New Technology: Saudi Aramco High Pressure Air Assist System (HPAAS) - - PowerPoint PPT Presentation

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New Technology: Saudi Aramco High Pressure Air Assist System (HPAAS) - - PowerPoint PPT Presentation

Sep 10, 2023 208 likes •676 views

New Technology: Saudi Aramco High Pressure Air Assist System (HPAAS) for Upgrading Existing Flares to Smokeless Combustion 2009 ZEECO, INC. World Flaring 2009 ZEECO, INC. Source:: US Government Accountability Office World Flaring

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 2009 ZEECO, INC.

New Technology: Saudi Aramco High Pressure Air Assist System (HPAAS) for Upgrading Existing Flares to Smokeless Combustion

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 2009 ZEECO, INC.

Source:: US Government Accountability Office

World Flaring

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 2009 ZEECO, INC.

Source:: US Government Accountability Office

World Flaring

Source: A Twelve Year Record of National and Global Gas Flaring Volumes Estimated Using Satellite Data Final Report to the World Bank - May 30, 2007

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 2009 ZEECO, INC.

Utility Flares

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 2009 ZEECO, INC.

  • Low Exit Velocity leads to:

 Smoke  Flame Pulldown  Shorter Tip Life  Higher Radiation Levels

 Flame Lean  Higher Flame Emissive Value

Utility Flares - Drawbacks

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 2009 ZEECO, INC.

Utility Flares – Smoke

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 2009 ZEECO, INC.

Utility Flares – Smoke

Poor Public Perception

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 2009 ZEECO, INC.

Utility Flares – Flame Pulldown

Crack due to heat

WIND WIND

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 2009 ZEECO, INC.

Utility Flares – Higher Radiation Levels

WIND

HIGH EXIT VELOCITY FLAME LOW EXIT VELOCITY FLAME

WIND

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 2009 ZEECO, INC.

  • Hundreds of flare systems in operation.
  • Most Aramco systems are utility flares

Solution Needed for Saudi Aramco’s Utility Flares

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 2009 ZEECO, INC.

  • Criteria for ideal solution:

 Easy retrofit to existing flares with minimal installation

time

 Robust design  Low installation and capital cost  Low utility costs for operation

Solution Needed for Saudi Aramco’s Utility Flares

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 2009 ZEECO, INC.

  • Analysis of Existing Technology

 Steam-Assisted Flares  High-Pressure Sonic Flares  Low-Pressure Air Assisted Flares

Solution Needed for Saudi Aramco’s Utility Flares

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 2009 ZEECO, INC.

Existing Technology: Steam Assist

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 2009 ZEECO, INC.

  • Inject steam into combustion zone
  • Steam entrains surrounding air
  • Smokeless Operation
  • Minimal Flame Pulldown
  • Low Radiation
  • DRAWBACKS:

 No Steam Available  Expensive Water

Existing Technology: Steam Assist

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 2009 ZEECO, INC.

Existing Technology: HP Sonic Flare

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 2009 ZEECO, INC.

  • Use the pressure in the flare gas to achieve a high exit

velocity

  • High velocity flare gas entrains surrounding air
  • Smokeless Operation
  • Minimal Flame Pulldown
  • Low Radiation
  • DRAWBACKS:

Most Saudi Aramco facilities were designed with low pressure relief systems

Existing Technology: HP Sonic Flare

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 2009 ZEECO, INC.

Existing Technology: Low Pressure Air Assist

GAS PLENUM AIR PLENUM

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 2009 ZEECO, INC.

  • Use a low-pressure blower to inject

additional combustion air

  • Assist air entrains some air from the

surroundings

  • Smokeless Operation
  • Minimal Flame Pulldown
  • Low Radiation
  • DRAWBACKS:

Poor retrofit for existing flares because the air duct is so large.

Loss of cooling air exponentially reduces service life of flare tip.

Existing Technology: Low Pressure Air Assist

GAS RISER AIR DUCT AIR BLOWER

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 2009 ZEECO, INC.

  • High Pressure Air Assist System
  • Developed and tested at Saudi

Aramco’s facilities

  • Invented by Mazen Mashour of

Saudi Aramco

  • Patented Technology

Saudi Aramco Solution: HPAAS

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 2009 ZEECO, INC.

Saudi Aramco Solution: HPAAS

Compressed Air Buffer Tank Air Control System

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 2009 ZEECO, INC.

HPAAS Animation

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 2009 ZEECO, INC.

HPAAS Flare Tip Components

High Pressure Air Line Air Injection Manifold Windshield Flare Tip Barrel

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 2009 ZEECO, INC.

  • Quick and Easy Retrofit
  • Robust Design
  • Minor Impact to Existing Flare

Structures

HPAAS Advantages

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 2009 ZEECO, INC.

  • Flare tip bolts in place
  • 3” or 4” air supply line added to flare stack
  • Air compressor can ship as a modular unit
  • Average installation time

3 DAYS

HPAAS Advantages: Quick and Easy Retrofit

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 2009 ZEECO, INC.

Low-Pressure Air Assist Flare Design HPAAS Flare Design

HPAAS Advantages: Robust Design

Flare tip damage due to loss of cooling air. HPAAS tip can be operated for long periods

  • f time with NO cooling air.
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 2009 ZEECO, INC.

HPAAS Advantages: Minor Impact to Existing Flare Structure

Low-Pressure Air Assist Flare Design HPAAS Flare Design Air Duct Flare Gas Riser Air Line

To Air Supply

New Guy Wires and Foundations

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 2009 ZEECO, INC.

  • Gold Medal at 2006 Saudi Inventors Convention
  • Excellent Achievement Award from the

Malaysian Association of Research Scientists in 2006

  • Gold Award and 2nd Place Overall at Geneva's

34th International Inventors' Conference in 2006

  • Winner of 2007 Arab Thought Foundation’s

Innovation Award

HPAAS Awards

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 2009 ZEECO, INC.

  • Upgrade Twenty-nine (29) Flare Systems in the Saudi

Aramco Southern Area Development

 HPAAS Smokeless Flare System Upgrades  CFD Modeling  Combustion Testing  New Flare Pilots  New FFG Ignition Systems  Retractable Thermocouples

Zeeco Southern Area Smokeless Upgrade Project

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 2009 ZEECO, INC.

  • Key Design Parameters Provided by Saudi Aramco

HPAAS Design Verification

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 2009 ZEECO, INC.

Testing & CFD Modeling – Supersonic Nozzles

Mach Number

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CFD Modeling – Cold Flow Modeling for System Layout

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CFD Modeling – Combustion Model

Without HPAAS Air Assist With HPAAS Air Assist

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Full-Scale Combustion Testing

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 2009 ZEECO, INC.

Full-Scale Combustion Testing

Without HPAAS Air Assist With HPAAS Air Assist

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Full-Scale Combustion Testing

Without HPAAS Air Assist With HPAAS Air Assist

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Full-Scale Combustion Testing: Video

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 2009 ZEECO, INC.

Field Success!!!

Without HPAAS Air Assist With HPAAS Air Assist

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 2009 ZEECO, INC.

Field Success!!!

Without HPAAS Air Assist With HPAAS Air Assist

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Future of HPAAS: Saudi Aramco Licensee Agreement

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 2009 ZEECO, INC.

Future of HPAAS: Zeeco Al-Rushaid Middle East Ltd.

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 2009 ZEECO, INC.

Future of HPAAS: Advantages of HPAAS

  • Easy retrofit to existing flares with short installation time
  • Robust design
  • Adaptable to range of conditions
  • Minor impact to existing flare structures
  • Low installation and capital costs
  • Low operating costs
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 2009 ZEECO, INC.

Future of HPAAS: Applications for HPAAS

  • Retrofits to existing flare

systems anywhere

  • New Installations

 Middle East  Russia  Africa  South America  Canada

  • Offshore Platforms / FPSO
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 2009 ZEECO, INC.

Contact Information

  • Zeeco USA Headquarters / Zeeco Al-Rushaid Middle East

– Greg Seefeldt

  • Zeeco Houston – Scott Reed
  • Zeeco Europe – Nigel Palfreeman
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 2009 ZEECO, INC.

Thank You IFRF!!!

  • Questions???
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 2009 ZEECO, INC.  2009 ZEECO, INC.