Flare Gas Recovery Compression Solutions

Flare systems provide a controlled disposal route for gases released during normal operation, start-up, shutdown, process disturbances and emergency relief events. Where suitable gas streams are sent to the flare header during routine operation, they may be recovered before reaching the flare.

A flare gas recovery compressor withdraws gas from the flare header and increases its pressure for further use. Depending on the plant configuration and gas quality, the recovered stream may be returned to the process, supplied to a fuel-gas system or routed to another treatment facility.

Flare gas flow, composition and suction pressure can vary considerably between operating cases. Streams may contain hydrocarbons, hydrogen, carbon dioxide, nitrogen, Hydrogen Sulfide (H₂S) and other gas mixtures. Condensable components, liquids, contaminants and corrosive substances must be identified when engineering the compression system.

Reliable control is required to recover available gas without interfering with flare-header pressure or the safety function of the flare. The compressor package must therefore be coordinated with upstream liquid separation, capacity control, downstream processing and the plant’s flare and relief-system design.

With more than 80 years of experience in reciprocating high pressure compressor technology, LMF develops tailor-made compressor solutions for flare gas recovery. Every solution is individually engineered according to the complete gas composition, expected flow range, suction conditions, required discharge pressure and applicable project specifications.

Recommended Compression Solutions by LMF

ISO 13631 Compressors

Recommended for continuous flare gas recovery applications requiring flexible capacity control, stable operation and project-specific package engineering.

  • Capacity:
    up to 15 100 Nm³/h
  • Pressure:
    up to 301 bar
  • Power consumption:
    6 MW

API 618 Compressors

Recommended for demanding heavy-duty flare gas recovery systems requiring high availability, continuous operation and project-specific engineering according to API 618.

  • Capacity:
    up to 27 000 Nm³/h
  • Pressure:
    up to 200 bar
  • Power consumption:
    6 MW

Selected References 

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Enter the gas compositions, minimum and maximum flow rates, suction and discharge pressures, temperatures and operating cases to estimate key process values, pre-select a suitable LMF compressor model and generate an inquiry for our experts.

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FAQs

Flare gas recovery captures suitable gas from a flare header and recompresses it for further processing or use. Depending on its composition, the recovered gas may be returned to the process, used as fuel gas or routed to another treatment system.

No. The flare remains an essential safety system for process upsets, emergency relief and gas quantities beyond the capacity or operating range of the recovery system. Flare gas recovery is primarily designed for specified recoverable streams and operating cases.

Flow rate, gas composition, molecular weight and suction pressure can change considerably. The stream may also contain liquids, corrosive components or contaminants. The compressor and capacity-control system must be designed for the complete specified operating range.

Not automatically. Recoverability depends on gas composition, available flow and pressure, contamination, downstream specifications and economic and safety considerations. Emergency relief flows are generally not sized as normal recovery duties.

Initial engineering requires gas analyses for all relevant operating cases, minimum and maximum flow rates, flare-header pressure range, required discharge pressure, temperatures, potential liquid carryover, contaminants and the intended destination of the recovered gas.