Elevated Flare System

Elevated Flare System

Ever-power’s elevated flare system delivers safe, smokeless combustion for refinery, LNG and petrochemical relief duty. Choose the patented three-path steam flare for hydrocarbon-rich streams or the pipe flare for low-calorific service. Both achieve 99.7% destruction efficiency, full 0–100% turndown and a 15-year mechanical service life backed by API 537 / API 521 documentation.

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Description


What Is an Elevated Flare System?

An elevated flare is a vertical stack that safely combusts hydrocarbon vapours released from process upsets, emergency depressurisation, start-up purges and routine venting. The flare tip is positioned high enough above grade to keep ground-level radiation, noise and sound pressure within the limits set by API 521 / ISO 23251 and Australian site permits. For operators across Gladstone, Kwinana, Geelong and the Surat Basin, the elevated flare is the last line of defence between an over-pressured process and the atmosphere — which is why specification choices matter.

Ever-power supplies two core configurations of elevated flare: the three-path steam-assisted flare for hydrocarbon-rich, smoke-prone streams, and the pipe flare for low-calorific or sonic-velocity duties. Both ship as fully integrated packages with pilot, ignition, knock-out drum, molecular seal and instrumentation. Engineering, fabrication, factory acceptance testing and on-site commissioning are handled by a single point of accountability.

Product Range

Three-path steam-assisted elevated flare tip with patented non-premixed nozzle

Three-Path Steam Flare

A non-premixed flare tip that uses medium-pressure steam to entrain combustion air directly into the flare gas at the tip exit. The patented three-path nozzle geometry achieves smokeless combustion while cutting steam consumption by more than 35% compared with conventional centre-steam designs.

  • Destruction efficiency: 99.7%
  • Steam saving: >35% versus baseline
  • Mechanical service life: up to 15 years at 0–100% load
  • Best for: heavy/unsaturated hydrocarbons, refinery FCC off-gas, ethylene plants

Pipe flare tip with perforated outlet for low-calorific gas service

Pipe Flare

An unassisted flare tip optimised for low-calorific value gases and a wide turndown band — from low-pressure purge flow to high-pressure sonic discharge. With no steam or air assist required, the pipe flare delivers the lowest operating cost in the elevated flare family while still achieving 99.7% hydrocarbon destruction.

  • Destruction efficiency: 99.7%
  • Turndown: purge to sonic velocity
  • Operating cost: lowest in class — no utilities
  • Best for: biogas, landfill gas, lean tail gas, emergency relief duty

Technical Specifications

Parameter Three-Path Steam Flare Pipe Flare
Hydrocarbon destruction efficiency 99.7% 99.7%
Smokeless capacity Up to 100% of design flow Inherent (low-MW gases)
Operating turndown 0–100% load Purge to sonic
Typical capacity Up to 1,500 t/h flare gas Up to 800 t/h flare gas
Stack height (typical) 30 m – 120 m 15 m – 90 m
Tip materials SS 310/253 MA / Hastelloy SS 310 / SS 316
Steam consumption 0.15–0.25 kg steam / kg HC Not required
Ignition FFG with redundant pilots FFG with redundant pilots
Design code API 537 / API 521 / ISO 25457 API 537 / API 521 / ISO 25457

Engineering Features That Move the Needle

Patented Tip Geometry

Three-path nozzle distributes steam into discrete velocity shells, maximising air entrainment per kilogram of steam. The result is documented 35%+ steam reduction at full smokeless rating — a meaningful OPEX line item over a 15-year asset life.

Flame Stability Across Turndown

Velocity-seal molecular seal plus continuously monitored pilots maintain flame stability from purge flow to design relief, eliminating flame-out risk during low-rate venting events.

Material Engineering

Heat-affected zone in SS 310 or 253 MA; non-heat zone in carbon steel with high-temperature coating. Tip life is verified by FEA thermal cycling and full-scale flame radiation testing.

Smart Pilot & Ignition

Flame-front generator with thermocouple and ionisation rod redundancy, optional UV/IR detection. Pilot fuel consumption is minimised through self-inspirated venturi design per ISO 25457.

Knock-Out Drum & Seal

Liquid removal upstream of the tip protects against burning droplets and tip damage. Liquid seal and molecular seal options prevent flashback and air ingress.

Compliance Documentation

Each elevated flare ships with complete API 521 sizing calculations, radiation contour modelling, dispersion analysis, and an as-built data book ready for regulatory submission to the relevant Australian state EPA.

Applications Across Australian Industry

  • LNG & gas processing: Gladstone, Curtis Island, Darwin, Karratha — pressure relief and dry-out flaring during commissioning and turnaround.
  • Oil refineries: Lytton, Geelong, Kwinana — FCC off-gas, depressurisation and sour-water stripper venting.
  • Petrochemical & olefins: ethylene cracker emergency relief, polymer plant blow-down.
  • Coal-seam gas & upstream: Surat and Bowen Basin well-pad and central processing facility relief.
  • Mining & chemical manufacturing: ammonia, methanol, sulphur recovery tail-gas.
  • Biogas & landfill: low-calorific lean-gas duty, aligned with NGER reporting.

Why Choose Ever-power

Decision Criterion Ever-power Advantage
Track record More than two decades of combustion engineering, hundreds of flare references across refining, LNG and petrochemical markets.
In-house IP Patented three-path tip and proprietary CFD design library — not a re-badged third-party tip.
Single-source EPC Process design, fabrication, instrumentation, FAT, site supervision and commissioning under one contract.
Lifecycle economics 35% steam reduction translates to documented six-figure annual OPEX savings on a typical 50 t/h refinery flare.
Australian project support Local project managers, regional spares stocking, AS/NZS-aligned documentation, and integration with site HAZOP/SIL studies.
After-sales Inspection, refurbishment, tip replacement and 24/7 technical support — learn more about our team on the company page.

Australian Project Highlights

QLD CSG Central Processing Facility

Location: Surat Basin, Queensland  |  Year: 2024

Ever-power supplied a 60 m three-path steam flare for emergency relief duty on a 220 TJ/d coal-seam gas processing facility. The tip replaced a legacy centre-steam design and reduced annual steam draw by 1,860 tonnes, freeing capacity at the existing utility boiler.

Outcome: Smokeless to 100% relief flow, EPA Queensland licence variation approved on first submission.

WA LNG Liquefaction Train

Location: Pilbara, Western Australia  |  Year: 2023

A high-pressure pipe flare package was engineered for end-flash gas duty during commissioning and routine venting. Sonic-velocity tip exits ensured smokeless operation without steam injection at a remote site where steam capacity was unavailable.

Outcome: Six-month delivery from purchase order; FAT witnessed and accepted with zero punch-list items.

Frequently Asked Questions

Q1. What is the difference between a steam-assisted and a pipe flare?
A steam-assisted flare uses medium-pressure steam to entrain combustion air, delivering smokeless burn for heavy or unsaturated hydrocarbons. A pipe flare uses gas exit velocity and natural buoyancy — cheaper to run, best for lighter or low-calorific streams.
Q2. How is elevated flare height determined?
Stack height follows API 521 radiation methodology so ground-level radiation, sound and dispersion stay within site permit limits. Australian projects typically land between 30 m and 120 m.
Q3. Will it meet AS 3814 and state EPA licences?
Every package ships with API 537 mechanical certification, API 521 sizing, radiation contour plots and a 99.7% destruction efficiency dossier — the standard pack used to support EPA approval in QLD, WA, NSW and VIC.
Q4. What is the expected service life?
Mechanical components on the three-path tip are rated up to 15 years across the full 0–100% load envelope. Pilots and ignition modules typically refurbish on a 5–7 year cycle.
Q5. What is the typical lead time?
Tip-only deliveries: 14–18 weeks. Full elevated flare packages with stack, KO drum and instrumentation: 28–36 weeks from purchase order.
Q6. Can you retrofit my existing flare stack?
Yes — tip retrofits are a regular scope. We review the existing structure aerodynamically and mechanically, then supply a drop-in tip to restore destruction efficiency or cut steam draw.
Q7. Do you support brownfield commissioning in remote Australian sites?
Yes. Our project managers mobilise to site for installation supervision, cold and hot commissioning, performance testing and operator training. Spares are stocked regionally to keep mean-time-to-repair short.

Ready to Specify Your Elevated Flare?

Send us your relief load, gas composition and site constraints. You will receive an engineered datasheet, indicative pricing and Australian-compliant documentation pack within five working days.

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