custom-engineered Flare System solution
Flare system is a terminal combustion system used to safely discharge flammable or harmful gases. Its main task is to completely oxidize the excess or non-recyclable gases generated during equipment operation through combustion to prevent gas accumulation, explosion or direct discharge to cause environmental pollution.
Ruichang offers state-of-the-art Flare System solutions tailored to meet the most demanding applications in the petrochemical, refining, LNG, and chemical processing sectors.
For more than 20 years, Ruichang has been committed to providing global customers with integrated flare system solutions from design, manufacturing, installation, commissioning to intelligent operation and maintenance. The custom-engineered flare system covers:
• All types of flare systems (process flare and utility flare)
• A complete range of flare accessories, control and recovery systems, including flare tip, steam/air assist, ignition system, flame detector, knock-out drum, PLC/DCS, flare stack, flare gas compressor.
industrial flare systems
Our flare system is not a single product, but a set of “system-level solutions” that can be flexibly combined according to different industries, scenarios, emission standards and investment budgets. From the height of the flare tower to the combustion form, from emission control to exhaust gas recovery, from on-site construction to remote maintenance, we have mature engineering and manufacturing capabilities to meet the diverse needs of global customers.
The flare systems we design can meet the following international standards and regulations:
- API 521 / API 537
- ISO 23251 (formerly API 521)
- EU IED / BAT requirements
- US EPA (Environmental Protection Agency) pollutant emission standards.
Each system is professionally customized to ensure high destruction efficiency (Destruction Efficiency), smokeless combustion (Smokeless Combustion) and coordinated optimization of intelligent control under harsh working conditions.
We list flare system products according to three dimensions to meet the comprehensive needs of different working conditions, structural conditions, environmental compliance and investment budgets.
By Structural Form
Ground Flare System
Flame is hidden inside an enclosure; low radiation and noise. Suitable for urban or environmentally sensitive areas.
Offshore Flare System
Designed for marine environments with resistance to wind and structural vibration. Used in offshore oil & gas platforms, FPSOs.
Elevated Flare System
The most common type, with flare tip elevated on a tall stack to ensure safe distance and effective dispersion. Widely used in the petrochemical and coal chemical industries.
Skid-Mounted / Mobile Flare System
Modular and compact units; ideal for pilot projects, temporary gas flaring, or small-scale LNG plants.
Enclosed Flare / Cold Flare System
Fully enclosed combustion chamber; no visible flame; suitable for areas with flame restrictions and strict emissions control.
By Functional Purpose
Process Flare System
Handles continuous or periodic venting of unutilized process gases. Designed for stable and efficient combustion. It is used in ethylene plants, refineries, and gasifiers.
Utility Flare System
Shared flare system for multiple units. Mainly for emergency depressurization and safety relief. It is mainly used in refinery offsite, utility areas.
Emergency Flare System
High-capacity and fast-response system to manage emergency gas release. Critical for plant safety. It is mainly used in LNG terminals, petrochemical sites.
Flare Gas Recovery System (FGRS)
Compresses and reuses flare gas, reducing emissions and improving energy efficiency. It is mainly used in refinery environmental upgrades.
By emission performance
Steam-Assisted Flare
Uses injected steam to enhance mixing and promote smokeless combustion.
Air-Assisted Flare
Uses blower-supplied air for combustion assistance; suitable where steam is unavailable.
Smokeless Flare
Employs structural and assistive technologies to ensure high-efficiency, smokeless burning.
Enclosed Flare
Fully enclosed design, invisible flame, very low noise and thermal radiation.
Low Emission Flare
High-efficiency combustion design with ultra-low NOx, CO, and VOC emissions.
core components of flare system
Flare Tip
Core component determining gas dispersion, flame shape, and combustion stability.
Flare Stack
Structural element to elevate the flare tip and ensure safety clearance.
Knock-Out Drum
Removes entrained liquids to prevent liquid carryover and flare instability.
Ignition System
Includes pilot burners, flame rods, high-voltage arcs, and redundant ignition modes.
Flame Detector
Real-time flame monitoring; ensures safe operation and automatic control.
Steam/Air Assist Module
Delivers air or steam to assist combustion, improve mixing and reduce emissions.
PLC/DCS/ESD
Supports remote ignition, flame monitoring, automatic shutdown, and interlock safety logic.
Flare Gas Compressor
Recovers low-pressure flare gas for reuse in the process or as fuel.
Technical advantages of flare system
- Highly Stable Combustion Control: Unique flare tip structure and optimized jet flow design ensure efficient gas burnout, meeting API 537 specifications.
- Environmentally Compliant Emissions: Optional steam-assisted/air-assisted technology effectively suppresses smoke, complying with EU, ANZ, and GB standards.
- Modular Skid-Mounted Structure: Prefabricated and hoisted, reducing construction time and on-site risks.
- Remote Monitoring and Cloud Diagnostics: Supports access to SCADA or cloud platforms for remote control and troubleshooting.
- Redundant Design: Dual redundancy in the ignition and detection systems, with emergency shutoff logic for critical valves.
- Intelligent Interlocking: Interlocks with the main unit’s ESD system to automatically respond to abnormal pressure or flow conditions.
- Corrosion-Resistant and Durable: Available in a variety of corrosion-resistant materials, including marine-grade stainless steel, ceramic coating, and silicon carbide.
Applications of flare system
Our flare systems are widely used in various industrial scenarios involving flammable gas treatment, venting and safe pressure relief. The following are the main application industries and process scenarios:
Refining
Atmospheric and Vacuum Distillation Unit (CDU/VDU).
Delayed Coking.
Desulfurization, Hydrocracking, and Catalytic Cracking Units (HDS/FCC/Hydrocracker).
Emergency Venting and Safety Interlock (ESD) System.
Tank Farm Venting, Fire and Pressure Relief, and Other Emergency Response Scenarios.
Petrochemical & Chemical Plants
Ethylene cracking, propylene plants, aromatics separation.
Fertilizers (ammonia/urea), methanol, methane chloride.
Treatment of vented gas from chemical plants (with toxic/high calorific value gases).
Combustion of waste gas during plant maintenance/process changeovers.
Natural Gas Processing / LNG
Natural gas purification unit tail gas venting (including acid gas).
Compressor skid startup/shutdown safety venting
BOG gas treatment at LNG receiving and liquefaction stations.
Natural gas dehydration, desulfurization, and gas treatment during storage and transportation.
Coal Chemical & Syngas
Coal gasification, coke oven gas purification, coal-to-olefins.
High-temperature, high-pressure, high-sulfur syngas flare.
Emergency venting and maintenance switchover exhaust for water-coal slurry/dry pulverized coal gasification units.
Pharmaceutical, Biotech, Food
Trace VOC (Volatile Organic Compound) Control.
Reactor Off-Gas/Organic Solvent Vapor Combustion Treatment.
Economical Utility Flare System for Pilot Plant Gas Treatment.
Environmental & Municipal
Biogas flare at municipal sewage treatment plants
Landfill gas flare control.
Centralized exhaust gas treatment in industrial parks.
Emergency emission control of hazardous waste incineration exhaust gases.
Why choose us?
- System Integration Capabilities: Full-process EPC for flare, recovery, automatic control, and thermal oxidation systems.
- Customization Capabilities: Providing integrated solutions for multiple gas sources and multiple operating conditions.
- Environmental performance indicators achieved: Smokeless combustion structure with proprietary intellectual property rights.
- Overseas Service: Multilingual technical team + local after-sales network.
- Guaranteed production and delivery schedules: In-house production lines + modular supply + fast delivery mechanism.
FAQ
Q1: Does the flare system generate black smoke pollution?
A: We offer steam-assisted and air-assisted technologies, combined with high-efficiency flare tips, to achieve smokeless combustion.
Q2: Can the height and flame distance be customized?
A: Yes, we can provide an optimal flare stack height design based on thermal radiation calculations.
Q3: Can the flare gas be recovered and reused?
A: The optional FGRS module allows exhaust gas to be recycled for use in boilers or heating furnaces via a compressor and condensing unit.
