Characterization of the incipient smoke point for steam-/air-assisted and nonassisted flares

Flares are important safety devices for pressure relief; at the same time, flares are a significant point source for soot and highly reactive volatile organic compounds (HRVOCs). Currently, simple guidelines for flare operations to maintain high combustion efficiency (CE) remain elusive. This paper fills the gap by investigating the characteristics of the incipient smoke point (ISP), which is widely recognized as the condition for good combustion. This study characterizes the ISP in terms of 100–% combustion inefficiency (CE), percent opacity, absorbance, air assist, steam assist, air equivalence ratio, steam equivalence ratio, exit velocity, vent gas net heating value, and combustion zone net heating value. Flame lengths were calculated for buoyant and momentum-dominated plumes under calm and windy conditions at stable and neutral atmosphere. Opacity was calculated using the Beer–Lambert law based on soot concentration, flame diameter, and mass-specific extinction cross section of soot. The calculated opacity and absorbance were found to be lognormally distributed. Linear relations were established for soot yield versus absorptivity with R² > 0.99 and power-law relations for opacity versus soot emission rate with R² ≥ 0.97 for steam-assisted, air-assisted, and nonassisted flares. The characterized steam/air assists, combustion zone/vent gas heating values, exit velocity, steam, and air equivalence ratios for the incipient smoke point will serve as a useful guideline for efficient flare operations.

Implications: A Recent EPA rule requires an evaluation of visible emissions in terms of opacity in compliance with the standards. In this paper, visible emissions such as soot particles are characterized in terms of opacity at ISP. Since ISP is widely recognized as most efficient flare operation for high combustion efficiency (CE)/destruction efficiency (DE) with initial soot particles formed in the flame, this characterization provides a useful guideline for flare operators in the refinery, oil and gas, and chemical industries to sustain smokeless and high combustion efficiency flaring in compliance with recent EPA regulations, in addition to protecting the environment.