Pilot Demonstration of a New Tip for Effective Gas Flaring in the Permian Basin: Part 1

In the oil and gas industry, gas flaring through flare stacks plays a critical role in safely and efficiently releasing and burning gases and other materials from pressure-relief and vapor-depressurizing systems. Gas flaring is a contentious and formidable environmental challenge, both regionally and globally. Its adverse impacts encompass pollution, contribution to global warming, and substantial economic losses. Shockingly, gas flaring squanders approximately 5% of the global gas supply, resulting in the annual production of over 350 million tons of CO2 gas. While alternatives to gas flaring exist, they are either undergoing investigation or currently lacking economic viability. Consequently, the development of a more efficient gas flaring system is imperative. In addition, the reliable and efficient operation of flares is paramount, as they are expected to function seamlessly over extended periods under various service conditions. In this paper, a novel gas flaring tip to address the limitations of existing flaring systems is introduced. This innovative tip features a distinctive configuration, incorporating a bullet-shaped device positioned atop the flare. This bullet device boasts four strategically placed apertures equipped with internal deflectors, facilitating the convergence of gases into a single vortex outlet at its apex. For operational flexibility, the bullet is affixed to the flare tip using a system of three springs, enabling it to elevate at a pressure of 2.0 psig and achieve full extension at 8 psig. This dynamic design harnesses the Coanda effect, promoting efficient oxygen utilization. The comprehensive evaluation of this tip spanned a wide range of gas capacities, 4.0 and 10.0 MMSCFD. In this analysis, parameters such as the fraction of heat radiated, transmissivity, atmospheric humidity level, solar radiation adjustment, ambient temperature, and horizontal wind velocity were factored. The evaluation included both theoretical analysis and experimental investigation. The theoretical analysis employed a simplified open pipe flare tip approach to predict thermal radiation levels around the tip using the Brzustowski and Sommer model. The experimental setup included equipment such as thermocouple thermometers, heat flux sensors, digital sound level meters, mass flowmeters, and portable flue gas analyzers. Throughout testing, thermal radiation levels, isopleths, noise levels, and flue gas composition were measured. The collected data were subsequently compared to predictions generated using the Brzustowski and Sommer model for identical gas flow rates, flare heights, and flare diameters. Due to technical challenges and safety concerns, flue gas composition was not available. The authors are exploring different alternatives to overcome these obstacles and data should be available in the near future. The resulting data of heat radiation and noise levels unequivocally demonstrate the superiority of the new tip when compared to conventional gas flaring systems. With its cost-effectiveness, smokeless operation, heightened efficiency, and cleaner flame characteristics, the authors, due to the groundbreaking design of this tip, strongly advocate its adoption as a means to mitigate the environmental impact of gas flaring.