Flare Systems and Solutions
Safe, Reliable and Compliant Hydrocarbon Disposal Systems
Flare systems are critical safety installations designed to safely dispose of excess hydrocarbons released during startup, shutdown, upset conditions, and emergency depressurization in oil & gas, refinery, petrochemical, LNG, and energy facilities. A properly engineered flare system prevents uncontrolled releases, protects equipment and personnel, and ensures compliance with environmental and regulatory requirements.
Mechasol Flare Systems and Solutions are engineered in accordance with API 521, API 537, ISO 23251, ASME, and local environmental regulations, delivering reliable, smokeless, and controlled combustion under all operating scenarios. Solutions are provided as stand-alone flare systems, integrated flare packages, or full EPC turnkey scopes.
Flare System Architecture
A complete flare system is an integrated safety network consisting of multiple engineered components designed to function together as a single disposal system.
Main System Components
Flare stack or ground flare assembly
Flare tip and burner system
Flare header and sub-header network
Knockout (KO) drum / liquid seal drum
Molecular or velocity seal
Ignition and pilot system
Flare control and monitoring system
Utility and support systems
Each component is individually engineered but optimized as part of the overall flare hydraulic, thermal, and safety philosophy.
Types of Flare Systems
Elevated Flare Systems
Elevated flares are the most commonly applied flare type and are used where thermal radiation, dispersion, and ground-level safety must be carefully controlled.
Key Characteristics
Tall stack construction (self-supported or guy-wired)
High-efficiency flare tips
Suitable for large flow rates and high-pressure relief scenarios
Typical Applications
Refineries and petrochemical complexes
Gas processing plants
LNG terminals
Offshore and onshore production facilities
Elevated flares allow safe combustion at height, reducing heat radiation and gas concentrations at grade level.
Ground Flare Systems
Ground flares are used where visual impact and radiation limits must be minimized, particularly near populated or environmentally sensitive areas.
Design Features
Multi-burner ground-level combustion
Radiation shielded by refractory or steel enclosures
Controlled air entrainment for clean combustion
Advantages
Low visible flame
Reduced noise and radiation footprint
Suitable for continuous or intermittent flaring
Enclosed Flare Systems
Enclosed flares provide the highest level of environmental and visual control, with combustion occurring inside a refractory-lined enclosure.
Key Benefits
Minimal visible flame
Very low radiation and noise levels
Enhanced smokeless operation
Typical Applications
Urban or industrial zones with strict environmental regulations
LNG terminals and satellite stations
Chemical and specialty process plants
Flare Tips and Combustion Technology
The flare tip is the heart of the system and directly affects combustion efficiency, smokeless performance, and noise levels.
Flare Tip Types
Sonic flare tips
Subsonic flare tips
Multi-point or staged flare tips
Steam-assisted flare tips
Air-assisted flare tips
Design Considerations
Gas composition and molecular weight
Flow range (turndown ratio)
Smokeless capacity requirements
Noise and vibration limits
Mechasol selects and engineers flare tips to ensure stable combustion across the entire operating envelope, from purge flow to emergency relief.
Knockout Drums and Liquid Seal Systems
Knockout (KO) Drums
KO drums are installed upstream of the flare stack to remove liquid hydrocarbons, water, and condensate, preventing liquid carryover to the flare tip.
Design Aspects
Vertical or horizontal configuration
Sizing based on droplet separation efficiency
Liquid handling and drainage systems
Designed to ASME Section VIII
Liquid Seal Drums
Liquid seal drums prevent air ingress into the flare system and provide flashback protection.
Functions
Maintain positive pressure in the flare header
Act as a flame arresting barrier
Stabilize low-flow operation
Flare Header and Piping Network
The flare header system collects relief flows from multiple units and safely transports them to the flare.
Engineering Focus
Hydraulic analysis to prevent backpressure exceedance
Two-phase flow considerations
Thermal expansion and stress analysis
Drainage and low-point management
Mechasol designs flare networks to handle simultaneous relief scenarios, ensuring system integrity under worst-case conditions.
Ignition, Pilots and Control Systems
Reliable ignition is essential to flare system safety.
Ignition Systems
High-energy electronic ignition
Flame front generators (FFG)
Redundant ignition systems for critical services
Pilot Burners
Continuous pilot operation
Multiple pilot configurations for redundancy
Wind-resistant and low-BTU ignition capability
Monitoring & Control
Flame detection systems
Pilot status monitoring
Automatic re-ignition logic
Integration with plant ESD and DCS systems
Environmental and Performance Considerations
Smokeless Operation
Mechasol designs flare systems to achieve smokeless combustion using:
Steam or air assist systems
Staged tip designs
Optimized mixing geometry
Noise and Radiation Control
Acoustic attenuation designs
Radiation modeling and setback analysis
Shielding and orientation optimization
Regulatory Compliance
Emissions control per local environmental limits
Compliance with API, ISO, and project-specific standards
Engineering & EPC Capabilities
Mechasol provides end-to-end flare system execution, including:
Relief and flare network simulations
Radiation, dispersion, and noise analysis
Mechanical and structural design
Fabrication and assembly
Site erection and commissioning
FAT, SAT, and documentation packages
Systems can be delivered as:
Individual flare components
Packaged flare skids
Fully integrated EPC turnkey solutions
Mechasol Advantage in Flare Systems
Proven engineering aligned with international standards
Custom-designed solutions for project-specific relief scenarios
Full integration with process, safety, and control systems
Modular and EPC delivery options
Focus on safety, reliability, and environmental performance