FLARE RECOVERY SYSTEMS AND THE “FLARE BULLET” Economic approach to flare minimisation

Jonathan MILES

Argo Environmental Engineering Limited

The Environment

• CO2 from Power Generation and Fuel Gas

• CO2 from Flaring

• VOC from tank emissions / transport

Environmental Emissions - UKOOA

Flaring rose in UK in 2006 to 1.725 m tonnes

CO2 emissions in 2006 fell by about 1m tonnes

UKOOA Commitment 47

• UK Flaring in 2001 represented about 30% of Industry CO2 emissions (5.5 m tonnes)

• Started Emission Trading Scheme

• Participants agreed target 10% emission reduction below consent agreements

Best In Class?

• Analysis 2000-2004 has shown:

–Best in class produces 0.63 ave kg CO2/boe Worst in class – 38.61 ave kg

–Of worst 10 performers in flaring only 3 had stranded gas reservoirs with 7 connected to gas gathering systems

–Foinhaven has stranded gas reservoir but achieves in top 10 CO2 from Flare / boe

• 7 of top 10 performers were BP operated

How does reduced flaring save cost

•The “Death Zone” on a flare – Turndown to 1-2%

•Flare and associated equipment damage

•Wasted Gas – especially if fuel gas deficient – burning diesel

•CO2 or trading or tax regime.

•Reputation•Potential revenue/cost

saving of $1million per year

What is zero flaring

Flare Gas Recovery

HP flare

XV

Check valve

HP K.O.Drum

Bursting Disc

Sources

PTHH

PTHH

LO LO

FOV

FE HH

N2 supply

Drain

To flare

FOV Layout

To flare

Tie in 1

Tie in 2Manual valve

Bursting disc

FOV

Fast Opening Valve

• Mokveld valve has SIL-level 3 (MTBF=2160 years of operation to "full stroke")

• Tyco valve has SIL-level 3 (MTBF=523 years of operation to "full stroke")

Flare Opening AssembliesRupture disc/Buckling pin valve

Bursting disc

Buckling pin valve

Flare Gas Recovery – economics

• Annual value assuming:–Quota trading

– Increased gas export

–2 flare change outs

–Annual revenue from flare gas recovery $1,000,000

• Typical Installed Cost - $2-4 million (cheaper on new facilities)

• Pay back time will typically be 2-4 years

Low Pressure System

Flare Gas Ignition

•LP ignition system:– Automatic Pellet Launching

cabinet and air launching bottle

– Guide pipe – Pellet collector unit (optional)

LP system typical installation

Flare Gas Ignition System

• Long-range ignition pellet• Armed by the launching pressure• Ignite when emerged from guide pipe• Independent of emerging velocity• Will not ignite if exposed to fire

Low pressure Ignition SystemEkulama II - SPDC Nigeria

Low pressure Ignition SystemEkulama II - SPDC Nigeria

Flare Gas Ignition

• No moveable parts or electronic equipment located near flare tip

• When required maintenance is performed at cabinet

• All equipment in heat radiation areas are heat in resistant material

• High reliability and long lifetime

Conclusions and Recommendations

• Install FGR if technically feasible– Increased revenue typically $1million

–Cost to install $2 – 4 million

• Install Pellet Ignition system – suit all systems– Increased reliability of ignition

– Increased safety

–Reduced maintenance cost

–Cost approx $150,000