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Terminal Flare Components
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Enclosed Stack - Combustion Chamber
MRW enclosed flare systems use a vertical, cylindrical, and self-supported refractory lined stack. The flame is completely hidden inside the combustor. The refractory used is designed for cold start-ups. The refractory is designed to withstand shrinkage from exposure to high temperatures. Destruction efficiencies of 99%+ are achieved by using an enclosed flare stack combustor. The stack includes lifting lugs for easy in field installation. MRW uses a special type of refractory attachment system designed for exposure to extremely high temperatures and is resistant against corrosion. The enclosed stack includes an MRW Anti-Flashback burner assembly to allow for safe operation and stable combustion at high and low vapor rates. The temperature is controlled via quench-air dampers that monitor the amount of air into the combustion chamber. Thus, fuel usage is controlled by maintaining a set point temperature usually of 1600°F to 1800°F depending upon the terminal needs, type of loading facility/chemical, and environmental requirements. |
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Elevated Stack and Flare Tip for Open Flame Flare
In situations where cost is of great concern and noise, radiation, and visible flame is not a hindrance, an elevated Open Flame Flare can be used. The DRE in these systems is 98% by EPA definition as long as the flare design meets certain EPA guidelines. The flare height is determined by the radiation from the resulting flame. This is determined by the composition of the waste gas fumes and the flow rate. Typically, an allowable radiation level of 1500 BTU/hr/ft2 is normally maintained. The open flame terminal flare is as safe as an enclosed system despite the fact the flame is visible. We design for safe radiation levels and locations of other ignition sources. External piping supports for mounting the pilot piping and conduit are included as is piping connections and mating flanges to match existing connections. MRW open terminal flares include a proprietary flashback resistant air assist flare tip. This is made of 309/310 stainless and includes a stainless steel flame holder design that allows for stable combustion at high exit velocities. The flare tip can be designed to be removable. Stainless mounting brackets are included for easy installation of pilot assembly. |
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Pilot and Burner
MRW manufactures continuous and energy efficient pilots designed for reliable flame stability during any operating condition including the harshest weather and extremely high wind speeds. Our pilot burners are fabricated out of 309/310 stainless adding extended life to the pilot burner assembly. The spark ignition rod is strategically placed in the tip for rapid ignition of pilot fuel gas. This design is based on experience from experience with over 1,000 flare installations. An air/fuel gas mixer is attached to the pilot burner assembly to allow for a combustible mixture at the pilot burner tip. No field welding is required as mounting brackets allow for easy field installation. The MRW local control panel powers the ignition transformer for automatic ignition of the pilot. The enclosed stack includes an MRW Anti-Flashback burner assembly to allow for safe operation and stable combustion at high and low vapor rates. MRW anti-flashback burners work to distinguish a flashback the same way a detonation/flame arrestor does by absorbing the heat of the flame into an element especially designed for distinguishing flame propagations. |
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Detonation Arrestor or Liquid Seal
Because waste gas fumes are in the explosive range, and/or there are extended pipe runs or multiple bends in pipe, a detonation arrestor should be used to prevent flashback upstream of the flare system. This is an important flashback prevention device but should never be the only line of defense to mitigate a flashback. MRW uses detonation arrestors approved by the US Coast Guard. In some situations, a liquid seal with a fluid barrier can be used in lieu of a detonation arrestor to keep air from penetrating the flare header. |
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Control/Ignition System
MRW can design our control systems to meet any electrical classification. Our control systems utilize state-of-the-art design techniques and technology to obtain optimum service potential. If you have a preference as to what type/brand of control system, we are happy to accommodate your needs. The control system automatically purges the combustor, completes flare permissives, ignites the pilot, initiates the blower, and enriches the waste gas stream. The control system has several safety shutdowns indicating an error in the system operation. MRW flare systems are designed for numerous safety and shutdown precautions. Our systems will detect and shutdown if the following situations occur:
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Knockout Drum (Optional)
Knockout drums are provided in situations where liquid separation is likely in the waste stream. The knockout drum will collect any liquids that are present in the waste stream prior to entering the flare system. A knockout drum is especially important if substantial cooling of heavy liquids is expected. If the liquid is corrosive, MRW uses non-corrosive materials of construction. A level gauge and drain connections are built into the knockout drum. |
Optional Equipment
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