Industrial Gas Flaring Practices

When properly used and maintained, flare gas systems can be a safe and reliable technology for system protection and in controlling emissions stemming from emergency releases. However, when misused and/or not carefully maintained, flaring operations can be a significant source of toxic emissions that adversely impact on air quality. Further to this, there are oftentimes misconceptions and misrepresentations on flaring efficiencies. This has led to under reporting of releases of toxins within communities.

Flares are widely used throughout the oil refining and petrochemical industries to manage waste gases and as a means of safety control of over pressurization of process units. Both industry and environmental statutes concerning the regulation of flares characterize flaring as a safe practice that is capable of controlling air emissions to high level of efficiency (typically 98+ % destruction reduction efficiency (DRE) of Volatile Organic Compounds (VOCs)). But flaring operations are conducted far more frequently than systems were originally intended to operate, and aging refineries and petrochemical plants have given low priority to the critical maintenance and replacement of flare system components. The consequences have been far greater emissions than are generally reported along with serious accidents that have caused loss of lives and extensive damages to facility infrastructure and community property.

These negatives should not be the basis for eliminating this technology. Flare gas operations are unquestionably critical to safe operations of high pressure operations involving flammable and toxic components. However, their efficient and safe operation requires that the owner/operator apply vigilance in ensuring that the flare operates within an optimum performance regime and be well maintained.

This volume is intended as technical reference for refineries and chemical plants. The information contained herein is the result of reviewing the general literature of flaring options and technologies, reviewing industry and U.S.EPA published studies, and from examining some of the practices of certain refinery operations where information has been accessible.