US20140170576A1 - Contained flame flare stack - Google Patents
Contained flame flare stack Download PDFInfo
- Publication number
- US20140170576A1 US20140170576A1 US14/101,312 US201314101312A US2014170576A1 US 20140170576 A1 US20140170576 A1 US 20140170576A1 US 201314101312 A US201314101312 A US 201314101312A US 2014170576 A1 US2014170576 A1 US 2014170576A1
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- Prior art keywords
- flare stack
- flame
- venting
- volatile compound
- electrical energy
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- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23N—REGULATING OR CONTROLLING COMBUSTION
- F23N5/00—Systems for controlling combustion
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23C—METHODS OR APPARATUS FOR COMBUSTION USING FLUID FUEL OR SOLID FUEL SUSPENDED IN A CARRIER GAS OR AIR
- F23C99/00—Subject-matter not provided for in other groups of this subclass
- F23C99/001—Applying electric means or magnetism to combustion
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
- F23G7/00—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals
- F23G7/06—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals of waste gases or noxious gases, e.g. exhaust gases
- F23G7/061—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals of waste gases or noxious gases, e.g. exhaust gases with supplementary heating
- F23G7/063—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals of waste gases or noxious gases, e.g. exhaust gases with supplementary heating electric heating
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
- F23G7/00—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals
- F23G7/06—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals of waste gases or noxious gases, e.g. exhaust gases
- F23G7/08—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals of waste gases or noxious gases, e.g. exhaust gases using flares, e.g. in stacks
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23Q—IGNITION; EXTINGUISHING-DEVICES
- F23Q5/00—Make-and-break ignition, i.e. with spark generated between electrodes by breaking contact therebetween
Definitions
- Flare stacks are used to burn off vented volatile organic compounds.
- a flare stack may be used to maintain a substantially atmospheric pressure at a node of the system.
- a flare stack may be used to burn off natural gas that is produced as a byproduct of crude oil production.
- a flare stack may be used to burn off methane released by decomposition processes. Because volatile organics are considered pollutants, it is generally considered more preferred to burn the volatile organics than to vent the volatile organics directly to the atmosphere.
- Enclosed flare stacks or ground flares can be used for burning off unusable waste field gas in a variety of oil and gas production applications, for example. Waste gases may be released during over-pressuring of plant equipment. The waste gases may be transported to a corresponding ground flare. Some ground flares are enclosed. By “enclosed” it is meant that a flame envelope is substantially blocked from view by persons outside a controlled access area.
- Flame length may determine a required height, girth, or other dimensions of the ground flare structure.
- a problem may arise when the flame becomes visible (e.g., is too high).
- One parameter that can cause undesirable flame lengthening is insufficient air in combustion regions of a ground flare. Poor mixing of fuel and air may similarly cause flame lengthening.
- Excessively high flame length may substantially halt operational permitting, and/or may be expressed as greater capital cost, increased operating expenses, and/or other remediation expenses.
- a ground flare structure is configured for the application of electrical effects to a flame.
- the application of electrical effects can include application of a charge or voltage to the flame, and/or application of an electric field to a flame.
- the ground flare structure can include a vertical stack, a burner to support the flame, air inlets to allow air flow necessary for combustion, piping that transports fuel or waste gas to burner, and a power source connected to one or more electrodes.
- a power source can generate a time-varying voltage waveform that can be applied to the flame through one or more electrodes.
- This time-varying voltage waveform can introduce alternating positive and negative charges to the flame, creating continuous expansion and contraction of the flame in an oscillating effect.
- This oscillating effect on the flame can enhance the mixing of air and fuel, improving combustion efficiency and reducing flame length.
- a power source can generate one or more DC voltages that can be applied to the flame through one or more electrodes.
- the DC voltages can be used to control the flame shape.
- a system for volatile compound venting with a flare stack can include a flare stack combustor configured to at least intermittently receive volatile compound flow and support a flame at least partially fueled by the volatile compound flow.
- An electrical energy application system can be configured to apply electrical energy to at least a portion of the flare stack combustor supporting the flame, and to cause the flame to be substantially contained within the flare stack.
- FIG. 1 is a diagram of a system for volatile compound venting with a flare stack including an electrical energy application system, according to an embodiment.
- FIG. 2 is a depiction of an electrode arrangement in a flare stack combustor, according to an embodiment.
- FIG. 3 is a diagram of a system for volatile compound venting with a flare stack including an electrical energy application system, according to an embodiment.
- FIG. 4 shows a ground flare structure configured for the application of a charge, voltage, and/or electric field to a flame. Power source is OFF as no time-varying waveform is applied to flame, which can exhibit a normal combustion stage and original length, according to an embodiment.
- FIG. 5 depicts ground flare structure when power source is ON as a time-varying voltage waveform is being applied to the flame through one or more electrodes. Flame can exhibit an oscillating effect, according to an embodiment.
- FIG. 6 illustrates ground flare structure and the effects of a continuous application of time-varying voltage waveform to flame through one or more electrodes. Flame can exhibit reduced length, according to an embodiment.
- FIG. 7 shows a time-varying voltage waveform for inducing oscillating effect on flame, according to an embodiment.
- FIG. 1 is a diagram of a system for volatile compound venting with a flare stack 102 including an electrical energy application system 108 , according to an embodiment.
- the system 100 for volatile compound venting with a flare stack 102 includes a flare stack combustor 104 .
- the flare stack 102 is configured to at least intermittently receive volatile compound flow and support a flame 106 at least partially fueled by the volatile compound flow.
- the system 100 for volatile compound venting with a flare stack 102 includes an electrical energy application system 108 configured to apply electrical energy to at least a portion of the flare stack combustor 104 supporting the flame 106 , and to cause the flame 106 to be substantially contained within the flare stack 102 .
- the electrical energy application system 108 can include a controller 110 , a voltage source 112 operatively coupled to and responsive to the controller 110 and one or more electrodes 114 operatively coupled to the voltage source 112 and the flare stack combustor 104 .
- the voltage source 112 can be disposed outside a grounded vertical stack 116 .
- the electrical energy application system 108 and/or the voltage source 112 can further include at least one electrical isolator and/or insulator 118 .
- the at least one electrical isolator and/or insulator 118 can be configured to maintain electrical insulation and/or isolation between the voltage provided by the voltage source 112 and ground.
- the one or more electrodes 114 can be configured to affect a rate of combustion in the flare stack combustor 104 .
- the one or more electrodes 114 can be configured to affect an ionic wind in the flare stack combustor 104 .
- the one or more electrodes 114 can be configured to flatten the flame 106 to substantially prevent flame height from exceeding the height of a visual barrier 120 .
- the visual barrier 120 can include a top edge of the flare stack.
- the flare stack combustor 104 can be configured to receive ignition fuel from an igniter fuel source 122 and to receive a volatile gas fuel from a volatile gas fuel source 124 , to maintain a pilot flame 106 or initiate ignition with the ignition fuel, and to maintain ignition of the volatile gas fuel using the pilot flame 106 or ignition.
- An igniter controller 126 can be configured to cause the flare stack combustor 104 to establish and/or maintain ignition.
- the electrical energy application system 108 can include a controller 110 , which can be referred to as an ECC controller 110 .
- the ECC controller 110 can be configured to control the application of an electrical voltage, an electrical charge, an electrical field, and/or a combination thereof to the flare stack combustor 104 .
- the electrical energy application system controller 110 may be configured to cause the electrical energy application system 108 to apply a spark discharge to the flare stack combustor 104 when fuel is present without ignition or a pilot flame 106 .
- the igniter controller 126 can be operatively coupled to the electrical energy application system controller 110 .
- portions of the igniter controller 126 and the ECC controller 110 can include hardware and/or software that is shared.
- the ECC controller 110 can include igniter control as part of its function.
- the igniter controller 126 can include electrical energy application system 108 control as part of its function.
- One or more electrodes 114 can cooperate to form a spark (or arc) discharge ignition source for the igniter fuel 122 and/or the volatile compound flow.
- FIG. 2 is a depiction of an electrode arrangement 200 in a flare stack combustor 104 , according to an embodiment.
- One or more electrodes 114 can be included.
- the one or more electrodes 114 can include a charge source 202 configured to apply a charge to the flame 106 .
- the charge source 202 can be configured to apply charge to one or more fuel streams 204 that support the flame 106 .
- the charge source 202 can include a serrated, ion-ejecting electrode.
- the serrated, ion ejecting electrode can be disposed to convey ejected ions to the flame 106 .
- the charge source 202 can include an ionizer configured to convey ions to the flame 106 .
- a current-limiting resistor 205 can be included.
- the current-limiting resistor 205 can be operatively coupled between the voltage source 112 and the charge source 202 .
- the current-limiting resistor 205 can be configured to reduce or eliminate the formation of electrical arcs to or from the charge source 202 .
- the one or more electrodes 114 can include a charge source 202 configured to supply a charge to the flame 106 and at least one field electrode 206 configured to flatten the flame 106 .
- the at least one field electrode 206 can include a distally-disposed repulsion electrode 208 configured to receive a voltage having the same polarity as the charge applied to the flame 106 .
- the distally-disposed repulsion electrode 208 can be configured to exert a downward Coulombic pressure on the flame 106 to cause the most distal tip of the flame 106 to be below a top edge 120 of the of the flare stack.
- the distally-disposed repulsion electrode 208 can be disposed at or below the top edge 120 of the flare stack. Additionally and/or alternatively, the distally-disposed repulsion electrode 208 can be disposed at or above a nominally designated flame tip.
- the at least one field electrode 206 can include a proximally-disposed attraction electrode 210 configured to receive a voltage having the opposite polarity as the charge applied to the flame 106 .
- the proximally-disposed attraction electrode 210 can be configured to exert a downward Coulombic attraction force on the flame 106 to cause a higher amount of combustion at or near a flame holder 212 than a flare stack combustor 104 not including the proximally-disposed attraction electrode 210 .
- a current limiting resistor 214 can be included and operatively coupled between the voltage source 112 and the attraction electrode 210 .
- the current-limiting resistor 214 can be configured to reduce or eliminate the formation of electrical arcs to or from the attraction electrode 210 .
- the flare stack combustor 104 can also include at least one fuel nozzle 216 .
- the fuel nozzle(s) 216 can optionally be maintained at a voltage relative to ground and/or relative to a voltage placed on a nearby electrode 114 , such as the ion-ejecting electrode 202 and/or the proximally disposed electrode 210 .
- the fuel nozzle can cooperate with a nearby electrode 114 to at least intermittently form an electric field therebetween.
- the flame holder 212 can include or consist essentially of a flame holding conductive surface, which can be referred to as an electrode 114 .
- FIG. 3 is a diagram of a system 300 for volatile compound venting with a flare stack including an electrical energy application system 108 , according to another embodiment.
- the electrical energy application system 108 can include an electrical energy application system controller 110 having a feedback loop configured to cause the controller to control the electrical energy application system 108 responsive to a fuel flow parameter or a flame parameter.
- the system can include a sensor 302 operatively coupled to the electrical energy application system controller 110 .
- the sensor 302 can be configured to sense a flame parameter.
- the sensor 302 can be configured to sense flame height.
- the sensor 302 can be configured to sense a parameter proportional to flame behavior. Additionally, the sensor 302 can include an infrared sensor and/or pyrometer.
- One or more fuel flow sensors can be included.
- the one or more fuel flow sensors can be operatively coupled to the electrical energy application system controller 110 and can be configured to detect a fuel flow rate to the flare stack combustor 104 .
- the electrical energy application system controller 110 can be configured to cause the electrical energy application system 108 to apply at least one of one or more voltages, one or more duty cycles, one or more charge densities, and/or one or more electric fields having a magnitude proportional to the fuel flow rate. Additionally or alternatively, the electrical energy application system controller 110 can be configured to dynamically modulate the electrical energy application system 108 responsive to dynamic changes in the fuel flow rate.
- the electrical energy application system controller 110 can include a proportional controller, an integral controller, a differential controller, and/or a combination thereof.
- the electrical energy application system 108 can be configured to apply one or more DC voltages to the flame 106 .
- the electrical energy application system 108 can be configured to apply one or more time-varying voltages to the flame 106 .
- the electrical energy application system 108 can be configured to apply one or more alternating current (AC) voltages to the flame 106 .
- the electrical energy application system 108 can be configured to apply one or more voltage waveforms to the flame 106 .
- the electrical energy application system 108 can be configured to apply one or more of a sinusoidal voltage waveform, a square voltage waveform, a sawtooth voltage waveform, a triangular voltage waveform, a truncated sawtooth or triangular voltage waveform, a logarithmic voltage waveform, or an exponential voltage waveform to the flame 106 .
- the one or more time-varying voltages can be selected to increase flame mixing to cause substantially complete consumption of fuel within the flare stack 102 .
- FIG. 4 shows a ground flare structure 400 configured for the application of a charge, voltage, and/or electric field to a flame 106 , according to an embodiment.
- a vertical stack 116 can contain a fuel nozzle(s) 216 for burning waste gas and which is open at the top for flue gas discharge.
- the fuel nozzle(s) 216 can be configured to support flame 106 enclosed in the vertical stack 116 .
- the vertical stack 116 can be properly grounded, and can be supported by stays.
- the dimensions or scale, geometric relationships and forms of the vertical stack 116 and the fuel nozzle(s) 216 can vary according to the application.
- Two or more air inlets 408 can be located at the bottom regions of the vertical stack 116 for allowing air 410 flow to support the combustion.
- a fuel stream 204 to be disposed by burning is fed to fuel nozzle(s) 216 through piping 414 .
- the fuel stream 204 can include waste gases originated from over-pressuring of plant equipment, or other hydrocarbon-based fuels.
- the fuel stream 204 can include a refinery mixture of 25% hydrogen, 50% methane, and 25% propane, where there is enough carbon content for the technique described herein to work accordingly.
- the flame 106 enclosed in the vertical stack 116 can include a plurality of charged and uncharged species.
- charged species such as ions 420 are produced within the flame 106 .
- Such ions 420 can include HCO+, C3H3+, H3O+, among others, along with their corresponding but dissociated electrons.
- Uncharged or neutral species can include uncharged combustion products, unburned fuel stream 204 and air 410 .
- One or more electrodes 114 can be configured to apply voltage, charge, and/or electric field to the flame 106 .
- One or more electrodes 114 can be isolated from the ground flare structure 400 and can be connected to a voltage source 112 .
- the voltage source 112 can be configured to produce a plurality of voltage waveforms for driving one or more electrodes 114 .
- a controller can be connected to the voltage source 112 to determine voltage waveforms for driving one or more electrodes 114 according to received combustion feedback or sensed combustion values from a plurality of sensors.
- fuel nozzle(s) 216 can be configured to apply voltage, charge, and/or electric field to the flame 106 .
- a charged pilot flame can be configured for the application of voltage, charge, and/or electric field to flame the 106 .
- voltage source 112 is in OFF mode as no voltage waveforms are applied to one or more electrodes 114 , and consequently no voltage, charge, and/or electric field can be applied to the flame 106 .
- the flame 106 can exhibit a normal combustion state, whereby the flame 106 length can reach the top of the vertical stack 104 as consequence of insufficient supply of air 410 and/or poor mixing between the fuel stream 204 and air 110 .
- FIG. 5 depicts a ground flare structure 500 when the voltage source 112 operates in ON mode.
- the voltage source 112 can drive one or more electrodes 114 for the application of a time-varying voltage waveform to the flame 106 .
- a time-varying voltage waveform 502 generated from voltage source 112 and applied through one or more electrodes 114 can first introduce a positive charge at high voltage but low amperage into the flame 106 to remove electrons and enhance the concentration of cations. Exit of electrons from the flame 106 can occur very rapidly as electrons are considerably less massive than ions 420 . As a result, the higher concentration of positive ions 420 in the flame 106 can disperse as charges of same polarity mutually repel. While charge imbalance affects primarily ions 420 , collisions between ions 420 and uncharged or neutral species can occur, producing a net dispersive bulk flow away from flame 106 and toward a region of lower electrical potential, in this case, the vertical stack 116 which is grounded. At this time, the flame 106 can expand toward the vertical stack 116 .
- Ions 420 within the flame 106 can capture electrons when reaching grounded the vertical stack 116 or any oppositely charged structure.
- the time-varying voltage waveform 502 generated from the voltage source 112 and applied through electrodes 114 can introduce a negative charge to the flame 106 to bring back electrons and reduce concentration of cations. With a higher concentration of electrons and lower concentration of cations, the flame 106 can repel from the vertical stack 116 and can contract to its original shape.
- the time-varying voltage waveform 502 can continue reversing the polarity of one or more electrodes 114 , producing continuous expansion/contraction of flame 106 . This can be referred to as oscillation 504 of the flame 106 .
- FIG. 6 illustrates the result of oscillation 504 of the flame 106 in the ground flare structure 400 .
- the oscillation 504 of the flame 106 continues with the application of the time-varying voltage waveform 502 through electrodes 114 , higher mixing of the fuel stream 204 and air 410 can be achieved in vertical stack 116 with no change in firing rate.
- a higher mixing between the fuel stream 204 and air 410 can significantly reduce the flame length as depicted in FIG.6 , while also improving combustion efficiency of the ground flare structure 400 .
- oscillation 504 of the flame 106 can provide higher entrainment and mixing with the neutral species without the need for additional excess air 410 .
- the excess air 410 requirements can be reduced since the bulk momentum of air 410 used for mixing can be assisted by increased turbulence originated from continuous oscillation 504 of the flame 106 .
- the reduced flame length can be maintained as long as the voltage source 112 operates at ON mode and continues driving one or more electrodes 114 for the application of time-varying voltage waveform to the flame 106 .
- the voltage source 112 is deactivated or at OFF mode, the flame 106 can immediately return to its normal combustion state as described in FIG. 4 .
- the flame length reduction can depend on the voltage amplitude and frequency of the time-varying voltage waveform 402 applied by one or more electrodes 114 , as well as fuel type and/or the overall ground flare structure 400 configuration.
- FIG. 7 is a representation of the time-varying voltage waveform 502 generated from the voltage source 112 and applied to the flame 106 through one or more electrodes 114 .
- the time-varying voltage waveform 502 can be modulated between high voltage V H and low voltage V L in a pattern characterized by period P.
- the high voltage V H and low voltage V L can be selected as equal magnitude variations above and below a mean voltage V o , whereby mean voltage V o can be a ground voltage.
- the period P can include a duration t L corresponding to low voltage V L and another duration t H corresponding high voltage V H , where t L plus t H can equal P.
- Frequency of the time-varying voltage waveform 502 can be the inverse of period P.
- flame length reduction can be controlled by modulating the frequency of time-varying voltage waveform 502 , which can vary between 10 Hz and 2 kHz, with 200 Hz being preferred.
- the time-varying voltage waveform 502 can apply a positive charge or high voltage V H via one or more electrodes 114 to the flame 106 , producing an expansion effect on flame 106 .
- This can be followed by a corresponding application of negative charge or low voltage V L which can generate a contracting effect on flame 106 .
- the continuous reversal between high voltage V H and low voltage V L in the time-varying voltage waveform 502 can generate the oscillation 504 effect on the flame 106 , which can translate into higher mixing of the fuel stream 204 and air 410 , and a corresponding flame 106 length reduction in the ground flare structure 400 .
- the technique herein described for the reduction of flame length can also be applicable to elevated flares or open flare arrays that can require improved mixing of air and fuel, and higher combustion efficiency.
Abstract
A flare stack may be equipped with an electrical energy application system configured to apply electrical energy to a flare stack combustor. The applied electrical energy may be selected to affect flare flame length, flare flame containment, and/or flare flame exhaust gas composition.
Description
- The present application claims priority benefit from U.S. Provisional Patent Application No. 61/736,524, entitled “CONTAINED FLAME FLARE STACK”, filed Dec. 12, 2012; which, to the extent not inconsistent with the disclosure herein, is incorporated by reference.
- Flare stacks are used to burn off vented volatile organic compounds. For example, in an oil refinery, a flare stack may be used to maintain a substantially atmospheric pressure at a node of the system. In an oil field, a flare stack may be used to burn off natural gas that is produced as a byproduct of crude oil production. In a landfill, a flare stack may be used to burn off methane released by decomposition processes. Because volatile organics are considered pollutants, it is generally considered more preferred to burn the volatile organics than to vent the volatile organics directly to the atmosphere.
- In flare stack applications, it can be important to control the height of a flame envelope created by the burner. In some applications, it may be required or desired that the flame not exceed the height of the flare stack itself. By keeping the flame inside the flare stack, safety may be improved. Moreover, aesthetics may be improved sufficiently to avoid complaints about a visible flame.
- Enclosed flare stacks or ground flares can be used for burning off unusable waste field gas in a variety of oil and gas production applications, for example. Waste gases may be released during over-pressuring of plant equipment. The waste gases may be transported to a corresponding ground flare. Some ground flares are enclosed. By “enclosed” it is meant that a flame envelope is substantially blocked from view by persons outside a controlled access area.
- Flame length may determine a required height, girth, or other dimensions of the ground flare structure. A problem may arise when the flame becomes visible (e.g., is too high). One parameter that can cause undesirable flame lengthening is insufficient air in combustion regions of a ground flare. Poor mixing of fuel and air may similarly cause flame lengthening.
- Excessively high flame length may substantially halt operational permitting, and/or may be expressed as greater capital cost, increased operating expenses, and/or other remediation expenses.
- For the foregoing reasons, it is desirable to reduce flame length and/or improve the overall combustion efficiency in ground flares.
- According to an embodiment, a ground flare structure is configured for the application of electrical effects to a flame. The application of electrical effects can include application of a charge or voltage to the flame, and/or application of an electric field to a flame. The ground flare structure can include a vertical stack, a burner to support the flame, air inlets to allow air flow necessary for combustion, piping that transports fuel or waste gas to burner, and a power source connected to one or more electrodes.
- According to an embodiment, a power source can generate a time-varying voltage waveform that can be applied to the flame through one or more electrodes. This time-varying voltage waveform can introduce alternating positive and negative charges to the flame, creating continuous expansion and contraction of the flame in an oscillating effect. This oscillating effect on the flame can enhance the mixing of air and fuel, improving combustion efficiency and reducing flame length.
- According to another embodiment, a power source can generate one or more DC voltages that can be applied to the flame through one or more electrodes. The DC voltages can be used to control the flame shape.
- According to an embodiment, a system for volatile compound venting with a flare stack can include a flare stack combustor configured to at least intermittently receive volatile compound flow and support a flame at least partially fueled by the volatile compound flow. An electrical energy application system can be configured to apply electrical energy to at least a portion of the flare stack combustor supporting the flame, and to cause the flame to be substantially contained within the flare stack.
- By reducing flame length within the vertical stack, material requirements for building ground flare structures can be significantly reduced as less material would be required to support a shorter flame. The technique for reducing flame length disclosed herein can assist compliance with regulation standards about flame length and can also be applicable for elevated flares and retrofit applications.
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FIG. 1 is a diagram of a system for volatile compound venting with a flare stack including an electrical energy application system, according to an embodiment. -
FIG. 2 is a depiction of an electrode arrangement in a flare stack combustor, according to an embodiment. -
FIG. 3 is a diagram of a system for volatile compound venting with a flare stack including an electrical energy application system, according to an embodiment. -
FIG. 4 shows a ground flare structure configured for the application of a charge, voltage, and/or electric field to a flame. Power source is OFF as no time-varying waveform is applied to flame, which can exhibit a normal combustion stage and original length, according to an embodiment. -
FIG. 5 depicts ground flare structure when power source is ON as a time-varying voltage waveform is being applied to the flame through one or more electrodes. Flame can exhibit an oscillating effect, according to an embodiment. -
FIG. 6 illustrates ground flare structure and the effects of a continuous application of time-varying voltage waveform to flame through one or more electrodes. Flame can exhibit reduced length, according to an embodiment. -
FIG. 7 shows a time-varying voltage waveform for inducing oscillating effect on flame, according to an embodiment. - In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, which are not to scale or to proportion, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative embodiments described in the detailed description, drawings and claims, are not meant to be limiting. Other embodiments may be used and/or and other changes may be made without departing from the spirit or scope of the present disclosure.
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FIG. 1 is a diagram of a system for volatile compound venting with aflare stack 102 including an electricalenergy application system 108, according to an embodiment. - The
system 100 for volatile compound venting with aflare stack 102 includes aflare stack combustor 104. Theflare stack 102 is configured to at least intermittently receive volatile compound flow and support aflame 106 at least partially fueled by the volatile compound flow. - The
system 100 for volatile compound venting with aflare stack 102 includes an electricalenergy application system 108 configured to apply electrical energy to at least a portion of theflare stack combustor 104 supporting theflame 106, and to cause theflame 106 to be substantially contained within theflare stack 102. - According to an embodiment, the electrical
energy application system 108 can include acontroller 110, avoltage source 112 operatively coupled to and responsive to thecontroller 110 and one ormore electrodes 114 operatively coupled to thevoltage source 112 and theflare stack combustor 104. - The
voltage source 112 can be disposed outside a groundedvertical stack 116. The electricalenergy application system 108 and/or thevoltage source 112 can further include at least one electrical isolator and/orinsulator 118. The at least one electrical isolator and/orinsulator 118 can be configured to maintain electrical insulation and/or isolation between the voltage provided by thevoltage source 112 and ground. - According to an embodiment, the one or
more electrodes 114 can be configured to affect a rate of combustion in theflare stack combustor 104. - The one or
more electrodes 114 can be configured to affect an ionic wind in theflare stack combustor 104. - The one or
more electrodes 114 can be configured to flatten theflame 106 to substantially prevent flame height from exceeding the height of avisual barrier 120. Thevisual barrier 120 can include a top edge of the flare stack. - The
flare stack combustor 104 can be configured to receive ignition fuel from anigniter fuel source 122 and to receive a volatile gas fuel from a volatilegas fuel source 124, to maintain apilot flame 106 or initiate ignition with the ignition fuel, and to maintain ignition of the volatile gas fuel using thepilot flame 106 or ignition. Anigniter controller 126 can be configured to cause theflare stack combustor 104 to establish and/or maintain ignition. - The electrical
energy application system 108 can include acontroller 110, which can be referred to as anECC controller 110. TheECC controller 110 can be configured to control the application of an electrical voltage, an electrical charge, an electrical field, and/or a combination thereof to theflare stack combustor 104. - The electrical energy
application system controller 110 may be configured to cause the electricalenergy application system 108 to apply a spark discharge to theflare stack combustor 104 when fuel is present without ignition or apilot flame 106. - According to various embodiments, the
igniter controller 126 can be operatively coupled to the electrical energyapplication system controller 110. For example, portions of theigniter controller 126 and theECC controller 110 can include hardware and/or software that is shared. TheECC controller 110 can include igniter control as part of its function. Theigniter controller 126 can include electricalenergy application system 108 control as part of its function. One ormore electrodes 114 can cooperate to form a spark (or arc) discharge ignition source for theigniter fuel 122 and/or the volatile compound flow. -
FIG. 2 is a depiction of anelectrode arrangement 200 in aflare stack combustor 104, according to an embodiment. One ormore electrodes 114 can be included. The one ormore electrodes 114 can include a charge source 202 configured to apply a charge to theflame 106. - The charge source 202 can be configured to apply charge to one or
more fuel streams 204 that support theflame 106. - The charge source 202 can include a serrated, ion-ejecting electrode. The serrated, ion ejecting electrode can be disposed to convey ejected ions to the
flame 106. - The charge source 202 can include an ionizer configured to convey ions to the
flame 106. - A current-limiting
resistor 205 can be included. The current-limitingresistor 205 can be operatively coupled between thevoltage source 112 and the charge source 202. The current-limitingresistor 205 can be configured to reduce or eliminate the formation of electrical arcs to or from the charge source 202. - The one or
more electrodes 114 can include a charge source 202 configured to supply a charge to theflame 106 and at least one field electrode 206 configured to flatten theflame 106. - According to an embodiment, the at least one field electrode 206 can include a distally-disposed repulsion electrode 208 configured to receive a voltage having the same polarity as the charge applied to the
flame 106. The distally-disposed repulsion electrode 208 can be configured to exert a downward Coulombic pressure on theflame 106 to cause the most distal tip of theflame 106 to be below atop edge 120 of the of the flare stack. - The distally-disposed repulsion electrode 208 can be disposed at or below the
top edge 120 of the flare stack. Additionally and/or alternatively, the distally-disposed repulsion electrode 208 can be disposed at or above a nominally designated flame tip. - According to an embodiment, the at least one field electrode 206 can include a proximally-disposed attraction electrode 210 configured to receive a voltage having the opposite polarity as the charge applied to the
flame 106. - The proximally-disposed attraction electrode 210 can be configured to exert a downward Coulombic attraction force on the
flame 106 to cause a higher amount of combustion at or near aflame holder 212 than aflare stack combustor 104 not including the proximally-disposed attraction electrode 210. - According to an embodiment, a current limiting
resistor 214 can be included and operatively coupled between thevoltage source 112 and the attraction electrode 210. The current-limitingresistor 214 can be configured to reduce or eliminate the formation of electrical arcs to or from the attraction electrode 210. - The
flare stack combustor 104 can also include at least onefuel nozzle 216. The fuel nozzle(s) 216 can optionally be maintained at a voltage relative to ground and/or relative to a voltage placed on anearby electrode 114, such as the ion-ejecting electrode 202 and/or the proximally disposed electrode 210. The fuel nozzle can cooperate with anearby electrode 114 to at least intermittently form an electric field therebetween. According to an embodiment, theflame holder 212 can include or consist essentially of a flame holding conductive surface, which can be referred to as anelectrode 114. -
FIG. 3 is a diagram of asystem 300 for volatile compound venting with a flare stack including an electricalenergy application system 108, according to another embodiment. The electricalenergy application system 108 can include an electrical energyapplication system controller 110 having a feedback loop configured to cause the controller to control the electricalenergy application system 108 responsive to a fuel flow parameter or a flame parameter. - The system can include a
sensor 302 operatively coupled to the electrical energyapplication system controller 110. Thesensor 302 can be configured to sense a flame parameter. - The
sensor 302 can be configured to sense flame height. Thesensor 302 can be configured to sense a parameter proportional to flame behavior. Additionally, thesensor 302 can include an infrared sensor and/or pyrometer. - One or more fuel flow sensors can be included. The one or more fuel flow sensors can be operatively coupled to the electrical energy
application system controller 110 and can be configured to detect a fuel flow rate to theflare stack combustor 104. - The electrical energy
application system controller 110 can be configured to cause the electricalenergy application system 108 to apply at least one of one or more voltages, one or more duty cycles, one or more charge densities, and/or one or more electric fields having a magnitude proportional to the fuel flow rate. Additionally or alternatively, the electrical energyapplication system controller 110 can be configured to dynamically modulate the electricalenergy application system 108 responsive to dynamic changes in the fuel flow rate. The electrical energyapplication system controller 110 can include a proportional controller, an integral controller, a differential controller, and/or a combination thereof. - The electrical
energy application system 108 can be configured to apply one or more DC voltages to theflame 106. - The electrical
energy application system 108 can be configured to apply one or more time-varying voltages to theflame 106. The electricalenergy application system 108 can be configured to apply one or more alternating current (AC) voltages to theflame 106. The electricalenergy application system 108 can be configured to apply one or more voltage waveforms to theflame 106. Additionally, the electricalenergy application system 108 can be configured to apply one or more of a sinusoidal voltage waveform, a square voltage waveform, a sawtooth voltage waveform, a triangular voltage waveform, a truncated sawtooth or triangular voltage waveform, a logarithmic voltage waveform, or an exponential voltage waveform to theflame 106. - According to an embodiment, the one or more time-varying voltages can be selected to increase flame mixing to cause substantially complete consumption of fuel within the
flare stack 102. -
FIG. 4 shows aground flare structure 400 configured for the application of a charge, voltage, and/or electric field to aflame 106, according to an embodiment. Avertical stack 116 can contain a fuel nozzle(s) 216 for burning waste gas and which is open at the top for flue gas discharge. The fuel nozzle(s) 216 can be configured to supportflame 106 enclosed in thevertical stack 116. As shown inFIG. 4 , thevertical stack 116 can be properly grounded, and can be supported by stays. - The dimensions or scale, geometric relationships and forms of the
vertical stack 116 and the fuel nozzle(s) 216 can vary according to the application. - Two or
more air inlets 408 can be located at the bottom regions of thevertical stack 116 for allowingair 410 flow to support the combustion. Afuel stream 204 to be disposed by burning is fed to fuel nozzle(s) 216 throughpiping 414. Thefuel stream 204 can include waste gases originated from over-pressuring of plant equipment, or other hydrocarbon-based fuels. For example, thefuel stream 204 can include a refinery mixture of 25% hydrogen, 50% methane, and 25% propane, where there is enough carbon content for the technique described herein to work accordingly. - The
flame 106 enclosed in thevertical stack 116 can include a plurality of charged and uncharged species. During combustion, charged species such asions 420 are produced within theflame 106.Such ions 420 can include HCO+, C3H3+, H3O+, among others, along with their corresponding but dissociated electrons. Uncharged or neutral species can include uncharged combustion products,unburned fuel stream 204 andair 410. - One or
more electrodes 114 can be configured to apply voltage, charge, and/or electric field to theflame 106. One ormore electrodes 114 can be isolated from theground flare structure 400 and can be connected to avoltage source 112. Thevoltage source 112 can be configured to produce a plurality of voltage waveforms for driving one ormore electrodes 114. In an embodiment, a controller can be connected to thevoltage source 112 to determine voltage waveforms for driving one ormore electrodes 114 according to received combustion feedback or sensed combustion values from a plurality of sensors. - In another embodiment, fuel nozzle(s) 216 can be configured to apply voltage, charge, and/or electric field to the
flame 106. Yet in another embodiment, a charged pilot flame can be configured for the application of voltage, charge, and/or electric field to flame the 106. - As shown in
FIG. 4 ,voltage source 112 is in OFF mode as no voltage waveforms are applied to one ormore electrodes 114, and consequently no voltage, charge, and/or electric field can be applied to theflame 106. During this operation mode, theflame 106 can exhibit a normal combustion state, whereby theflame 106 length can reach the top of thevertical stack 104 as consequence of insufficient supply ofair 410 and/or poor mixing between thefuel stream 204 andair 110. -
FIG. 5 depicts aground flare structure 500 when thevoltage source 112 operates in ON mode. When operating in ON mode, thevoltage source 112 can drive one ormore electrodes 114 for the application of a time-varying voltage waveform to theflame 106. - A time-varying
voltage waveform 502 generated fromvoltage source 112 and applied through one ormore electrodes 114 can first introduce a positive charge at high voltage but low amperage into theflame 106 to remove electrons and enhance the concentration of cations. Exit of electrons from theflame 106 can occur very rapidly as electrons are considerably less massive thanions 420. As a result, the higher concentration ofpositive ions 420 in theflame 106 can disperse as charges of same polarity mutually repel. While charge imbalance affects primarilyions 420, collisions betweenions 420 and uncharged or neutral species can occur, producing a net dispersive bulk flow away fromflame 106 and toward a region of lower electrical potential, in this case, thevertical stack 116 which is grounded. At this time, theflame 106 can expand toward thevertical stack 116. -
Ions 420 within theflame 106 can capture electrons when reaching grounded thevertical stack 116 or any oppositely charged structure. In order to avoid this condition, the time-varyingvoltage waveform 502 generated from thevoltage source 112 and applied throughelectrodes 114 can introduce a negative charge to theflame 106 to bring back electrons and reduce concentration of cations. With a higher concentration of electrons and lower concentration of cations, theflame 106 can repel from thevertical stack 116 and can contract to its original shape. - The time-varying
voltage waveform 502 can continue reversing the polarity of one ormore electrodes 114, producing continuous expansion/contraction offlame 106. This can be referred to asoscillation 504 of theflame 106. -
FIG. 6 illustrates the result ofoscillation 504 of theflame 106 in theground flare structure 400. As theoscillation 504 of theflame 106 continues with the application of the time-varyingvoltage waveform 502 throughelectrodes 114, higher mixing of thefuel stream 204 andair 410 can be achieved invertical stack 116 with no change in firing rate. A higher mixing between thefuel stream 204 andair 410 can significantly reduce the flame length as depicted inFIG.6 , while also improving combustion efficiency of theground flare structure 400. - In addition,
oscillation 504 of theflame 106 can provide higher entrainment and mixing with the neutral species without the need for additionalexcess air 410. Theexcess air 410 requirements can be reduced since the bulk momentum ofair 410 used for mixing can be assisted by increased turbulence originated fromcontinuous oscillation 504 of theflame 106. - The reduced flame length can be maintained as long as the
voltage source 112 operates at ON mode and continues driving one ormore electrodes 114 for the application of time-varying voltage waveform to theflame 106. When thevoltage source 112 is deactivated or at OFF mode, theflame 106 can immediately return to its normal combustion state as described inFIG. 4 . - Different levels of flame length reduction can be achieved according to application requirements. The flame length reduction can depend on the voltage amplitude and frequency of the time-varying voltage waveform 402 applied by one or
more electrodes 114, as well as fuel type and/or the overallground flare structure 400 configuration. -
FIG. 7 is a representation of the time-varyingvoltage waveform 502 generated from thevoltage source 112 and applied to theflame 106 through one ormore electrodes 114. The time-varyingvoltage waveform 502 can be modulated between high voltage VH and low voltage VL in a pattern characterized by period P. The high voltage VH and low voltage VL can be selected as equal magnitude variations above and below a mean voltage Vo, whereby mean voltage Vo can be a ground voltage. - The period P can include a duration tL corresponding to low voltage VL and another duration tH corresponding high voltage VH, where tL plus tH can equal P. Frequency of the time-varying
voltage waveform 502 can be the inverse of period P. According to an embodiment, flame length reduction can be controlled by modulating the frequency of time-varyingvoltage waveform 502, which can vary between 10 Hz and 2 kHz, with 200 Hz being preferred. - As described in
FIG. 5 , the time-varyingvoltage waveform 502 can apply a positive charge or high voltage VH via one ormore electrodes 114 to theflame 106, producing an expansion effect onflame 106. This can be followed by a corresponding application of negative charge or low voltage VL which can generate a contracting effect onflame 106. As such, the continuous reversal between high voltage VH and low voltage VL in the time-varyingvoltage waveform 502 can generate theoscillation 504 effect on theflame 106, which can translate into higher mixing of thefuel stream 204 andair 410, and acorresponding flame 106 length reduction in theground flare structure 400. - The technique herein described for the reduction of flame length can also be applicable to elevated flares or open flare arrays that can require improved mixing of air and fuel, and higher combustion efficiency.
- While various aspects and embodiments have been disclosed herein, other aspects and embodiments may be contemplated. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.
Claims (39)
1. A system for volatile compound venting with a flare stack, comprising:
a flare stack combustor configured to at least intermittently receive volatile compound flow and support a flame at least partially fueled by the volatile compound flow; and
an electrical energy application system, the electrical energy application system being configured to apply electrical energy to at least a portion of the flare stack combustor supporting the flame, and to cause the flame to be substantially contained within the flare stack.
2. The system for volatile compound venting with a flare stack of claim 1 , wherein the electrical energy application system further comprises:
a controller;
a voltage source operatively coupled to and responsive to the controller; and
one or more electrodes operatively coupled to the voltage source and the flare stack combustor.
3. The system for volatile compound venting with a flare stack of claim 2 , wherein the voltage source is disposed outside a grounded flare stack wall.
4. The system for volatile compound venting with a flare stack of claim 3 , further comprising at least one electrical isolator or insulator configured to maintain electrical insulation or isolation between the voltage provided by the voltage source and ground.
5. The system for volatile compound venting with a flare stack of claim 2 , wherein the one or more electrodes are configured to affect a rate of combustion in the flare stack combustor.
6. The system for volatile compound venting with a flare stack of claim 2 , wherein the one or more electrodes are configured to affect an ionic wind in the flare stack combustor.
7. The system for volatile compound venting with a flare stack of claim 2 , wherein the one or more electrodes are configured to flatten the flame to substantially prevent flame height from exceeding the height of a visual barrier.
8. The system for volatile compound venting with a flare stack of claim 7 , wherein the visual barrier includes a top edge of the flare stack.
9. The system for volatile compound venting with a flare stack of claim 1 , further comprising an igniter controller configured to cause the flare stack combustor to establish or maintain ignition.
10. The system for volatile compound venting with a flare stack of claim 9 , wherein the electrical energy application system includes a controller configured to control the application of an electrical voltage, an electrical charge, an electrical field, or a combination thereof to the flare stack combustor; and
wherein the igniter controller is operatively coupled to the electrical energy application system controller.
11. The system for volatile compound venting with a flare stack of claim 10 , wherein the electrical energy application system controller is configured to cause the electrical energy application system to apply a spark discharge to the flare stack combustor when fuel is present without ignition or a pilot flame.
12. The system for volatile compound venting with a flare stack of claim 9 , wherein the one or more electrodes include a charge source configured to apply a charge to the flame.
13. The system for volatile compound venting with a flare stack of claim 12 , wherein the charge source is configured to apply charge to one or more fuel streams that support the flame.
14. The system for volatile compound venting with a flare stack of claim 12 , wherein the charge source includes a serrated, ion-ejecting electrode disposed to convey ejected ions to the flame.
15. The system for volatile compound venting with a flare stack of claim 12 , wherein the charge source includes an ionizer configured to convey ions to the flame.
16. The system for volatile compound venting with a flare stack of claim 12 , further comprising a current-limiting resistor operatively coupled between the voltage source and the charge source, the current-limiting resistor being configured to reduce or eliminate the formation of electrical arcs to or from the charge source.
17. The system for volatile compound venting with a flare stack of claim 9 , wherein the one or more electrodes further comprise:
a charge source configured to supply a charge to the flame; and
at least one field electrode configured to flatten the flame.
18. The system for volatile compound venting with a flare stack of claim 17 , wherein the at least one field electrode includes a distally-disposed repulsion electrode configured to receive a voltage having the same polarity as the charge applied to the flame.
19. The system for volatile compound venting with a flare stack of claim 18 , wherein the distally-disposed electrode is configured to exert a downward Coulombic pressure on the flame to cause the most distal tip of the flame to be below a top edge of the of the flare stack.
20. The system for volatile compound venting with a flare stack of claim 18 , wherein the distally-disposed electrode is disposed at or below the top edge of the flare stack.
21. The system for volatile compound venting with a flare stack of claim 18 , wherein the distally-disposed electrode is disposed at or above a nominally designated flame tip.
22. The system for volatile compound venting with a flare stack of claim 17 , wherein the at least one field electrode includes a proximally-disposed attraction electrode configured to receive a voltage having the opposite polarity as the charge applied to the flame.
23. The system for volatile compound venting with a flare stack of claim 22 , wherein the proximally-disposed electrode is configured to exert a downward Coulombic attraction force on the flame to cause a higher amount of combustion at or near a flame holder than a flare stack combustor not including the proximally-disposed attraction electrode.
24. The system for volatile compound venting with a flare stack of claim 22 , further comprising a current limiting resistor operatively coupled between the voltage source and the attraction electrode, the current-limiting resistor being configured to reduce or eliminate the formation of electrical arcs to or from the attraction electrode.
25. The system for volatile compound venting with a flare stack of claim 1 , wherein the electrical energy application system further comprises:
an electrical energy application system controller having a feedback loop configured to cause the controller to control the electrical energy application system responsive to a fuel flow parameter or a flame parameter.
26. The system for volatile compound venting with a flare stack of claim 25 , further comprising:
a sensor operatively coupled to the electrical energy application system controller, the sensor being configured to sense a flame parameter.
27. The system for volatile compound venting with a flare stack of claim 26 , wherein the sensor is configured to sense flame height.
28. The system for volatile compound venting with a flare stack of claim 26 , wherein the sensor is configured to sense a parameter proportional to flame behavior.
29. The system for volatile compound venting with a flare stack of claim 26 , wherein the sensor includes an infrared sensor or pyrometer.
30. The system for volatile compound venting with a flare stack of claim 26 , further comprising one or more fuel flow sensors operatively coupled to the electrical energy application system controller and configured to detect a fuel flow rate to the flare stack combustor.
31. The system for volatile compound venting with a flare stack of claim 30 , wherein the electrical energy application system controller is configured to cause the electrical energy application system to apply at least one of one or more voltages, one or more duty cycles, one or more charge densities, or one or more electric fields having a magnitude proportional to the fuel flow rate.
32. The system for volatile compound venting with a flare stack of claim 30 , wherein the electrical energy application system controller is configured to dynamically modulate the electrical energy application system responsive to dynamic changes in the fuel flow rate.
33. The system for volatile compound venting with a flare stack of claim 25 , wherein the electrical energy application system controller includes a proportional controller, an integral controller, a differential controller, or a combination thereof.
34. The system for volatile compound venting with a flare stack of claim 1 , wherein the electrical energy application system is configured to apply one or more DC voltages to the flame.
35. The system for volatile compound venting with a flare stack of claim 1 , wherein the electrical energy application system is configured to apply one or more time-varying voltages to the flame.
36. The system for volatile compound venting with a flare stack of claim 35 , wherein the electrical energy application system is configured to apply one or more alternating current (AC) voltages to the flame.
37. The system for volatile compound venting with a flare stack of claim 35 , wherein the electrical energy application system is configured to apply one or more voltage waveforms to the flame.
38. The system for volatile compound venting with a flare stack of claim 37 , wherein the electrical energy application system is configured to apply one or more of a sinusoidal voltage waveform, a square voltage waveform, a sawtooth voltage waveform, a triangular voltage waveform, a truncated sawtooth or triangular voltage waveform, a logarithmic voltage waveform, or an exponential voltage waveform to the flame.
39. The system for volatile compound venting with a flare stack of claim 35 , wherein the one or more time-varying voltages is selected to increase flame mixing to cause substantially complete consumption of fuel within the flare stack.
Priority Applications (1)
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US14/101,312 US20140170576A1 (en) | 2012-12-12 | 2013-12-09 | Contained flame flare stack |
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US201261736524P | 2012-12-12 | 2012-12-12 | |
US14/101,312 US20140170576A1 (en) | 2012-12-12 | 2013-12-09 | Contained flame flare stack |
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