EPA~600/2-83-052 July 1983 FLARE EFFICIENCY STUDY by Marc McDaniel Engineer ing-Science, Inc. 2901 North Interregional Austin, Texas 78722 EPA Contract 68-02-3541-6 EPA Task Officer: Bruce A. Tichenor Industrial. Processes Branch Industrial Environmental Research Laboratory Research Triangle Park, NC 27711 Prepared for: U.S. ENVIRONMENTAL PROTECTION AGENCY Office of Research and Development. Washington, OC 20460ABSTRACT A full-scale experimental study was performed to determine the effi- ciencies of flare burners as devices for the disposal of hydrocarbon emissions from refinery and petrochemical processes. The primary objectives of the study were to determine the combustion efficiency and hydrocarbon destruct ion efficiency for both air- and steam-assisted flares under a wide range of operating conditions. Test results indicate that flaring is generally an efficient hydrocarbon disposal method for the conditions as evaluated. The study provides a data base for defining the air quality impact of flaring operations. The test methodology utilized during the study employed a specially constructed 27-foot sample probe suspended by a crane over the flare flame. The sample extracted by the probe was analyzed by continuous emission monitors to determine concentrations of carbon dioxide (COz), carbon monoxide (CO), total hydrocarbons (THC), sulfur dioxide (S02), oxides of nitrogen (NOx), and’ oxygen (02). In addition, the probe tip temperature, ambient air temperature, and wind speed and direction were measured. Integrated samples of the relief gas were collected for hydrocarbon species analysis by gas chromatograph. Particulate matter samples were also collected during the smoking flare tests. The rigorous test program included flare testing under thirty-four dif- ferent operating conditions during a three-week period in June 1982. Test variables included Btu content of the relief gas (propylene diluted with nitrogen), relief gas flow rates, steam flow rates, and air flow rates. When flares were operated under conditions representative of good industrial opera- ting practices, the combustion efficiencies at the sampling probe were determined to be greater than 98 percent. Combustion efficiencies were observed to decline under conditions of excessive steam (steam quenching) and high exit velocities of low Btu gases. ifSection 1 Section 2 Section 3 Section 4 CONTENTS Page Eto con ono non dn oo non GondoO . i FAgues See see sence y ee . vi ables tte es ree . vii Abbreviations and Symbols . 2... ee eee eee wviti Introduction... eee ee ee ee ee 1 Conclusions... 2. ee ee ee ee eee oe Technical Summary... eee eee ae Conclusions and Observations .... 5 Testing Methodology... +e eee eee - 6 Experiment Design and Flare Operation . 6 Sampling and Analysis... 2. 23s - 8 Types of Flare Burners Tested... « 8 Flare Test Procedures........ + 1B Background Measurements... ..... 14 Continuous Emission Analyzers... . . 15 Hydrocarbon Species Analysis... « . 15 Temperature Measurements ...... » Particulate Analyses .....-.. ~ ig Moisture Determinations... ... + . 18 Meteorological Measurements... . - 19 Audio and Video Recordings .... « 19 Data Collection and Calculations... . . + 20 Continuous Analyzers' Data Acquisition + 20 iit