Flare Stack Emissions Monitoring

Fast online reporting of flare gas composition

Flare stacks emit excess hydrocarbon gases that cannot be recovered or recycled. These gases, combined with steam and/or air, are burnt off in the flare system to produce water vapor and carbon dioxide. Increasingly, national and local government bodies require processing companies to monitor the various emissions from their plant stacks and flares to reduce the amount of pollution entering the atmosphere.

Flare stack emissions regulations

The US Environmental Protection Agency (EPA) has published amendments to Refinery Sector Rule RSR) 40 CFR Part 63 affecting flares; refineries must bring flares into compliance with new §63.670 ‘Requirements for Flare Control Devices’.

The requirements define five flare operating limits:

  1. Combustion zone net heating value (NHVCZ)
  2. Dilution net heating value (NHVdil)
  3. Flare tip exit velocity
  4. Pilot flame presence
  5. Visible emissions that specifies an NHVCZ minimum operating limit of 270 BTU/scf, based on a 15 minute block period.

NHVCZ can be calculated by measuring the net heating value of the vent gas (NHVVG), making flue gas analysis a vital part of any compliance strategy. If the NHVCZ approaches 270 BTU/scf, additional fuel gas such as propane or natural gas must be added. This may then require the addition of steam to the flare, to avoid the production of visible emissions. Analysis of these complex mixtures of gases is required for producers of emissions to keep within regulatory guidelines.

Advanced flare gas composition monitoring technologies

Prima PRO Process Mass Spectrometer

The Thermo Scientific Prima PRO Process Mass Spectrometer is a leading process mass spectrometer, designed to operate reliably in harsh production environments.

 

Key features:

  • The Prima PRO Spectrometer uses scanning magnetic sector technology for fast, flexible, precise multi-component analysis. Concentrations of the full composition of the flare gas stream are reported in seconds.
  • A selection of 32- or 64-port Rapid Multistream Sampler (RMS) is available for fast, reliable monitoring of multiple sample points from Flare flare or Process process streams.
  • Performance metrics have been independently evaluated by the world-renowned test laboratory Effectech UK.
  • Magnetic Sector technology is resistant to contamination and operates for several months between fully automated calibration.

SOLA iQ On-line Sulfur Analyzer

Determine the total sulfur content of liquid or gas phase samples with the Thermo Scientific SOLA iQ On-line Sulfur Analyzer. Utilizing unique Pulsed Ultraviolet Fluorescence (PUVF) technology and the proven Pyrolysis system, the  SOLA iQ Flare Sulfur Analyzer builds on the success of the Thermo Scientific SOLA II Flare Analyzer.


Key features:

  • Two fully independent calibration ranges enable total sulfur measurement from ppm to 100% concentration.
  • Automatic range switching ensures continuous measurement during flaring events.
  • Low cost of ownership, using only air for combustion.
  • Intuitive color touchscreen user interface with comprehensive online diagnostics and extensive user configurable I/O.

OPGAL EyeCGas Optical Gas Imaging Camera

The OPGAL EyeCGas™ Multi Optical Gas Imaging Camera is designed to revolutionize gas leak detection and ensure environmental safety. This advanced handheld camera is one of the most sensitive OGI cameras available, capable of detecting over 400 hydrocarbon and VOC gases, including methane and CO2. Ideal for use in various industrial applications, the EyeCGas Camera helps maintain regulatory compliance and enhances operational safety by providing real-time gas detection and quantification.


Key features:

  • Exceptional Sensitivity: The EyeCGas Camera is a highly sensitive handheld optical gas imaging camera, capable of detecting even the smallest gas leaks. 
  • Intrinsically Safe: Certified for use in hazardous environments, ensuring safety and reliability during operations. 
  • Advanced Connectivity: Features real-time data integration with advanced connectivity options, allowing for seamless communication and data transfer. 
  • Versatile Use: Equipped with multi-spectral filters and advanced thermography, making it suitable for a wide range of applications and environments. 
  • Regulatory Compliance: Helps meet EPA standards for fugitive gas emissions, ensuring compliance and avoiding costly fines. 
  • Durable Design: Built to withstand harsh environments, with robust construction and high resistance to environmental factors. 
  • Warranty and Support: Comes with a four-year warranty and free firmware updates, ensuring long-term reliability and continuous improvement.

Related technologies

Learn more about gas analysis mass spectrometry

Learn more about emissions and source gas monitoring

Learn more about industrial hygiene instruments

Learn more about methane emissions regulations and detection

FAQ for flare stack emissions monitoring

Flare stack emissions are the gases released when excess hydrocarbons are burnt off in a flare system. These emissions typically include a mix of inorganic and organic species, and their composition can vary significantly over time.

Monitoring flare stack emissions is crucial for compliance with environmental regulations, reducing pollution, and ensuring the safety and efficiency of industrial operations. Accurate monitoring helps identify the source of emissions and allows for timely corrective actions.

In the United States, the Environmental Protection Agency (EPA) has set regulations under the Refinery Sector Rule (RSR) 40 CFR Part 63, which includes specific requirements for flare control devices. These regulations define limits for combustion zone net heating value (NHVCZ), dilution net heating value (NHVdil), flare tip exit velocity, pilot flame presence, and visible emissions.

Process mass spectrometers, such as the Thermo Scientific Prima PRO, provide fast, accurate, and multi-component analysis of flare gas streams. They can measure the concentrations of individual components, helping to identify the source of emissions and ensuring compliance with regulatory requirements.

  • Fast, flexible, and precise multi-component analysis using scanning magnetic sector technology. 
  • Reports concentrations of the full composition of flare gas streams in seconds. 
  • Available with 32- or 64-port Rapid Multistream Sampler (RMS) for reliable monitoring of multiple sample points. 
  • Resistant to contamination and operates for several months between calibrations.

The SOLA iQ On-line Sulfur Analyzer determines the total sulfur content of liquid or gas phase samples using Pulsed Ultraviolet Fluorescence (PUVF) technology and a proven Pyrolysis system. It offers continuous measurement during flaring events and has a low cost of ownership.

Optical gas imaging cameras provide real-time visualization of gas leaks and emissions, enabling quick detection and repair. They are particularly useful for identifying invisible gas leaks and ensuring compliance with environmental regulations.

Thermo Fisher Scientific offers a range of resources, including application notes, eBooks, infographics, and videos, to help you understand and implement effective flare stack emissions monitoring solutions. Visit their website for more information.

You can contact Thermo Fisher Scientific through their website to request more information or to speak with a sales representative about their flare stack emissions monitoring solutions.

 

 

Service and product availability may vary by country and are subjected to varying regulatory requirements. Please contact your local sales representative for availability.