EP1979677B1 - Longevity and performance improvements to flare tips - Google Patents

Longevity and performance improvements to flare tips Download PDF

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Publication number
EP1979677B1
EP1979677B1 EP07704896A EP07704896A EP1979677B1 EP 1979677 B1 EP1979677 B1 EP 1979677B1 EP 07704896 A EP07704896 A EP 07704896A EP 07704896 A EP07704896 A EP 07704896A EP 1979677 B1 EP1979677 B1 EP 1979677B1
Authority
EP
European Patent Office
Prior art keywords
coating
flare tip
flare
low
burner
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Not-in-force
Application number
EP07704896A
Other languages
German (de)
French (fr)
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EP1979677A1 (en
Inventor
Naiping Zhu
Louis Karambis
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Fosbel Intellectual Ltd
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Fosbel Intellectual Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Fosbel Intellectual Ltd filed Critical Fosbel Intellectual Ltd
Priority to PL07704896T priority Critical patent/PL1979677T3/en
Publication of EP1979677A1 publication Critical patent/EP1979677A1/en
Application granted granted Critical
Publication of EP1979677B1 publication Critical patent/EP1979677B1/en
Not-in-force legal-status Critical Current
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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G7/00—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals
    • F23G7/06—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals of waste gases or noxious gases, e.g. exhaust gases
    • F23G7/08—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals of waste gases or noxious gases, e.g. exhaust gases using flares, e.g. in stacks
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G7/00—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals
    • F23G7/06—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals of waste gases or noxious gases, e.g. exhaust gases
    • F23G7/08—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals of waste gases or noxious gases, e.g. exhaust gases using flares, e.g. in stacks
    • F23G7/085—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals of waste gases or noxious gases, e.g. exhaust gases using flares, e.g. in stacks in stacks
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23M—CASINGS, LININGS, WALLS OR DOORS SPECIALLY ADAPTED FOR COMBUSTION CHAMBERS, e.g. FIREBRIDGES; DEVICES FOR DEFLECTING AIR, FLAMES OR COMBUSTION PRODUCTS IN COMBUSTION CHAMBERS; SAFETY ARRANGEMENTS SPECIALLY ADAPTED FOR COMBUSTION APPARATUS; DETAILS OF COMBUSTION CHAMBERS, NOT OTHERWISE PROVIDED FOR
    • F23M5/00—Casings; Linings; Walls
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23D—BURNERS
    • F23D2900/00—Special features of, or arrangements for burners using fluid fuels or solid fuels suspended in a carrier gas
    • F23D2900/00018—Means for protecting parts of the burner, e.g. ceramic lining outside of the flame tube
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23M—CASINGS, LININGS, WALLS OR DOORS SPECIALLY ADAPTED FOR COMBUSTION CHAMBERS, e.g. FIREBRIDGES; DEVICES FOR DEFLECTING AIR, FLAMES OR COMBUSTION PRODUCTS IN COMBUSTION CHAMBERS; SAFETY ARRANGEMENTS SPECIALLY ADAPTED FOR COMBUSTION APPARATUS; DETAILS OF COMBUSTION CHAMBERS, NOT OTHERWISE PROVIDED FOR
    • F23M2900/00—Special features of, or arrangements for combustion chambers
    • F23M2900/05004—Special materials for walls or lining

Definitions

  • the present invention relates generally to flare tips employed in the petrochemical industry for burning off-gases associated with the production and/or refining of petroleum-based products.
  • the present invention relates to flare tips coated with a low emissivity (low-E) material so as to improve the longevity and performance thereof.
  • low-E low emissivity
  • Flare tips are notoriously well known in the petroleum industry and are used typically to burn off-gases associated with petroleum production and/or refining. US 7 247 016 describes such a flare tip. Flare tips are therefore exposed to direct flame during their service life which can of course be quite damaging. As a result, flare tips need to periodically be taken out of service and refurbished which adds to production costs.
  • EP 0,139,353 (A1 ) describes an improved burner which is suitable for use in a ground flare.
  • the present invention is directed to applying a low emissivity (low-E) coating onto flare tips to achieve longer flare tip service life, improved flare tip structural integrity and/or a more stable flame pattern under a wide range of operating conditions.
  • low-E coatings may be applied to the flare tip burner as well as associated internal and/or external component surfaces to reduce direct flame radiation and also conductive heat transfer.
  • the low-E coating material has an emissivity of less than about 0.80, preferably between about 0.20 to about 0.78.
  • the coating thickness of the low-E material is preferably between about 0.0254 mm (1 mil) to about 0.635 mm (25 mils), and more preferably between about 0.0508 mm (2 mils) to about 0.2032 mm (8 mils).
  • Coating densities of the low-E material in the coating will preferably be at least about 65%, more preferably between about 80% to about 100%.
  • the improved flare tips in accordance with the present invention therefore result in significantly less deformation and distortion of the flare tip burner as well as its associated internal and/or external components thereby prolonging its useful service life.
  • the low-E ceramic coatings of the present invention will also provide enhanced corrosion and oxidation resistance and further improve the longevity of the flare tip burner as well as its associated internal and/or external components.
  • FIGURE 1 is a perspective view of an exemplary flare tip in accordance with the present invention.
  • a low emissivity (low-E) coating material is applied to the flare tip burner as well as associated internal and/or external component surfaces to reduce direct flame radiation and also conductive heat transfer.
  • An exemplary flare tip 10 is depicted in accompanying FIGURE 1 as having a flare barrel 12 which terminates in a baffled burner element 14.
  • Flame stabilization tabs 16 are provided at circumferentially spaced-apart locations about the burner element 14 so as to ensure stable and high efficiency flaring through a range of gas flows.
  • all exterior and interior surfaces of the flare tip 10 which may have exposure to the flame and its attendant radiation are coated with a low-E ceramic material. Coated structures therefore include, for example, at least an upper portion of the flare barrel 12, the burner element 14, and/or the stabilization tabs 16.
  • the emissivity (E) of a material is meant to refer to a unitless number measured on a scale between zero (total energy reflection) and 1.0 (a perfect “black body” capable of total energy absorption and re-radiation).
  • a relatively low emissivity (low-E) is meant to refer to coating materials having an emissivity of less than about 0.80, and especially materials having an emissivity of between about 0.20 to about 0.78.
  • one presently preferred low-E ceramic coating includes CERAK M700 ceramic coating commercially available form Cetek, Ltd..of Berea, Ohio, having an emissivity of about 0.75.
  • Coating thicknesses of the low-E ceramic coating material are not critical but will vary in dependence upon the desired resulting thermal flux and/or the particular material forming the coating. Thus, coating thicknesses of from about 0.0254 mm (1 mil) to about 0.635 mm (25 mils), usually about 0.0508 mm (2 mils) to about 0.2032 mm (8 mils) may be appropriate. Coating densities will typically be greater than about 65%, more specifically 80% or greater. Coating densities will typically be greater than about 65%, more specifically 80% or greater, including up to 100%. By “coating density” is meant the amount (wt.%) of the low-E ceramic coating material that is present in the coating.
  • the low-E coating material may be applied to flare tip components in any conventional manner.
  • the low-E coating material may thus be applied to the flare tip components via any pressurized spray system while the flare tip is being manufactured or while off-line (i.e., is not at its operational temperatures) during refurbishment.
  • a high temprerature low-emissivity coating (CETEK M720 high-temperature ceramic coating having an emissivity value of about 0.75) was applied to a flare tip manufactured by Callidus Technologies LLC.
  • the low-E coating utilized a non-toxic, non-flammable carrier, with a high temperature ceramic binder and was sprayed onto the flare tip structures to be exposed to direct flame during operation by conventional spray equipment.
  • the sprayed coating was thereafter allowed to dry in air for 4 hours and cured at 815 °C (1500°F). After curing, the coating on the flare tip surfaces exhibited a thickness of about 3 mils at a coating density of the low-E material of about 100%.
  • the coating was intended to provide excellent thermal barrier protection, oxidation and corrosion resistance to metallic substrates at elevated temperatures up to 1315 °C (2400°F), as well as a reduction in warpage, stress corrosion cracking, and alloy leaching.
  • the coating also was intended to provide uniform heat distribution for enclosed flare systems.
  • the flare tip with the low-E coating material applied thereto was placed into service to burn off-gases. After approximately six months of continuous operation, the condition of the coated flare tip surfaces was visually inspected and determined to be satisfactory indicating that the coating material provided protection against the direct flame during flare tip operation.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Environmental & Geological Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Incineration Of Waste (AREA)
  • Surface Treatment Of Glass (AREA)

Description

    FIELD OF THE INVENTION
  • The present invention relates generally to flare tips employed in the petrochemical industry for burning off-gases associated with the production and/or refining of petroleum-based products. In especially preferred forms, the present invention relates to flare tips coated with a low emissivity (low-E) material so as to improve the longevity and performance thereof.
    • BACKGROUND AND SUMMARY OF THE INVENTION
  • Flare tips are notoriously well known in the petroleum industry and are used typically to burn off-gases associated with petroleum production and/or refining. US 7 247 016 describes such a flare tip. Flare tips are therefore exposed to direct flame during their service life which can of course be quite damaging. As a result, flare tips need to periodically be taken out of service and refurbished which adds to production costs.
  • It would therefore be highly desirable if the service life of flare tips could be extended. It would also be especially desirable if the performance characteristics of flare tips could be enhanced. It is towards fulfilling such needs that the present invention is directed.
  • EP 0,139,353 (A1 ) describes an improved burner which is suitable for use in a ground flare.
  • US 6,626,663 (B1 ) teaches solutions to establish a more equal heat flux distribution about an entirety of an exterior circumferential surface region of a process tube as compared to the heat flux distribution thereabout in the absence of a coating.
  • Broadly, the present invention is directed to applying a low emissivity (low-E) coating onto flare tips to achieve longer flare tip service life, improved flare tip structural integrity and/or a more stable flame pattern under a wide range of operating conditions. In accordance with some embodiments of the present invention, low-E coatings may be applied to the flare tip burner as well as associated internal and/or external component surfaces to reduce direct flame radiation and also conductive heat transfer.
  • In accordance with some embodiments of the invention, the low-E coating material has an emissivity of less than about 0.80, preferably between about 0.20 to about 0.78. The coating thickness of the low-E material is preferably between about 0.0254 mm (1 mil) to about 0.635 mm (25 mils), and more preferably between about 0.0508 mm (2 mils) to about 0.2032 mm (8 mils). Coating densities of the low-E material in the coating will preferably be at least about 65%, more preferably between about 80% to about 100%.
  • The improved flare tips in accordance with the present invention therefore result in significantly less deformation and distortion of the flare tip burner as well as its associated internal and/or external components thereby prolonging its useful service life. The low-E ceramic coatings of the present invention will also provide enhanced corrosion and oxidation resistance and further improve the longevity of the flare tip burner as well as its associated internal and/or external components.
  • These and other aspects and advantages will become more apparent after careful consideration is given to the following detailed description of the preferred exemplary embodiments thereof.
    • BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
  • Reference will hereinafter be made to the accompanying drawings, wherein like reference numerals throughout the various FIGURES denote like structural elements, and wherein;
  • FIGURE 1 is a perspective view of an exemplary flare tip in accordance with the present invention.
    • DETAILED DESCRIPTION OF PREFERRRED EMBODIMENTS
  • According to a presently preferred embodiment of the present invention, a low emissivity (low-E) coating material is applied to the flare tip burner as well as associated internal and/or external component surfaces to reduce direct flame radiation and also conductive heat transfer. An exemplary flare tip 10 is depicted in accompanying FIGURE 1 as having a flare barrel 12 which terminates in a baffled burner element 14. Flame stabilization tabs 16 are provided at circumferentially spaced-apart locations about the burner element 14 so as to ensure stable and high efficiency flaring through a range of gas flows. According to especially preferred embodiments of the present invention, all exterior and interior surfaces of the flare tip 10 which may have exposure to the flame and its attendant radiation are coated with a low-E ceramic material. Coated structures therefore include, for example, at least an upper portion of the flare barrel 12, the burner element 14, and/or the stabilization tabs 16.
  • As used herein, the emissivity (E) of a material is meant to refer to a unitless number measured on a scale between zero (total energy reflection) and 1.0 (a perfect "black body" capable of total energy absorption and re-radiation). According to the present invention, a relatively low emissivity (low-E) is meant to refer to coating materials having an emissivity of less than about 0.80, and especially materials having an emissivity of between about 0.20 to about 0.78.
  • Virtually any commercially available low-E coating material may be employed satisfactorily in the practice of the present invention. For example, one presently preferred low-E ceramic coating includes CERAK M700 ceramic coating commercially available form Cetek, Ltd..of Berea, Ohio, having an emissivity of about 0.75.
  • Coating thicknesses of the low-E ceramic coating material are not critical but will vary in dependence upon the desired resulting thermal flux and/or the particular material forming the coating. Thus, coating thicknesses of from about 0.0254 mm (1 mil) to about 0.635 mm (25 mils), usually about 0.0508 mm (2 mils) to about 0.2032 mm (8 mils) may be appropriate. Coating densities will typically be greater than about 65%, more specifically 80% or greater. Coating densities will typically be greater than about 65%, more specifically 80% or greater, including up to 100%. By "coating density" is meant the amount (wt.%) of the low-E ceramic coating material that is present in the coating.
  • The low-E coating material may be applied to flare tip components in any conventional manner. The low-E coating material may thus be applied to the flare tip components via any pressurized spray system while the flare tip is being manufactured or while off-line (i.e., is not at its operational temperatures) during refurbishment.
  • The present invention will be further understood from the following non-limiting Example.
    • EXAMPLE
  • A high temprerature low-emissivity coating (CETEK M720 high-temperature ceramic coating having an emissivity value of about 0.75) was applied to a flare tip manufactured by Callidus Technologies LLC. The low-E coating utilized a non-toxic, non-flammable carrier, with a high temperature ceramic binder and was sprayed onto the flare tip structures to be exposed to direct flame during operation by conventional spray equipment. The sprayed coating was thereafter allowed to dry in air for 4 hours and cured at 815 °C (1500°F). After curing, the coating on the flare tip surfaces exhibited a thickness of about 3 mils at a coating density of the low-E material of about 100%. The coating was intended to provide excellent thermal barrier protection, oxidation and corrosion resistance to metallic substrates at elevated temperatures up to 1315 °C (2400°F), as well as a reduction in warpage, stress corrosion cracking, and alloy leaching. The coating also was intended to provide uniform heat distribution for enclosed flare systems.
  • The flare tip with the low-E coating material applied thereto was placed into service to burn off-gases. After approximately six months of continuous operation, the condition of the coated flare tip surfaces was visually inspected and determined to be satisfactory indicating that the coating material provided protection against the direct flame during flare tip operation.
  • While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims.

Claims (14)

  1. A method of improving service longevity and performance of a flare tip (10) comprising applying a coating comprised of a low emissivity (low-E) material, the low-E coating material having an emissivity of less than about 0.80, to one or more component surfaces of the flare tip (10) so as to reduce direct flame radiation and conductive heat transfer during flare tip operation.
  2. Method as in claim 1, wherein the coating is applied to surfaces of a flare barrel (12), a burner element (14) and/or a stabilization tab (16) of the flare tip (10).
  3. Method as in claim 1 or 2, wherein the surface(s) to which the coating is applied are exposed to a direct flame during flare tip operation.
  4. Method as in any preceding claim, wherein the flare tip (10) includes a flare tip burner, and wherein the method comprising applying the coating to the burner.
  5. Method as in claim 4 further comprising applying the coating to internal and/or external components of the flare tip (10) other than the burner.
  6. Method as in any preceding claim, wherein the coating of the low-E material has a thickness of between about 0.0254 mm (1 mil) to about 0.635 mm (25 mils).
  7. Method as in any preceding claim, wherein the low-E material is present in the coating at a density of at least about 65%.
  8. A flare tip which comprises a coating on one or more component surfaces thereof comprised of a low-emissivity (low-E) material, wherein the low-E coating material has an emissivity of less than about 0.80.
  9. A flare tip (10) as in claim 8, wherein the flare tip (10) comprises a flare barrel (12), a burner element (14) and at least one stabilization tab (16), and wherein the coating is applied to surfaces of at least one of the flare barrel (12), the burner element (14) and the stabilization tab (16).
  10. A flare tip (10) as in claim 8 or 9, wherein the coating is on surfaces of the flare tip (10) which are exposed to a direct flame during flare tip operation.
  11. A flare tip (10) as in any one of claims 8 to 10, wherein the flare tip (10) includes a flare tip burner, and wherein the coating is applied to the burner.
  12. A flare tip (10) as in claim 11, wherein the coating is applied to internal and/or external components of the flare tip other than the burner.
  13. A flare tip (10) as in any one of claims 8 to 12, wherein the coating of the low-E material has a thickness of between about 0.0254 mm (1 mil) to about 0.635 mm (25 mils).
  14. A flare tip (10) as in any one of claims 8 to 13, wherein the low-E material is present in the coating at a density of at least about 65%.
EP07704896A 2006-01-27 2007-01-12 Longevity and performance improvements to flare tips Not-in-force EP1979677B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PL07704896T PL1979677T3 (en) 2006-01-27 2007-01-12 Longevity and performance improvements to flare tips

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US76253106P 2006-01-27 2006-01-27
PCT/GB2007/000068 WO2007085793A1 (en) 2006-01-27 2007-01-12 Longevity and performance improvements to flare tips

Publications (2)

Publication Number Publication Date
EP1979677A1 EP1979677A1 (en) 2008-10-15
EP1979677B1 true EP1979677B1 (en) 2012-10-10

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EP07704896A Not-in-force EP1979677B1 (en) 2006-01-27 2007-01-12 Longevity and performance improvements to flare tips

Country Status (16)

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US (1) US20070238058A1 (en)
EP (1) EP1979677B1 (en)
JP (1) JP5066103B2 (en)
KR (1) KR20080098383A (en)
CN (1) CN101375102A (en)
AR (1) AR059208A1 (en)
AU (1) AU2007209180B2 (en)
BR (1) BRPI0707271A2 (en)
CA (1) CA2637943A1 (en)
DK (1) DK1979677T3 (en)
ES (1) ES2396997T3 (en)
PL (1) PL1979677T3 (en)
PT (1) PT1979677E (en)
RU (1) RU2433346C2 (en)
WO (1) WO2007085793A1 (en)
ZA (1) ZA200806553B (en)

Cited By (2)

* Cited by examiner, † Cited by third party
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US9816705B2 (en) 2014-11-18 2017-11-14 Honeywell International Inc. Flare burner for a combustible gas
US10598375B2 (en) 2016-11-01 2020-03-24 Honeywell International Inc. Asymmetrical and offset flare tip for flare burners

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WO2021055813A1 (en) 2019-09-18 2021-03-25 Emisshield Inc. Flare tips

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9816705B2 (en) 2014-11-18 2017-11-14 Honeywell International Inc. Flare burner for a combustible gas
US10598375B2 (en) 2016-11-01 2020-03-24 Honeywell International Inc. Asymmetrical and offset flare tip for flare burners
US11105508B2 (en) 2016-11-01 2021-08-31 Honeywell International Inc. Asymmetrical and offset flare tip for flare burners

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Publication number Publication date
PT1979677E (en) 2013-01-07
AU2007209180A1 (en) 2007-08-02
BRPI0707271A2 (en) 2011-04-26
RU2433346C2 (en) 2011-11-10
CA2637943A1 (en) 2007-08-02
PL1979677T3 (en) 2013-02-28
RU2008134888A (en) 2010-03-10
US20070238058A1 (en) 2007-10-11
AR059208A1 (en) 2008-03-19
AU2007209180B2 (en) 2011-11-24
WO2007085793A1 (en) 2007-08-02
EP1979677A1 (en) 2008-10-15
ZA200806553B (en) 2009-11-25
JP2009524795A (en) 2009-07-02
ES2396997T3 (en) 2013-03-01
KR20080098383A (en) 2008-11-07
DK1979677T3 (en) 2013-01-14
CN101375102A (en) 2009-02-25
JP5066103B2 (en) 2012-11-07

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