What Do You Know About "Chimneys" In Chemical Plants?

In chemical plants, you can always see a kind of "chimney" with a flame, which burns day and night. Some would say, how much fuel does that burn? What a waste. Actually, it's not a chimney. It's called a gas flare.

What's A Gas Flare?

Gas flare, also known as a flare stack or flare, is a system used in various industries to burn off or dispose of unwanted or excess gases in a safe manner. A combustion device burns flammable gases released during industrial processes, oil and gas production, or chemical plant operations.

Gas flares are typically tall metal structures with a vertical pipe or stack that releases the gas at the top. The flammable gases, such as methane, ethane, propane, and butane, are routed to the flare stack through a network of pipes and valves. At the top of the stack, the gases are ignited, creating a visible flame.

What are the tall metal structures with vertical pipes or stacks?

The combination of the tall metal structure, vertical pipe or stack, and gas release at the top allows for the controlled burning of flammable gases in a safe and efficient manner. This design ensures that the combustion takes place at an elevated height, minimizing the risks associated with handling and dispersing flammable gases while reducing the impact on the surrounding environment.

1. Tall Metal Structures: Gas flares are designed as tall structures to elevate the combustion process above ground level. The height of the flare is determined based on factors such as the required dispersion of combustion products, safety considerations, and regulatory requirements. The tall structure helps to minimize the impact of heat, emissions, and potential hazards on the surrounding environment.
2. Vertical Pipe or Stack: At the center of the gas flare system, there is a vertical pipe or stack. This pipe serves as the conduit for releasing the flammable gases from the source to the top of the flare. The pipe is typically made of metal, chosen for its durability and heat resistance.
3. Gas Release at the Top: The flammable gases, such as methane, ethane, propane, or other hydrocarbons, are routed through a network of pipes and valves to the top of the flare stack. At the top, there is a designated area called the flare tip or burner, where the gases are released into the open air. The flare tip is carefully designed to ensure proper mixing of the gases with air or steam for efficient combustion.
4. Combustion Process: Once the gases are released at the top of the flare stack, they are ignited by an ignition system, such as a pilot flame or spark igniter. The combustion process occurs at the flare tip, where the flammable gases react with oxygen, resulting in the visible flame. The combustion consumes the gases, converting them into carbon dioxide, water vapor, and other byproducts of complete combustion.

The primary purposes of gas flaring are safety and environmental protection. Flaring prevents the buildup of potentially explosive gases, reducing the risk of accidents. It also helps control the emission of harmful gases, such as methane, which is a potent greenhouse gas contributing to climate change.

Gas flares can be found in various industrial sectors, including oil and gas exploration and production, refineries, chemical plants, and wastewater treatment facilities. However, it is important to note that gas flaring is considered a waste management practice and efforts are being made globally to reduce or eliminate routine flaring due to its environmental impact.

Expert Gas Flare Structures Fabrication

Openex has the capability to manufacture your flare and vent stacks – with years of metal fabrication experience. Our in-house designers and manufacturing team have an excellent track record developing custom stacks ranging from 20 feet to well over 300 feet in height.

• Unique Geometries
• Welding Dis-similar metals & exotic alloys
• Logistics review to ensure components are maximized transportation efforts to the site
• Complete project manufacturing available – Stack & Flare with auxiliary components such as Liquid Seal Drums, Process Piping, Pressure Piping, Ducting, Ladders, and platforms

Openex has manufactured stacks and flares for the following industries:

• Power and steam generation industry
• Refining, production, power
• LNG
• Biogas
• Pulp and paper
• Cement
• Oil & Gas

We welcome the opportunity to quote on your needs.