Retrofits and Upgrades

Thermal Oxidizer Retrofits

Flare System Retrofits

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Replacement Flare Tips, Parts, Flare Stacks and Service


Complete System Evaluation
  • Review original design requirements and specifications
  • Size and type of stack and flare tip
  • Evaluate flare tip design, flare type, size, and flare tip configuration if multiple-tip
  • Oxygen and fuel requirements
  • Review all other necessary design elements relating to cause of problems
  • Ensure all design criteria meets 40CFR 60.18 for flare design criteria

Why Retrofit or Refurbish a Flare Tip or Flare Stack?

Because New Flare Technologies can improve flare and plant performance. Recent technology innovations and improvements include:
  • Better ignition systems
  • Improved smokeless capacity
  • Increased fuel efficiency
  • Increased flare tip capacity
  • Safety considerations


Flare Tip and Flare Stack System Retrofit Examples
  • Flare tip replacement and flare parts
  • Flare tip refurbishment
  • Flare stack replacements: self-supported flare stacks, Guyed flare stacks, Derrick flare stacks
  • Purge reduction replacement, improvement, or modification: molecular seals, water seals, air lock seals, static seals, velocity seals
  • Replacement pilots w/energy-efficient pilots
  • Ignition systems
  • Flare gas recovery
  • Refurbish and upgrade old McGill flares and John Zink flares
  • Mass tuned dampeners


Flare Tip Velocity: actual operating design of all flare tips must be determined and compared to expected maximum flow rates.

Existing PSV (Header) Design:
  • Review all pressure relief devices to make sure they are still the same as originally specified for the flare system
  • Also review for addition of PSVs since original installation

Waste Gas Stream: flowing to the flare should be reviewed to determine if they must be aligned to the flare, or if they could possibly be diverted to other abatement devices, eliminated or recovered.

Ignition Systems:
  • Increased reliability
  • Electric ignition systems
  • Flame front backup
  • Improved thermocouple life
Improved Smokeless Capacity:
  • Lower steam consumption
  • Quieter flare tips
  • Invisible flaring

Increased Fuel Efficiency:
  • New purge devices reduce natural gas consumption
  • Low gas consumption pilots
  • Pulse purge systems

Increased Flare Capacity:
  • Additional streams
  • Larger flares
  • Multi-tip flare systems or flare tips


Flare Gas Recovery

Advantages:
  • 100% recovery
  • No emissions
  • No visible flames
  • Reduced natural gas consumption

Disadvantages:
  • Relatively large investment
  • Maintenance
  • No product separation
  • Potential impact on plant gas

Design Considerations:
  • Potentially combustible vapors
  • Varying inlet conditions
  • 3Wide variety of compounds/corrosion
  • Liquids removal



Email mrw@mrw-tech.com for a quote for your retrofit needs.






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MRW Technologies, Inc.
2301 West 171st Street S | Glenpool | OK | 74033
PH: 918.827.6030 | FX: 918.827.6034 | EM: mrw@mrw-tech.com
Web: www.mrw-tech.com