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Flare Gas Recovery

 A flare gas recovery unit (FGRU) is a system that captures flare gases and redirects them back into production workflows for reuse as fuel gas. This process helps to reduce routine flaring and emissions while saving operators on long-term production costs.

How Does a Zeeco Flare Gas Recovery Unit Work?

The flare gas recovery process consists of several steps. To begin, gases are redirected from the flare header to the FGRU. Gases pass through a compressor or an ejector and then go to a separator to remove any liquids. The gases then leave the separator, are cooled, and proceed to a knockout drum to remove any condensates before being returned to the plant or facility for reuse. If, at any point, an upset occurs that requires a flaring event, the flare gas recovery process is stopped so that waste gases can be safely destroyed by the facility's flare.

 Typical FGRU Sizing:

  • Flowrate ranges: 0.1 to 10MM SCFD (11,100 NM3/hr) — maximum recovery rates can be infinite

  • Pressure ranges: 15 to 1,200 psig (83 barg)

Advantages of Ejectors in FGRU Systems

In certain situations, ejectors may offer distinct advantages over traditional compression technologies. They have no moving parts in the compression zone and can handle a wide range of process conditions. Ejectors may also offer improved reliability, reduced maintenance requirements, and substantial cost savings.

The operation is based on Bernoulli’s principle. In an ejector, the velocity of the motive fluid increases as it passes through the nozzle, creating a low-pressure region within the ejector suction chamber. This action creates a suction, and low-pressure flare gas/vapor is entrained. As the combined high-pressure motive and flare gas or low-pressure gas streams pass through the ejector’s diffuser section, the velocity decreases, and the result is the desired outlet pressure conditions. If high-pressure water or steam is used, a separator is required downstream of the ejector to separate gas from water. If high-pressure gas is used, no downstream separator is needed.

Ejectors