FLARE GAS

RECOVERY SYSTEMS

Envirocomb Limited

LIquid RIng COmpressor Standard System

GASES
Acid Gases
H2S
CO2
COS

APPLICATION

Others

PROCESS

NOX
H2
Condensable
HC mixtures
etc.

Topping
FCC
Vacuum
Coking
Visbreaking
etc.

RECOVERY
Flare Gas
Off Gas
Steamer Off Gas
Flash Gas
VOC
etc.

WHY INSTALL
A FLARE GAS
RECOVERY SYSTEM?

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THE ENVIRONMENT
Removal of three types of pollution:

Atmospheric (smoke, SO2, NOx, etc.)

Light
Noise

NB: In many parts of the world continuous flaring is not permitted.

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THE ECONOMIC ARGUMENT

Consider a typical plant with continuous flaring of 1 ton/h:

Value of flared gas: 8000 x 1 x $150 = US$ 1,200,000 per year

First Year Operational Costs (Electricity & Water): = US$ 150,000 (approx)
Total installed cost of flare gas recovery system: = US$ 700,000 (approx)

Payback achieved in 8.5 months!

Subsequent yearly operational savings = US$ 1.050,000!
For larger systems the payback is shortened!

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TYPICAL FLARE GAS

RECOVERY SYSTEM
& COMPONENTS

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FGRS COMPONENTS

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TYPICAL FLARE GAS RECOVERY SYSTEM

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Envirocomb Limited

THE
COMPRESSOR

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TYPES OF COMPRESSOR
Generally three types of compressor have been used for flare
gas recovery systems:

Reciprocating, screw and liquid ring

Reciprocating and screw type compressors are more efficient

but they are also more expensive, require more maintenance
and downtime, result in compressed gases being at high
temperature and are not tolerant to condensates being present
in the gas.

For flare gas recovery liquid ring compressors have many

advantages.

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ADVANTAGES OF
LIQUID RING COMPRESSORS
Liquid ring compressors are generally the best to use for flare
gas recovery systems for the following reasons:
Able to handle gases containing condensates
Able to handle gases containing particulates
Able to handle wet gases
Able to handle toxic, flammable and corrosive gases
Works without lubricants
Gas temperature rise is low - 10OC
Because of liquid ring, compressors are inherently safe
System tolerates sudden gas and condensate surges

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Envirocomb Limited

DESIGN BASIS

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TYPICAL LIQUID RING VACUUM PUMP

Radial Forces

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THE GARO DESIGN

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THE GARO DESIGN

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GARO is the preferred supplier of liquid ring compressors due to many

technical advantages.
Double lobe casing to balance radial pressures acting on overhung
impeller with a single mechanical seal.

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Noise is dictated by the electric motor

Reduced vibration levels give bearings
a longer life
Potential
leakage
point
with
atmosphere reduced to one mechanical
seal
The mechanical seal is the only
component subject to wear and is easily
replaced.

FRONT PULL OUT

Fast access to compressor

internals without putting the
machine in vertical position.

DISTRIBUTION CONE

Lower power consumption

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CONE & IMPELLER ALIGNMENT

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Easy checking of internal

clearances without any need to
open the machine (two spanners
and a dial gauge are all thats
required)

Cone

Casing

Impeller

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The GARO machines are custom

engineered
to
meet
process
requirements. Dimensional changes to
internal
components
alter
the
machines operational capability.
Each size of compressor can be
adjusted to vary pressures, flow rates
and power consumption within a range.
This optimizes performance in relation
to the required conditions of service.
Post supply process changes can often
be accommodated without the need to
replace the machine.

CROSS SECTION

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TYPICAL LIQUID RING COMPRESSOR

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MAINTENANCE

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EASY MAINTENANCE

OVERHUNG IMPELLER
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EASY MAINTENANCE

OVERHUNG IMPELLER
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EASY MAINTENANCE

OVERHUNG IMPELLER
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BETWEEN BEARINGS DESIGN

TRADITIONAL DESIGN
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Liquid ring compressor AM 850 maintenance costs

T he tab le und erneath sho w s the re a l m aintenance co sts o f a single stage G aro 's co m p resso r A M
at a refinery p lant in S annazzaro d e B urgund i, P avia -Italy- fro m 1 9 8 9 up to 1 9 9 8 .

D ate

C au se

1 7 .0 8 .8 9
1 4 .0 9 .8 9
1 8 .1 0 .8 9

S u lp h u r re m o val* fro m filte r

S u lp h u r re m o val* fro m filte r
S u lp h u r re m o val* fro m filte r, p ip e an d
valve u p stre am filte r.
N e w filte r in stalle d *
M e c h . se al rin g s
S e t o f b e arin g s
M e c h . se al g ask e sts
N e w filte r c artrid g e
C o m p le te m e c h . se al
R in g + g ask e ts o f m e c h . se al
R e fittin g d u e to w ro n g asse m b ly
S e t o f b e arin g s
M e c h . se al
N e w filte r c artrid g e
-

0 7 .1 1 .8 9
1990
0 3 .0 6 .9 1
1 6 .1 0 .9 1
0 5 .0 5 .9 2
1 6 .1 1 .9 2
1993
2 6 .0 1 .9 4
0 9 .0 2 .9 5
2 1 .0 2 .9 5
2 0 .0 8 .9 5
1996
1 2 .0 2 .9 7
2 6 .0 5 .9 7
1998

S h u t d o w n in
h o u rs
1
1
12

T o tal co sts in U S D ,
in cl. lab o r co sts* *
18
38
300

48***
8
12***
8
4
12***
8
4
12***
8
4
T o tal U S D

4 .9 0 0
1 .3 3 0
1 .5 4 3
170
913
2 .1 4 8
1 .4 5 0
190
1 .6 8 0
3 .2 8 5
1 .3 6 1
1 9 .3 2 6

A v e ra g e a n n u a l c o s t:
(C o st calcu latio n m eth o d : fro m 17.08.89 u n til 31.12.98 = 112 m o n th s.

8 5 0 o p erating

U S D 2 .0 7 0

1 9.326/ 112 x12= 2.070 U S D p er y ear.)

* In 1 9 8 9 the refinery p lant started refining crud e o il w ith high sulp hur co ntent w hich led to freq uent filters
clo gging: in N o vem b er 1 9 8 9 the filter w as rep laced b y a self cleaning typ e.
* * 1 U S D = 1 ,0 7 1 2 E U R O
* * * D uring general p lant shutd o w n.

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FLARE SAFETY

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NORMAL OPERATION
Pilots Only

1000 m3/h
0 am3/h
P3 = 0.01 bar g

P1 = 0.03 bar g
1000 m3/h

P2= 0.02 bar g

PT

NO BY- PASS REQUIRED

1000 m3/h

1000 m3/h

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REDUCED GAS FLOW

Pilots Only

800 m3/h
0 am3/h
P3 = 0.01 bar g

P1 = 0.02 bar g
800 m3/h

P2= 0.016 bar g

PT
BY- PASS OPEN

200 m3/h

800 m3/h

1000
m3/h

Envirocomb Limited

NO GAS FLOW
Pilots Only

No gas = 0 m3/h
0 am3/h
P3 = 0,01 bar g

P1 = 0,01 bar g
0 m3/h

P2= 0,01 bar g

PT
100% BY- PASS OPEN
1000 m3/h

PSL

0 m3/h

Shut-down of compressor

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1000 m3/h

CAPACITIES

Envirocomb Limited

Vol. capacity
in Tonnes / h

^P 5 ^P 7
bar abs bar abs

Mod.

Garo

Flow
in m 3/h

power cons.
in kW
Approx. operating conditions

0,4 - 0,8

AM 400

400 - 800

AB 600

"

AM 800

800 - 1100

AB 850

"

AM 1100

1100 - 1400

AB 1100

"

AM 1500

1400 - 2000

AB 1500

"

AM 2500

2500 - 3200

C 250-6,3 X/SP

"

AM/AB 5000

4000-7500

x
0,8 - 1,1

x
x

1,1 - 1,4

x
x

1,4 - 2,0

2,5 - 3,0

*** 4,0 - 5,0

88
107

1200 - 1800 RPM

71 kW - 143 kW

140
170

1300 - 1600 RPM

143 kW - 197 kW

185
280

1100 - 1400 RPM

197 kW - 251 kW

251
305

900 - 1200 RPM

251 kW - 359 kW

444
538

800 - 980 RPM

420 kW - 568 kW

Inlet Press.

1 bar abs

Inlet Tem p.

20 -40 C

Cooling w ater

30 - 35 C

Frequency
Mol. Weight

660 - 1200 RPM

430 - 620 Kw

15-45 Kg/kmol.

*** Double support compressor

System

Single or duoble stage Garo compressor ( mech.seals, flushing system, couplings, baseframe )
Garo basic scope of supply as per enclosed annexe 1

Execution:

All parts in carbon steel.

Compressor in 316 and other parts in carbon steel ( for H2S )
Other materials required ( S.S., Duplex etc. )

NOTES

1) Garo AB 600-850-1500 can reach 14 bar abs

2) Different eccentricity of the impeller and cone can change performances for each GARO COMPRESSOR TYPE

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50 Hz

AM=Single Stage AB=Double stage

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PLOT SIZE

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PLOT SIZE

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TWO COMPRESSOR SYSTEM G.A.

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REFERENCES
FLARE GAS RECOVERY

Envirocomb Limited

REFERENCE LIST FOR FLARE GAS &

HYDROCARBONS RECOVERY SYSTEMS
1986/1992

AGIP PETROLI, SANNAZZARO DE BURGONDI REFINERY (PV) - ITALY

Three liquid ring compressors type AM 850 each handling 850 m^3/h of flare gas from 1 to 4 bar abs

1996

ISAB PRIOLO, COOGENERATION PLANT ERG PETROLI, PRIOLO (SR) - ITALY

One liquid ring compressor type AB 1500 handling 1400 m^3/h of flare gas from 1 to 7 bar abs

1997

AGIP PETROLI, GELA REFINERY (CL) - ITALY

Four liquid ring compressors type AB 2500 (former C250-X/SP) each handling 2700 m^3/h of flare gas
from 1 to 6,5 bar abs

1997

AGIP PETROLI, TARANTO REFINERY - ITALY

One liquid ring compressor type AM 2500 handling 2700 m^3/h of flare gas from 1 to 3,8 bar abs

1997

SARAS, SARROCH REFINERY (CA) - ITALY

Two liquid ring compressors type AB 850 each handling 900 m^3/h of flare gas from 1 to 7 bar abs

1998

ITALIA ENERGIA E SERVIZI (I.E.S.), MANTOVA REFINERY - ITALY

One liquid ring compressor type AB 850 handling 900 m^3/h of flare gas from 1 to 7 bar abs

1999

ERG PETROLI, PRIOLO GARGALLO REFINERY, PRIOLO (SR) - ITALY

One liquid ring compressor type AM 1500 handling 1600 m^3/h of flare gas from 1 to 4 bar abs

2000

SHELL, DOCK SUD, AVELLANEDA - ARGENTINA

Two liquid ring compressors type AB 850 IX each handling 600 m^3/h of flare gas from 1 to 8 bar abs

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2000

SNP PETROM BRANCH PETROBRAZI, BRAZI PRAHOVA - ROMANIA

One liquid ring compressor type AM 2500 handling 2800 m^3/h of flare gas from 1,05 to 4,05 bar abs

2001

LION OIL, EL DORADO, ARKANSAS - U.S.A.

Seven liquid ring compressors type AB 1100 each handling 1200 m^3/h of flare gas from 1,05 to 7,5 bar abs

2001

ADCO, SAHIL - UNITED ARAB EMIRATES

One liquid ring compressor type AB 850 IX handling 450 m^3/h of flare gas from 1 to 6,5 bar abs

2001

REPSOL YPF, ESCOMBRERAS, CARTAGENA - SPAIN

One liquid ring compressor type AB 850 handling 950 m^3/h of flare gas from 1,05 to 7,5 bar abs

2001

CONOCO REEFINERY, PONCA CITY, OKLAHOMA U.S.A.

Three liquid ring compressor type AB 1500 handling 1820 m^3/h of flare gas from 1,08 to 6,85 bar abs

2001

R.A.M. RAFFINERIA DI MILAZZO (ME) - ITALY

One liquid ring compressor type AB 2500 (former C250-X/SP) handling 2300 m^3/h of flare gas from
1 to 7,85 bar abs

2001

REPSOL YPF PETRONOR, REF. DE SOMORROSTRO, BILBAO SPAIN

One liquid ring compressor type AB 850 handling 900 m^3/h of flare gas from 1 to 8 bar abs

2001

STATOIL, MONGSTAD REFINERY - NORWAY

Two liquid ring compressors type AB 2500 (former C250-X/SP) each handling 2600 m^3/h of flare gas
from 1 to 5 bar abs

2001

BP OIL, CASTELLON - SPAIN

One liquid ring compressor type AB 1500 handling 1450 m^3/h of flare gas from 1 to 7, 5 bar abs
(from different flare)

Envirocomb Limited

2002

SHELL OIL CO. PORT ARTHUR, TX - U.S.A.

Four liquid ring compressors type AB 1500 each handling 1500 m^3/h of flare gas from 1 to 8 bar abs

2002

SHELL OIL CO. NORCO, LA - U.S.A.

Three liquid ring compressors type AB 1500 each handling 1500 m^3/h of flare gas from 1 to 8 bar abs

2002

SHELL OIL CO. CONVENT, LA - U.S.A.

Four liquid ring compressors type AB 1500 each handling 1500 m^3/h of flare gas from 1 to 8 bar abs

2002

SHELL OIL CO. DEER PARK, TX - U.S.A.

Five liquid ring compressors type AB 1500 each handling 1500 m^3/h of flare gas from 1 to 8 bar abs

2002

CARMEL OLEFINS - ISRAEL

Two liquid ring compressorstype AB 600 each handling 570 m^3/h of flare gas from 1,1 to 9 bar abs

2002

AGIP ECUADOR EPSS VILLANO

Two liquid ring compressors type AB 600 each handling 720 m^3/h of flare gas from 1,2 to 6,5 bar abs

2002

RELIANCE INDUSTRIES LIMITES INDIA

One liquid ring compressor type AB 1500 handling 3600 m^3/h of flare gas from 1,1 to 8 bar abs

2003

REPSOL YPF PETROLEO RAFFINERIA DE PUERTOLLANO SPAIN

Two compression systems each with four liquid ring compressors type AB 1500 each handling 1650 m^3/h
of flare gas from 0,95 to 7 bar abs

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GAS WASHING

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1
5

1.
2.
3.
4.
5.
6.

Sour gas
Regenerated amine
Skimmed hydrocarbons
Semi-rich amine to be sent to a medium pressure absorber or to regenerator
Regenerated amine to the final clean up column
Sweet gas to fuel gas network

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FLARE GAS RECOVERY INTEGRATED SYSTEM

EQUIPPED WITH LIQUID RING COMPRESSOR
Fuelgas
Am ine w ashing unit
B low D ow n

Process w ater
SW S treatm ent

Slop
Cooling w ater
Am ine regeneration unit

M edium pressure absorber

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LIQUID RING
COMPRESSOR
APPLICATIONS

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Main applications

Chlorine (wet and dry)

Vinyl Chloride Monomer
Ethylene
Flare and vent gases (any kind)
Carbon monoxide / dioxide
Hydrogen
Hydrogen sulphide
Nitrogen oxides
Hydrochloric acid
Ethylene dichloride

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Typical Applications
A P P L IC A T IO N

G A S H AN D LED

S E R V IC E L IQ U ID

V in yl A c e ta te

E th yle n e (R e c o ve ry)

A c e tic A c id

P VC

V C M (R e c o ve ry)

W a te r

P u lp & P a p e r

W e t C h lo rin e

W a te r

P u lp & P a p e r

C O 2 (R e c o ve ry)

W a te r

C h lo rin e

D ry C h lo rin e

S u lp h u ric A c id

S ugar

CO 2

W a te r

S ugar

CH4

W a te r

H 2O 2

H 2 (R e c o ve ry)

S o lve n t (U h d e )

H 2O 2

H 2 (R e c o ve ry)

W a te r

EDC

S u lp h u ric A c id

EDC

D ry C h lo rin e
E D C (R e c o ve ry)

EDC

V e n t G a s e s (C O 2 )

C e n trifu g a l

T iO 2

D ry C h lo rin e

S u lp h u ric A c id

VC M

V e n t G a s e s (C 2 H 4 )

EDC

A d ip ic A c id

NO x

N itric A c id & w a te r

F e rtilis e r

NO x

N itric A c id & w a te r

C a p ro la c ta m

NO x

N itric A c id & w a te r

E xp lo s ive s

NO x

N itric A c id & w a te r

N2

NO x

N itric A c id & w a te r

HCl

HCl

S u lp h u ric A c id

EDC

N u c le a r P o w e r

H 2S

W a te r

O le fin s

B F 3 (B o ro n F lu o rid e )

X ylo ls

P o lyo le fin s

O le fin s

W a te r

E n e rg y R e c o ve ry (R e fin e ry)

B lo w D o w n G a s e s

W a te r/G a s o lin e

D e s a lin a tio n

CO 2

W a te r

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REFERENCES
GENERAL APPLICATIONS

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GENERAL REFERENCE LIST

Envirocomb Limited

GENERAL REFERENCE LIST

Envirocomb Limited

GENERAL REFERENCE LIST

Envirocomb Limited

GENERAL REFERENCE LIST

Envirocomb Limited

GENERAL REFERENCE LIST

Envirocomb Limited

GENERAL REFERENCE LIST

Envirocomb Limited