gas Industry
Guidelines for Greenhouse Gas Reduction Projects. Prepared by URS Corporation,
March 2007

• The World Bank. Global Gas Flaring Reduction, a Public-Private Partnership.

“Estimated Flared Volumes from Satellite Data, 2005-2007”.
http://go.worldbank.org/G2OAW2DKZ0
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THANK
YOU!
Any Question ?

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