Industrial flares for refineries and hydrogen plants

A flare acts as a last safety element to manage process gases in conditions that do not allow their recovery. Its function is not to “burn for the sake of burning”, but to ensure controlled combustion when the system demands it.

Typical service situations:

• Starts and stops

• Controlled purging and venting

• Maintenance operations

• Relief scenarios and operational contingencies

Hydrogen requires a specific approach due to its high reactivity, low ignition energy and the potential presence of oxygen (for example, in electrolysis-based processes).

Our flare systems are designed for:

• Hydrogen production facilities (electrolysis or pyrolysis routes).
• Purges, start-ups, shutdowns and maintenance operations.
• Streams containing H₂/O₂ mixtures.

Upstream of the flare, the system can include flow and composition measurement. Where oxygen is in excess, controlled methane injection can be incorporated to balance the mixture and maintain stable, safe combustion.

Depending on project scope and plant philosophy, a flare package may include, in addition to the flare stack/enclosure:

• Flare tip and flame stabilisation devices
• A barrier between the process relief header and the flare (as required by the applicable standard)
• Ignition system and flame detection
• Instrumentation and associated control elements
• Utilities where applicable (for example, steam-assisted operation)

The safety configuration is defined against the applicable codes and project specification. It typically covers:

• Ignition and flame monitoring systems
• Instrumentation and electrical equipment suitable for hazardous areas (ATEX/DSEAR as applicable)
• Design aligned with relevant EN / ASME requirements (and other codes where specified)
• A complete technical dossier prepared for HAZOP, integrity reviews and safety audits

In refining, chemicals or hydrogen, flares are not selected from a catalogue. They are validated by engineering, process safety and compliance. That is why we start early with clear design criteria, integration requirements and documentation ready for internal reviews (including HAZOP).

What we bring:

• Single-scope engineering and supply: flare system design, selection of arrangement (elevated or enclosed) and integration with the relief header and utilities.
• Designed for real operating conditions: stable combustion across variable flows/compositions, solutions for low-calorific-value gases and hydrogen services.
• Process safety and compliance: hazardous-area considerations, safety barriers, ignition/detection logic, and thermal radiation/noise assessment per site constraints.
• A technical package for engineering and procurement: design basis, calculations, drawings and documentation to speed up internal approvals, audits and bid cycles.
• Industrial and international experience: projects in sectors with demanding availability, safety and emissions expectations.

Flare performance depends on gas–air mixing quality, flame stability and operating conditions. Design targets the most complete combustion achievable, considering gas composition, flow variability and environmental requirements.

Operational factors that influence design include:

• CO: typically linked to insufficient mixing or uneven air distribution
• NOₓ: depends on flame temperature, composition and operation; addressed in the design where requirements apply

For elevated flares, the flare tip and configuration (single/multi-tip, assisted operation where required) are critical to stability and combustion quality.

When the gas has a low heating value, flame stability can be compromised. In these cases, the flare can be designed to operate with support gas to ensure reliable ignition and sustained combustion.

This enables safe, controlled handling of low-calorific-value streams, defining from the outset the stabilisation strategy and operational requirements.

A flare should not be treated as an isolated piece of equipment, but as a plant system governed by real operating conditions. From early phases we incorporate process, safety and site constraints to deliver a solution that is installable, operable and maintainable.

Depending on project needs, this approach can include coordination of structures and associated pipework to ensure mechanical integrity and compatibility with the existing installation.

Scope is project-specific, but to accelerate technical definition and reduce iterations we work with a deliverables set focused on engineering and safety validation:

• Design basis and scenario definition (normal, minimum, maximum and relief cases)
• Selection of flare type and siting criteria (radiation, noise, visual impact)
• Sizing and combustion criteria (flame stability, gas–air mixing, assisted operation where applicable)
• Plant integration and relief header interfaces: key tie-ins, layout/space envelope and integration constraints aligned with plant philosophy
• Documentation for internal review: design basis, main criteria, agreed drawings and a technical data list/specification sheets (including HAZOP support where applicable)

Describe your situation and your concerns. We will get back to you within 48 hours to align on a flare solution that fits your operation and site requirements.