Industrial-Scale
Flare Testing
Advanced flare testing at full-scale can help
Jianhui Hong ensure that the system operates as designed.
Charles Baukal This article explains what’s involved
Robert Schwartz
Mahmoud Fleifil and the parameters that should be
John Zink Co. measured and evaluated to demonstrate
performance, reliability and safety.
■ Figure 1. An industrial-scale flare test facility should be able to evaluate a wide range of flows.
T
oday’s process industries expect more from flare acceptable disposal of waste gases produced from industri-
systems than ever before. Chemical and petroleum al operations (1, 2), and it’s easy to understand why pro-
processing plants depend on flares to burn hydro- cessing industries can benefit from flare testing as a safe-
carbons, such as propane, propylene, ethylene, butadiene, guard against unexpected problems in the field. Testing a
butane and natural gas, found in waste gases. Landfills and flare before installation is a proactive measure to minimize
wastewater treatment plants, oil-and-gas exploration and the uncertainty of flare performance, emission levels, and
production facilities, and loading terminals also use flares the expense of repairs in the event of a problem.
to destroy potentially harmful gases. But testing flares in the field is generally difficult or
In each case, the flare system must separate the gases impossible for several reasons. Operating flares usually do
from any liquids present, ignite the gases, and provide the not have the instrumentation required for assessing per-
stable combustion necessary for destruction, while mini- formance. Operating conditions are not easily modified or
mizing smoke, thermal radiation and noise. And, it must controlled, and taking the plant off-line to test the flare is
operate reliably and safely under a wide range of operating impractical. In addition, flares are nearly impossible to test
conditions, including weather extremes. under critical design conditions once installed.
With a greater demand for increased smokeless capaci- Characterizing flare performance for reliability and safe-
ties, higher turndown and more-efficient plant production, ty requires comprehensive, accurate testing at full-scale and
a flare failure can carry a big price tag. Factor in the under controlled conditions to collect and analyze critical
essential role flares play in the safe and environmentally data. Although flare performance might be estimated based
■ Figure 2. A
comprehensive
test facility
includes ground,
enclosed and
elevated flares.
on scaled-down experimentation and empirical data, industri- and 2) should offer industrial-scale testing and measurement of
al-scale testing is the most reliable method due to the com- smokeless capacity, required purge rate, blower horsepower or
plexity of the process. While testing custom-designed burn- steam requirements for assisted flares, radiation and noise. To
ers for process heaters has been common for decades, that properly characterize flare performance, a test facility must
has not been true for large industrial flares, primarily due to have the capability and flexibility to evaluate a wide range of
the lack of adequate testing facilities. With the advent of ground, enclosed and elevated flares, including a variety of
state-of-the-art flare test facilities, large-scale flare testing is flare sizes, operating conditions at full-scale, fuel compositions,
recommended to ensure proper performance. flowrates, assist media and other factors. Advanced flow con-
trol and data acquisition systems are required to control the
Advanced flare testing tests and ensure accurate measurements.
Just as flares have evolved into modern-day, technology- Safety is one of two critical features of a world-class
based systems, flare test facilities must also mature into flare test facility. In addition to in-plant safety protocols,
state-of-the-art, full-scale operations, offering extensive equipment safety features and trained specialists, a test
capabilities with sophisticated tools and instrumentation. facility should include exhaustive, redundant safety meas-
While flare manufacturers view these flare test facilities as ures within its controls, automation software and operating
the vehicle for developing cleaner, more-efficient flare procedures to protect against potential problems.
innovations, global industries and environmental agencies The second critical feature is flexibility. A test facility
recognize them as a valuable resource to measure flare per- should support a wide range of fuel flowrates and test fuels,
formance, system reliability and environmental compliance. such as propane, propylene, ethylene, butane, natural gas, and
In the past, industry lacked the ability to test flares in a com- blends of these, including inerts such as nitrogen. Higher
prehensive manner. Today’s test facilities (such as in Figures 1 flowrates can be achieved with a storage vessel filled with fuel
120% tocol. For assisted flares, the steam or air flowrate to the
100% flare is generally controlled for a given test point.
80% Atmospheric conditions (wind speed and direction, ambi-
60%
ent temperature and pressure, and relative humidity),
Automatic Control while not controllable, need to be measured because they
40% Manual may have a significant effect on flare performance.
20%
Outputs, on the other hand, include noise, thermal radi-
0% ation, flame stability, smokeless capacity and flame quali-
p m :2 3
pm : 5 8
pm : 1 5
p m :4 8
pm :06
p m :4 0
p m :3 1
3
1
2
1
3 :1
3 :1
3:1
3:1
3 :1
3:1
3 :1
Btu/h-ft2 kW/m2
1 500.00 1.58
–400 2 1,000.00 3.15
3 1,500.00 4.73
Wind 4 2,000.00 6.31
–300 Speed = 20 m/s
Direction = 109 deg.
–200
–100
Distance, ft
100
4
200 3
2
■ Figure 6. This microphone is part of the sound measurement
300 1
system used for flare testing.
400 flux at the ground will be higher than desired, which may
–400 –200 0 200 400 be dangerous to personnel and equipment in the area dur-
Distance, ft ing a flaring event.
Figure 5 is a plot of constant radiation lines (isoflux
■ Figure 5. Isoflux radiation profiles for a high-pressure flare. lines) at ground level for a high-pressure flare test. This
plot was generated using measurements from an array of
used to determine the coordinates of the effective epicen- radiometers positioned at various distances and angles
ter of the flame and the radiant fraction (i.e., the fraction from the flare.
of heat released from combustion that is emitted as ther-
mal radiation). Noise
Numerous calculation methods have been proposed for Noise from a flare must be adequately controlled to
estimating the radiation from a flare. Predictions can vary protect personnel in the vicinity of a flare event. To study
over a wide range, depending on which model is used and the effects of noise from flares, a test facility requires a
what assumptions are made (4). Overestimating radiation sound measurement system that includes multiple micro-
results in a flare stack that is taller and more costly than phones, such as the one shown in Figure 6. The duration
necessary. Underestimating radiation means the radiant of measurements, microphones, type of data recorded, and
JIANHUI HONG, PhD, is an advanced development engineer at John Zink Co. LLC ROBERT E. SCHWARTZ, P.E., is a senior technical specialist at John Zink Co.
(11920 E. Apache, Tulsa, OK 74116; Phone: (918) 234-5845; Fax: (918) 234- LLC (11920 E. Apache, Tulsa, OK 74116; Phone: (918) 234-5753; Fax: (918)
1827; E-mail: jianhui.hong@johnzink.com). He has several U.S. patents on 234-1986; E-mail: bob.schwartz@johnzink.com). He has over 40 years of
the ultra-stable WindProof flare pilot, low-NOx incinerator control apparatus experience in the fields of combustion, heat transfer and fluid flow, and
and methods, steam-assisted and air-assisted flares, and flare control has been granted 51 patents for inventions on a wide range of combustion-
methods. He has also worked in the areas of kinetic simulation involving and process-related products and methods. He has authored numerous
NOx, SOx, and soot; global optimization of steel stack structures; and articles and papers on flares, and is a contributing author and associate
phased array of thermal radiometers for measuring the flame epicenter and editor of “The John Zink Combustion Handbook.” He holds BSME and
radiant fraction of industrial flares. He holds a BS from Tsinghua Univ. MSME degrees from the Univ. of Missouri.
(Beijing) and a PhD from Brigham Young Univ., both in chemical engineering. MAHMOUD FLEIFIL, PhD, is an acoustics engineer with John Zink Co. LLC
CHARLES E. BAUKAL, Jr., PhD, P.E., is the director of the John Zink Institute (11920 E. Apache, Tulsa, OK 74116; Phone: (918) 234-2748; Fax: (918) 234-
(11920 E. Apache, Tulsa, OK 74116; Phone: (918) 234-2854; Fax: (918) 234- 1827; E-mail: mahmoud.fleifil@johnzink.com). His areas of expertise are
5895; E-mail: charles.baukal@johnzink.com). He has over 25 years of fluid dynamics, combustion instability and noise control. He has over 23
experience in the field of industrial combustion in the metals, minerals, publications on active control of combustion instability in IEEE,
petrochemical, textile and paper industries. He has nine U.S. patents and Combustion Science and Technology, and Combustion and Flame Journals.
has authored two books, edited four books, and written numerous He has a PhD in mechanical engineering from a co-supervisory program
technical publications. He holds a BS and an MS from Drexel Univ. and a between Ain Shams Univ. and MIT. He is listed in Who’s Who in America,
PhD from the Univ. of Pennsylvania, all in mechanical engineering, and an Who’s Who in Science and Engineering, and Lexington Who’s Who, and on
MBA from the Univ. of Tulsa. He is a Board Certified Environmental The National Aviation and Space Exploration Wall of Honor. He is a member
Engineer (BCEE) and a Qualified Environmental Professional (QEP), and is a of ASME and AIAA.
member of ASME, AWMA and the Combustion Institute.