Tel: +1 908 500 7500 Stephen R. Parker, Sales Engineer
Ringoes, New Jersey steve@hitemptech.com
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Enclosed Gas Flares

HiTemp Technology has developed a system that mixes the methane stream with sufficient combustion air to maintain a consistent temperature that assures maximum destruction of any methane present in the exhaust gas.

Click to enlarge
2,000 SCFM Enclosed Flare System
Linden, NJ

A standard system includes: Waste gas burner, flame arrestor, combustion air blower (VFD), waste gas ID blower (VFD), water separation drum, electronic ignition, system alarm with cell dialer for Alarm text, dual data logger for temp and flow, refractory stack, and weatherproof controls.

The HiTemp system utilizes modular components that are interchangeable and allow easy access for repairs and maintenance. The design utilizes basic control and combustion systems. With this type of approach, we can design, build, and ship in half the time normally required by standard site assembled units. In special situations, we can have a system on site and in operation within 3-4 months of order placement. Because the systems are modular, replacement parts and capacity increases are made without major changes in the basic design.

Design

For special applications, we have designed a custom burner system, with an induced draft/combustion blower sized for the waste gas volume. Also available will be a optional dual input valve train including, solenoid shutoff valves, UV detection and gas butterfly valve with modulating control motor, keeping the system in compliance with FM/IRI requirements.

Waste gas streams with a CH4 content of more than 20% will not require any auxiliary fuel for operation. A small LP gas tank is used only for the ignition pilot, typically just during startup.

At startup, the combustion air blower VFD will be set as required for minimum output and the waste gas blower VFD will be set at maximum output. This is adjusted to bring the flare up, and will be controlled at the set point as required. Once the unit approaches set point, the air will automatically adjust with the VFD until the temperature set point is maintained.

LOW BTU WASTE GAS STREAMS REQUIRE AUXILIARY FUEL

The system is designed to control the secondary air and fuel separately. Adding only as much air as the process requires will lower overall operating costs and keep the chamber at temperature in standby condition. The system will start up with minimal secondary air as the burners bring the unit up to operating temperature. Once temperature is reached, the system will open the secondary valve train to direct the flow to the secondary burner injection point. The gases will enter the chamber, mix with the secondary air and will pass through the burner flame.

Since the waste gases contain a high fuel value, the temperature will rise in the chamber, causing the burner controls to decrease burner output. If the heat content is high enough, the burners will drop to low fire and the temperature will continue to rise. The secondary air dampers will be operated from the second controller.

Click to enlarge
2,000 SCFM Enclosed Flare System - includes:
methane blower
combustion air blower
304 stainless-steel knock out tank
Yokogawa data recorder system
Linden, NJ

Once this set-point is reached, the damper 0pens and the secondary air is increased as it is the secondary air volume that controls the temperature. Typically, this air set-point is 75oF above the burner set-point. As the heat value of the gas changes, the secondary air damper will adjust. The system includes a 6-inch ceramic fiber refractory-lined horizontal or vertical chamber. The waste gas connection will be on the side of the unit, or at the blower inlet and the exhaust stack connection will be on the top.

Installation requires setting up the unit, utility connections and bolting on the stack. The customer is to provide any necessary supply ducts.

GAS FIRED THERMAL SYSTEM DESIGN DATA

Flow Rate CH4 gasses - SCFM
Destruction Efficiency - Greater than 99%
CH4 Concentration - 20 to 60%
CH4 Heat Input - MM BTU/Hour
Operating Temperature - Higher than 1500oF
Refractory Lining - 6 inches
Residence Time - More than 0.5 seconds at 1500oF
Chamber Volume - Cubic Feet (ft3)
Maximum Burner Input - MM BTU/Hour
Operating Fuel Usage - MM BTU/Hour

Specific Requirements and Performance Specifications:

1. Complete flare/oxidizer system to treat landfill gas methane in accordance with the NJDEP air permit including the moisture knock-out pot, blower package, motors, drives, flame arrestor, valves, piping, burners, flare/oxidizer, stack, safeties, monitoring sensors, control panel, controls, power panel, conduit, wiring and other features as needed.

2. Associated documents such as shop drawings (4 copies), equipment submittals, (4 copies), maintenance and operating manuals, (4 copies), foundation templates, spare parts (recommended parts and quantities), start-up support services and operator training.


3. Start-up support services include a start-up test report to confirm that flare is operating correctly and conforms with performance requirements.


4. Provide an option for the installation of a flanged exhaust gas nozzle to be installed on the side of the enclosed stack (or other proposed solution) for a future heat recovery system. The use of direct heat recovery has been proposed to recover heat for the adjoining warehouse building. This may be accomplished by drawing exhaust gasses through a gas-to-water heat exchanger incorporating a variable speed forced draft fan.
The nozzle should be sized to take advantage of the maximum amount of exhaust gas heat recovery but without reducing or eliminating stack draft to reduce stack temperatures below minimum requirements.While not required as part of the system, accommodations for a direct heat recovery system may be requested as an option.

5. Flare/Oxidizer Capacity of 500-1000 SCFM expected typical operating range of landfill gas shall be 30% to 50% methane by volume for use to vent the vertical well landfill gas and provide combustion through the flare with minimal supplemental fuel.


6. Combustion Blower package capacity of up to 3,000 SCFM @ 10 inches of water column for combustion air through the Flare/Oxidizer. Blower shall be operated through a VFD with a control signal provided by the Temperature Controller.


7. CH4 Blower package consists of one (1) blower with the full capacity of the unit. A flow regulation mechanism using variable frequency motor drives is provided for each blower so flow can be adjusted from 300-500 CFM. (or lower as needed).


8. High "turn down" (ability to handle high variation in landfill gas flow rates)

Click to enlarge
2,000 SCFM Enclosed Flare System - includes:
methane blower
combustion air blower
304 stainless-steel knock out tank
Yokogawa data recorder system
Linden, NJ
9. Smokeless design with no visible emissions

10. VOC Removal Efficiency greater than, or equal to ninety-nine percent (99%)


11. Minimum exhaust temperature greater than, or equal to 1,500oF


12. Residence Time greater than, or equal to 0.5 seconds


13. Auto shutdown if combustion chamber temperature of 1,500oF cannot be maintained for 10 minutes


14. Provision to monitor/alarm the pilot flame


15. Provision to monitor/alarm the flame


16. Provision to monitor/record temperature in the combustion chamber


17. Provision to monitor/record/alarm methane, oxygen, carbon dioxide and gas flow rates


18. Automatic system to relight the flare


19. Auto shut-off of landfill gas supply and alarm if auto relight fails to start the flare


20. High temperature switch that turns off waste gas supply and alarm indication if a "flame-back" is detected


21. Integration into a control panel of telemetry associated with the blower


22. Multi-point monitoring and recording for temperature and waste gas flow with readouts from the control panel


23. All wiring, equipment, lighting and ventilation in accordance with current version of the National Electrical Code, "Special Occupancy, Hazardous Location"


24. Alarm system actuating an automatic cell or mobile phone dialer system. Text messages may be sent to up to 10 cellular or mobile phones. System may be designed to use text messaging with password to start, stop or notify of system status

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