White Paper

Liquid Ring
Compressors for
Flare Gas Recovery
Systems
Gas Flaring Overview
The demand for energy has increased globally due to population growth and an increase in living
standards, especially in developing countries. Oil and gas production, upstream at production sites,
midstream, and downstream at refineries has also increased to meet this demand.

All crude oil produced from wells has associated gas dissolved in the liquid. As part of the production
process, the associated or co-produced gas is flashed from the liquids through a series of gas/liquid
separators. The midstream process stabilizes the crude and light condensate for transport to the
downstream refineries, and refines the gas to be sold commercially for use as fuel, while the oil liquids
are processed in downstream refineries to be used as motor fuels, lubricants, and asphalt.

All upstream, midstream, and downstream facilities have flares that are used to safely and efficiently
destroy waste gases generated. However, all combustion of volatile organic compounds (VOCs) produces
carbon monoxide (CO), carbon dioxide (CO2), nitrogen oxides (NOx) and potentially sulfur oxides (SOx)
if there are sulfur containing compounds in the gas being burned. We do not live in a perfect world,
and no combustion process is 100% efficient and that means that there is also some small amount of
VOCs emitted from flares during the combustion process. As global demand and energy production has
increased, so too have the global emissions of pollutants as a result of the flaring process.

Flares are an integral safety device at all of the above mentioned facilities, protecting plants from excessive
pressure build-up from normal operations that produce gases and vapor, or from process upsets, start-ups
and shutdowns. Flares prevent the release of unburnt VOCs to the atmosphere. An uncontrolled relief of
VOC gas to atmosphere could lead to an explosion inside the production facility, or outside of the plant
once the vapor cloud reaches an ignition source. Waste gases are collected in piping headers, commonly
referred to as the flare network, and delivered to the flare for safe disposal using the combustion process.

A production/processing facility may have multiple flares to treat various sources of waste gas. Flare gas
can come from utilities, safety valves in process units, vent gas connection feeds, product storage tanks,
and pressure control valves used to control pressure within a process unit. The flare gas composition
depends on the process units and utilities which are connected the flare networks. This leads to a wide
variation of gas composition from flare network to flare network.

Flare gas flows can be lumped into two broad categories. The first category is flow that is a result of a
plant emergency. This can be cause by events such as electrical power loss, instrument air loss, runaway
reactions, loss of cooling, etc. Usually this results in a very large flow of gases in the flare network
that must be destroyed safely. The second flow category are flows that are generated from normal
plant operation, including purge gas, sweep gas, vent gas, valve leakages, and the depressurization of
equipment for maintenance. Flare gas recovery (FGR) systems are typically designed to recover the
second flow category.
An FGR system is designed to capture waste gases that would go to the flare tip during normal
operations. The FGR system is located upstream of the flare to capture and recover some or all of the
waste gases before they are flared. Most flares operate at pressures just above atmospheric pressure,
and therefore the gas must be compressed to a higher pressure for transport throughout the plant
and for use at the intended destination.

There are many potential benefits of an FGR system. The flare gas may have a substantial heating
value and could be used as fuel within the plant to reduce the amount of purchased fuel. FGR systems
also reduce the amount of vapor/gas being continuously burned in the flare, which subsequently
reduces the utilities required for flare operation (if the flare tip is an assisted flare tip), the associated
smoke, thermal radiation, noise and pollutant emissions associated with flaring, as well as extending
the life of the flare tip.

Flare gas recovery systems are rarely sized for emergency flare loads. Sometimes, economics dictate
the capacity be provided for a normal flare rate, above which gas is flared. Flare loads vary over time,
and the normal rate may represent some average flare load or a frequently encountered maximum
load. Actual loads on these systems will vary widely, and they must be designed to operate over a
wide range of dynamically changing loads. Flare gas recovery systems are sometimes installed to
comply with local regulatory limits on flare operation and, therefore, must be sized to conform to any
such limits.

Basic Requirements for Flare Gas Recovery

The primary safety risk to integrating a FGR system is air ingress into the flare header. The
ingress of air could result in a flammable mixture inside the flare system being ignited by the
flare pilots. There are two potential avenues for air ingress into the flare network. One is through
the flare tip itself, since flares are open flame combustion devices, the flare tip exit is open to
atmosphere. The other is through leaking
flanges in the flare header network.

There are two primary safety protocols to

follow to ensure that air does not enter the
flare header network. The flare tip requires a
certain amount of gas flow through to tip to
keep air from entering the tip, known as the
flare tip purge rate. The implementation of an
FGR system does not remove the requirement
to purge the flare tip. The other protocol is to
maintain positive pressure, above atmospheric
pressure, within the flare header network at
all times to ensure that any leakage will be
directed out of the flare network.
A liquid seal vessel (LSV) is a critical piece of equipment for the safe and successful operation of an
FGR system. LSVs were initially developed as flashback prevention devices for flares, if there was a
detonation in the flare stack, the LSV would stop the propagation of the flame front into the flare header
network. The liquid seal vessels have an internal down spout that is inserted into a liquid, typically water,
this creates a hydrostatic seal in the dip tube. If there is enough gas flow to displace the hydrostatic
head created by the seal in the down comer, the gas will bubble through the liquid to flow out of the
LSV up to the flare tip to be safely combusted.

Typical flare liquid seal vessels designed for flashback prevention have a fairly shallow dip tube depth
of around 6 to 9 inches (150 - 230 mm). To ensure that a positive pressure is maintained within the
entire flare header network and to provide enough operation control bandwidth for the FGR system,
the depth of dip tube insertion into the seal liquid needs to be increased to around 30 inches (760 mm)
at a minimum. LSVs used in conjunction with FGR systems are commonly termed “deep liquid seals”.
It is crucial that the LSV is properly designed and sized to handle the changes in flow and transition
safely from normal gas flow rates to any emergency flare gas flow rate. Typically, the LSV is installed
downstream of the flare Knock-Out Vessel near the base of the flare stack.

The flow of gas through the seal liquid will induce

a series of wave dynamics within the vessel.
These wave dynamics become more pronounced
with deeper liquid seal depth. These unwanted
fluctuations of water levels inside the liquid seal
drum can lead to operational problems to both
the flare tip and for the operation of the FGR
system. These problems may include vibrations,
suction pressure instability, and cyclic puffing of
the flare. The liquid seal internals design should
carefully consider how to counteract these wave
dynamics to ensure the continued proper and safe
operation of both the flare and the FGR system.

The suction to the flare gas recovery system is tied into the flare
header network between the flare Knock-Out Vessel and the
liquid seal vessel. This ensures that the implementation of flare
gas recovery does not interfere with the emergency operations
of the flare, but allows for the FGR system to capture the normal
operational flows in the flare header prior to being combusted
at the flare. If the volume of gas flow exceeds the capacity of
the FGR system, the excess gas will bubble through the liquid
seal and be burned safely at the flare tip. If the volume of the
flare gas flow is less than the capacity of the FGR system, the
inlet volume to the FGR is controlled by recycling the gas from
the discharge of the system through a control valve back to the
suction of the system.
Process Description
The gas (1) coming from the flare Process Unit enters the Liquid Ring Compressor (2) along with
the process water (3). After the compression phase, the gas, water and hydrocarbon mixture enters
the separator (4) where the three elements are parted: the gas passes through a demister (5) to
have minimum water and leaves the vessel from the top, while condensed hydrocarbons and water
are separated by gravity due to lower gas speed. The water is pushed back to the compressor, after
being cooled again by a cooler (6). Moreover, a continuous process water make up line (7) in the
compressor suction line is provided to ensure a continuous water ring in the compressor. The condensed
hydrocarbons are discarded (8). The gas exiting the separator finally heads to the Flare gas Amine
Washing Unit (9) where it is amine treated to remove H2S. The treated gas is then pushed to the Fuel
Gas header to be used as fuel.

FLARE GAS RECOVERY SYSTEM - TYPICAL PROCESS SCHEME

Flare Gas Recovery System

Spillback

9. Gas Outlet to the

Amine Washing Unit

1. Gas Inlet from 5. Demister

the Process Unit 3. Liquid Ring Compressor

4. Separator
2. Process Water
Supply

7. Process Water
Make up

6. Cooler
Cooling Water 8. Condensated
Hydrocarbons

Sour Water to SWS

Liquid Ring Compressors for Flare Gas
Recovery Systems
GARO liquid ring compressor systems have been provide economic advantages for operators. a
used in flare gas recovery systems since 1986. FGR systems can help operators recover valuable,
There are distinct advantages of using the liquid high heat gas to be used as a fuel within the plant,
ring compression for flare gas recovery. The re-used as feed stock, or sold as a product of the
compression occurs inside a liquid bath (typically facility.
water), making the compression cycle intrinsically
safe. The liquid bath also absorbs the majority
of the heat generated by compression, actively Trust the Experts in Flare Gas
cooling the gas during the compression cycle. Recovery Systems
The seal liquid is also cooled to remove heat,
and maintain near isothermal compression within With over 200 flare gas recovery systems installed
the system. The liquid bath is also effective at worldwide, Garo has the expertise and experience
removing fine particulate matter entrained in to help optimize oil & gas plant operations and
the flare gas. Liquid ring compressors can also minimize their environmental footprint.
withstand some small amount of free liquids in
the incoming gas stream, potentially removing
the need for suction knock-out.

Reliable, capable of running low speeds, reducing

noise and vibration, and with low maintenance
requirements, liquid ring compressors can be
constructed from a range of materials to meet
customer specific application needs. liquid ring
compressor systems can also handle a range of
gas compositions including dirty, explosive, and
corrosive gasses and vapors; as well as being
suitable for gasses or vapors with a high potential
condensate formation at discharge. Did you know?
GARO’s liquid ring compressors are ideal
for handling gasses and vapors with a high The first GARO Flare Gas
concentration of H2S and / or CO2; as evidenced
by GAROs patented Washing Amine Integrated
Recovery System was installed
System (WAIS), which is capable of scrubbing H2S in one of the most productive
and CO2 to acceptable levels during a standard
compression cycle. Italian Refinery in 1986.
With a global effort to reduce pollution associated
with normal flaring, a Flare Gas Recovery System
from Garo can not only reduce the amount of toxic
gas released into the atmosphere, boosting your
facilities environmental credentials, but can also
GARO® Customized & Packaged Solutions for
EPC Companies
Founded as a liquid ring compressor manufacturer in 1947, we quickly became experts in the engineering,
configuration and design of custom packaged solutions. Every day we use our extensive knowledge of
liquid ring technology to support customers and EPC companies throughout every step of the project:
from the concept/FEED study to the start-up of the system. We also provide customer care and assistance
on the long term basis through our global network of GARO CERTIFIED™ Service & Support.

1. From the concept & FEED 5. Before the products leave our
study, we provide estimates and facility, we take all necessary tests,
possible process reevaluation to including, if required, a complete
help end-users and consultancy unit running test to demonstrate
companies to choose the right the full integrity of the compression
technology. package.

2. During the project definition 6. GARO Service & Support not

with EPC, we sustain the clients only takes care of the erection,
in the choice and comprehension commissioning and start-up
of the best solutions. We are not supervision of the system, but also
suppliers; we are part of your trains the customer how to run the
team. package.

3. In the detailed engineering 7. We never forget our customers

phase, our qualified engineers after the sale phase: guarantees
design customized systems and warranties are always included.
based on project requirements, Moreover, GARO Service &
to create a tailor made product. Support is always ready to help
you to protect your investment
by maintaining performance and
4. We take care of the package reliability.
manufacturing choosing only
the best suppliers and providing
scrupulous quality controls.
GARO | ABOUT US

About Garo
Gar+ delivers a broad range of compressors and custom designed packages to end-users and OEM
customers worldwide. We provide reliable and efficient equipment that is put to work in a
multitude of demanding industrial process applications. Our products and systems serve industries
including oil & gas, chemical, petrochemical, and pulp and paper. Our global offering also includes a
comprehensive suite of aftermarket products and services to complement our products.

For further information please visit www.GDGaro.com or

contact our sales representatives for more information
on Garo’s range of flare gas and vapor recovery systems.

Credits for this article go to Brian Blackwell, former Area Sales

Manager of Garo in North America.

Information contained in this publication is provided “as is”

and without warranty. .+ƫ disclaims all warranties, express or
implied, and makes no warranty regarding the accuracy or
applicability of the information contained in this publication,
and is therefore explicitly not responsible for any damage, injury
or death resulting from the use of or reliance on the information.
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