BURNER FLARE TIP

Abstract

Provided is a flare tip. The flare tip, according to one embodiment, includes a flare tip enclosure. The flare tip, according to this embodiment, additionally includes two or more flare tip arms extending from the flare tip enclosure, wherein the two are more flare tip arms are largely equidistance from one another, and two or more flare tip orifices located in each of the two or more flare tip arms.

Description

TECHNICAL FIELD

This application is directed, in general, to a burner flare tip and, more specifically, to a burner flare tip having a plurality of spaced apart flare tip arms.

BACKGROUND

Flaring is a high temperature oxidation process used to burn combustible components, mostly hydrocarbons, of waste gases from industrial operations. Natural gas, propane, ethylene, propylene, butadiene and butane constitute over 95% of the waste gases flared. Flares are used extensively to dispose of (1) purged and waste products from refineries, (2) unrecoverable gases emerging from oil and gas well instillation, (3) vented gases from blast furnaces, (4) unused gases from coke ovens, and (5) gaseous wastes from chemical industries.

There are generally two types of flares, elevated and ground flares. Elevated flares include a flare riser, which can extend from a few feet to several hundred feet above the ground to a flare tip from which the waste gases exit. A waste gas stream is fed through the riser and is combusted at the flare tip. A typical elevated flare system consists of (1) a gas collection header and piping for collecting gases from processing units, (2) a knockout drum (disentrainment drum) to remove and store condensables, entrained liquids and particulates, (3) a flare stack riser, (4) a flare tip, and (5) an igniter e.g., a gas pilot or an electronic igniter, to ignite the mixture of waste gas and air.

What is needed in the art is a new flare tip that does not experience the drawbacks of prior art flare tips.

BRIEF DESCRIPTION

Reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:

FIG. 1 illustrates a flare tip manufactured and designed according to the disclosure;

FIG. 2 illustrates a top down view of the flare tip illustrated in FIG. 1;

FIG. 3 illustrates an enlarged view of the flare tip enclosure and a single flare tip arm illustrated in FIGS. 1 and 2;

FIG. 4 illustrates an alternative embodiment of a flare tip manufactured and designed according to the disclosure; and

FIGS. 5 to 8 illustrate various different view of a burner assembly manufactured and designed according to the disclosure.

DETAILED DESCRIPTION

Turning initially to FIG. 1, illustrated is a flare tip 100 manufactured and designed according to the disclosure. The flare tip 100 includes a flare tip enclosure 110. One end of the flare tip enclosure 110 could be coupled (e.g., through one or more other enclosures, pipes, tubes, hoses, etc.) to a combustible gas source. In the illustrated embodiment, the other end of the flare tip enclosure 110 could have two or more flare tip arms 120 in fluid communication with and extending outward from the flare tip enclosure 110. The flare tip arms 120 may extend in a variety of different directions from the flare tip enclosure 110 and remain within the purview of the disclosure. Nevertheless, in one certain embodiment the flare tip arms 120 extend radially outward from the flare tip enclosure 110, and are located proximate a tip of the flare tip enclosure 110.

A flare tip 100 according to the disclosure should have at least two flare tip arms 120. In this two flare tip arm 120 embodiment, the flare tip arms 120 are spaced largely equidistance apart from one another. In another embodiment, the flare tip arms 120 are spaced substantially equidistance apart from one another, and in another embodiment the flare tip arms 120 are spaced ideally equidistance apart from one another. The terms “largely equidistance,” “substantially equidistance,” and “ideally equidistance,” as used herein, mean that the flare tip arms 120 are spaced within 10%, 6% and 2%, respectively, of exactly equidistance from one another. Thus, in the embodiment wherein two flare tip arms 120 are used, exactly equidistance would be 180 degrees, ideally equidistance would be from about 178.2 degrees to about 181.8 degrees, substantially equidistance would be from about 174.6 degrees to about 185.4 degrees, and largely equidistance would be from about 171 degrees to about 189 degrees.

In other embodiments, three, four, five, six or more flare tip arms 120 could be used. In such a configuration, the flare tip spacing could approximate:

	Degrees
		Ideally	Substantially	Largely
# Of		Equidistance	Equidistance	Equidistance
Flare	Exactly	Lower	Upper	Lower	Upper	Lower	Upper
Tips	Equidistance	Limit	Limit	Limit	Limit	Limit	Limit
3	120	118.8	121.2	116.4	123.6	114	126
4	90	89.1	90.9	87.3	92.7	85.5	94.5
5	72	71.28	72.72	69.84	74.16	68.4	75.6
6	60	59.4	60.6	58.2	61.8	57	63

While embodiments have been discussed with two, three, four, five and six flare tip arms 120, those skilled in the art understand that additional flare tip arms 120 may be used and remain within the purview of the disclosure. The present disclosure, however, believes that improved results may be achieved when three to six flare tip arms 120 are employed, as such configurations introduce the most oxygen and thus provide the most effective burn for the flare tip 100.

In accordance with one embodiment of the disclosure, each of the two or more flare tip arms 120 are capped at their end, and have two or more flare tip orifices 130. The two or more flare tip orifices 130 may be specifically sized, located and numbered to increase the amount of oxygen to the flare tip 100 combustion process. In accordance with the embodiment shown in FIG. 1, the two or more flare tip orifices 130 may be separated into a proximate group 133 (e.g., those closer to the flare tip enclosure 110) and a distal group 138 (e.g., those closer to the capped end). In this embodiment, the flare tip orifices 130a of the proximate group 133 are positioned at a substantially vertical position (e.g., within 5 degrees of perfect vertical), whereas the flare tip orifices 130b of the distal group 138 are radially offset by an angle (θ) from perfect vertical. The angle (θ) may vary based upon the amount of oxygen that one desires to introduce into the combustion process. In one embodiment, however, the angle (θ) ranges from about 15 degrees to about 75 degrees, and in another embodiment the angle (θ) ranges from about 30 degrees to about 60 degrees. In the illustrated embodiment of FIG. 1, the angle (θ) is about 60 degrees.

In accordance with one embodiment of the disclosure, the proximate group 133 could have at least one, but preferably two or more flare tip orifices 130a, and the distal group 138 could have at least one, but preferably two or more flare tip orifices 130b. In the illustrated embodiment, the proximate group 133 has two flare tip orifices 130a, and the distal group 138 has 10 flare tip orifices 130b (e.g., two sets of five flare tip orifices 130b radially offset by minus 60 degrees and plus 60 degrees, respectfully). In one embodiment, the flare tip orifices 130 are substantially equally sized (e.g., diameter) and spaced. As will be understood further below, in other embodiments, such as that shown, the flare tip orifices 130 are not substantially equally sized or spaced. Other embodiments exist, however, where the sizing and spacing of the flare tip orifices 130 may vary for a given flare tip arm 120, or for that matter amongst different flare tip arms 120.

Turning briefly to FIG. 2, illustrated is a top down view of the flare tip 100 illustrated in FIG. 1. FIG. 2 is particularly useful in seeing that the distal group 138 may be broken into two sets of openings.

Turning briefly to FIG. 3, illustrated is an enlarged view of the flare tip enclosure 110 and a single flare tip arm 120 illustrated in FIGS. 1 and 2. FIG. 3 additionally illustrates the spacing and diameters for the various different features of the flare tip 100. In the illustrated embodiment, the flare tip enclosure 110 has a diameter (D₁) and the flare tip arm 120 has a diameter (D₂). These two diameters may vary depending on the design of the flare tip 100. In one example, the diameter (D₁) ranges from about 10 inches to about 16 inches, and in one specific embodiment from about 12 inches to about 14 inches. In one example, the diameter (D₂) ranges from about 2 inches to about 6 inches, and in another specific embodiment from about 3 inches to about 5 inches.

In the illustrated embodiment, the diameter of the flare tip orifices 130 (D₃, D₄, D₅, D₆, D₇, D₈, D₉) vary as they move away from the flare tip enclosure 110. For example, the diameter of the flare tip orifices 130 (D₃, D₄, D₅, D₆, D₇, D₈, D₉) may incrementally change as they move away from the flare tip enclosure 110. As one example, D₃ could range from about 0.3 to about 0.4 inches (e.g., 0.357 inches in one embodiment), D₄ could range from about 0.42 to about 0.46 inches (e.g., 0.434 inches in one embodiment), D₅ could range from about 0.34 to about 0.38 inches (e.g., 0.353 inches in one embodiment), D₆ could range from about 0.37 to about 0.41 inches (e.g., 0.394 inches in one embodiment), D₇ could range from about 0.42 to about 0.46 inches (e.g., 0.431 inches in one embodiment), D₈ could range from about 0.44 to about 0.48 inches (e.g., 0.465 inches in one embodiment) and D₉ could range from about 0.48 to 0.52 inches (e.g., 0.496 inches in one embodiment). While specific ranges and actual diameters have been described, those skilled in the art understand that other values are within the scope of the disclosure.

In the illustrated embodiment, spacing (S₁) between the center of the flare tip enclosure 130 and the next closest flare tip orifice 130 may vary. In one embodiment, however, the spacing (S₁) ranges from about 8 to about 10 inches, and in one specific embodiment ranges from about 8.5 to about 9.5 inches. Also, the spacing of the flare tip orifices 130 (S₂, S₃, S₄, S₅, S₆, S₇) may vary as they move away from the flare tip enclosure 110. For example, the spacing of the flare tip orifices 130 (S₂, S₃, S₄, S₅, S₆, S₇) may incrementally change (e.g., within the proximate group 133 and distal group 138, and alternatively across the proximate group 133 and distal group 138) as they move away from the flare tip enclosure 110. As one example, S₂ could range from about 3.0 to about 4.0 inches (e.g., 3.5 inches in one embodiment), S₃ could range from about 2.5 to about 3.5 inches (e.g., 3.0 inches in one embodiment), S₄ could range from about 3.5 to about 4.5 inches (e.g., 4.0 inches in one embodiment), S₅ could range from about 3.5 to about 4.5 inches (e.g., 4.0 inches in one embodiment), S₆ could range from about 3.5 to about 4.5 inches (e.g., 4.0 inches in one embodiment), and S₇ could range from about 3.5 to about 4.5 inches (e.g., 4.0 inches in one embodiment). Thus, in the illustrated embodiment, the flare tip orifices 130a are equally spaced and the flare tip orifices 130b are equally spaced, but the flare tip orifices 130b have a greater spacing. While specific ranges and actual spacing have been described, those skilled in the art understand that other values are within the scope of the disclosure.

Turning to FIG. 4, illustrated is an alternative embodiment of a flare tip 400 manufactured and designed according to the disclosure. The flare tip 400 includes the flare tip enclosure 410. The flare tip enclosure 410, in the illustrated embodiment, includes an outer radius (R_a). The outer radius (R_a), in one embodiment, ranges from about 4 inches to about 10 inches, and in one particular embodiment is about 6 inches. The flare tip enclosure 410, in the illustrated embodiment, additionally includes a center hole for safety bypass having a diameter (D_a). The diameter (D_a) may vary and remain within the scope of the disclosure. In one embodiment, the diameter (D_a) ranges from about 6 inches to about 10 inches, and in one particular embodiment ranges from about 7.5 inches to about 8.5 inches.

Extending from the flare tip enclosure 410 in the embodiment of FIG. 4 are six flare tip arms 420. Each of the flare tip arms 420 may have a diameter (D_b). The diameter (D_b) of the flare tip arms 420 may vary according to different embodiments of the disclosure. In certain embodiments, the diameter (D_b) ranges from about 2 inches to about 6 inches, and in one more specific embodiment from about 3 inches to about 5 inches. Each of the six flare tip arms 420 additionally includes a plurality of flare tip orifices 430. In the particular embodiment of FIG. 4, the flare tip orifices 430 increase in diameter (D) (e.g., sequentially, or as part of a group) as they move away from the flare tip enclosure 410. In this instance, diameters (D_c, D_d) have similar diameters, diameters (D_e, D_f, D_g) have similar diameters but larger than diameters (D_c, D_d), and diameter (D_h) has a larger diameter than diameters (D_e, D_f, D_g). For example, the diameters (D_c, D_d) could range from about 0.5 to about 1.5 inches, the diameters (D_e, D_f, D_g) could range from about 1.5 to about 2.5 inches, and the diameter (D_h) could range from about 2.0 to about 3.0 inches. While specific ranges and actual diameters/spacing have been described, those skilled in the art understand that other values are within the scope of the disclosure.

The diameters of the openings diameters (D_c, D_d, D_e, D_f, D_g, D_h) in the flare tips may be designed based upon the cross-sectional diameter of the pipe leading to the flare tip arms 420. Thus, in one embodiment, the collective areas of the openings diameters (D_c, D_d, D_e, D_f, D_g, D_h) in the flare tip arms 420 may be plus or minus 20percent of the cross-sectional area of the pipe leading to the flare tip arms 420. In another embodiment, the collective areas of the openings diameters (D_c, D_d, D_e, D_f, D_g, D_h) in the flare tip arms 420 may be plus or minus 10 percent of the cross-sectional area of the pipe leading to the flare tip arms 420. In yet another embodiment, the collective areas of the openings diameters (D_c, D_d, D_e, D_f, D_g, D_h) in the flare tip arms 420 may be plus or minus 5 percent of the cross-sectional area of the pipe leading to the flare tip arms 420.

Turning now to FIGS. 5 to 8, illustrated are different views of a burner assembly 500 designed and manufactured according to the disclosure. The burner assembly 500, in accordance with the disclosure, includes a flare tip 510 (e.g., which may be similar to one or more of the flare tips illustrated in FIGS. 1 to 4 above) positioned within a cylinder 520. The cylinder 520, in this example, may be from about 20 to about 50 feet long, and in a certain embodiment from about 30 feet to about 50 feet long, and in one particular embodiment comprises a metal or metal alloy. The cylinder 520, in one particular embodiment, is open at the top and furthermore includes one or more openings 530 proximate the lower surface thereof. As those skilled in the art appreciate, the openings 530 proximate the lower surface are configured to provide the necessary oxygen for combustion. Accordingly, the openings 530 may be adjusted in size, whether manually adjusted, or automatically adjusted using one or more control systems (e.g., a feedback loop based upon the appropriate burn conditions, as might be employed using a SCADA type system).

The cylinder 520, in the illustrated embodiment, is an insulated cylinder. For example, the cylinder 520 could have one or more different types of insulation positioned along an exterior or interior thereof. In the illustrated embodiment, brick type insulation is positioned along an inner surface of the cylinder 520. The brick type insulation, in this embodiment, is configured to reduce fatigue on the cylinder 520 (e.g., metal cylinder in one embodiment), as well as keep heat from the burning process moving toward an upper surface of the cylinder 520.

In the illustrated embodiment, gas enters the cylinder 520 into the flare tip 510 from a position proximate a bottom surface of the cylinder 520. The flare tip, in this embodiment, is positioned from about 4 to about 15 feet above a base plate 540 of the burner assembly 500. In another embodiment, the flare tip 510 is positioned from about 6 to about 10 feet above the base plate 540. The positioned of the flare tip 510 may be adjusted in certain embodiments. Accordingly, the flare tip 510 may be adjusted in height, whether manually adjusted, or automatically adjusted using one or more control systems (e.g., a feedback loop based upon the appropriate burn conditions, as might be employed using a SCADA type system). Additionally, the burner assembly 500 may have sensor 545 for providing feedback to the control system.

The burner assembly 500, in the illustrated embodiment, further includes a trailer 550 having one or more sets of wheels 560 associated therewith. Additionally, the burner assembly 500 may have one or more lifting means 570 (e.g., electric or hydraulic cylinders in one embodiment) for moving the cylinder 520 from a substantially horizontal state to a substantially vertical state. Accordingly, the burner assembly 500 may be moved from one physical location to another using a combination of the trailer 550, wheels 560 and lifting means 570.

Those skilled in the art to which this application relates will appreciate that other and further additions, deletions, substitutions and modifications may be made to the described embodiments.

Claims

1. A flare tip, comprising: a flare tip enclosure;two or more flare tip arms extending from the flare tip enclosure, wherein the two are more flare tip arms are largely equidistance from one another; andtwo or more flare tip orifices located in each of the two or more flare tip arms.

2. The flare tip as recited in claim 1, wherein the two are more flare tip arms are substantially equidistance from one another.

3. The flare tip as recited in claim 1, wherein the two are more flare tip orifices are ideally equidistance from one another.

4. The flare tip as recited in claim 1, wherein the two are more flare tip arms range from about three to about six flare tip arms.

5. The flare tip as recited in claim 1, wherein the two are more flare tip arms are separated into a proximate group and a distal group.

6. The flare tip as recited in claim 5, wherein the proximate group includes two or more flare tip orifices and the distal group includes two or more flare tip offices.

7. The flare tip as recited in claim 6, wherein the two or more orifices in the proximate group or the two or more orifices in the distal group are substantially vertically positioned.

8. The flare tip as recited in claim 7, wherein the other of the two or more orifices in the distal group or the two or more orifices in the proximate group are radially offset by an angle (θ) from perfectly vertical.

9. The flare tip as recited in claim 8, wherein the two or more orifices in the proximate group are substantially vertically positioned, and the two or more orifices in the distal group are radially offset by the angle (θ).

10. The flare tip as recited in claim 1, wherein diameters of the two or more orifices vary as they move away from the flare tip enclosure.

11. The flare tip as recited in claim 10, wherein the diameters of the two or more orifices increase as they move away from the flare tip enclosure.

12. The flare tip as recited in claim 11, wherein the diameters of the two or more orifices incrementally increase as they move away from the flare tip enclosure.

13. The flare tip as recited in claim 11, wherein the diameters of the two or more orifices incrementally increase as part of groups as they move away from the flare tip enclosure.

14. A burner assembly, comprising: a cylinder; anda flare tip located within the cylinder, the flare tip including: a flare tip enclosure;two or more flare tip arms extending from the flare tip enclosure, wherein the two are more flare tip arms are largely equidistance from one another; andtwo or more flare tip orifices located in each of the two or more flare tip arms.

15. The burner assembly as recited in claim 14, further including a trailer, wherein the cylinder and flare tip are rotatably positioned on the trailer to move from a substantially horizontal position to a substantially vertical position.

16. The burner assembly as recited in claim 15, wherein an electric or hydraulic cylinder moves the cylinder and flare tip from the substantially horizontal position to the substantially vertical position.

17. The burner assembly as recited in claim 14, further including openings located proximate a bottom surface of the cylinder.

18. The burner assembly as recited in claim 17, wherein the openings are adjustable.

19. The burner assembly as recited in claim 18, wherein the openings are manually adjustable.

20. The burner assembly as recited in claim 18, wherein the openings are automatically adjustable based upon a signal from a control system.