Validation of a new method for measuring and continuously monitoring the efficiency of industrial flares

A new method has been developed for a direct and remote measurement of industrial flare combustion efficiency (CE). The method is based on a unique hyper-spectral or multi-spectral Infrared (IR) imager which provides a high frame rate, high spectral selectivity and high spatial resolution. The method can be deployed for short-term flare studies or for permanent installation providing real-time continuous flare CE monitoring.  In addition to the measurement of CE, the method also provides a measurement for level of smoke in the flare flame regardless of day or night. The measurements of both CE and smoke level provide the flare operator with a real-time tool to achieve “incipient smoke point” and optimize flare performance.  The feasibility of this method was first demonstrated in a bench scale test. The method was recently tested on full scale flares along with extractive sampling methods to validate the method. The full scale test included three types of flares – steam assisted, air assisted, and pressure assisted. Thirty-nine test runs were performed covering a CE range of approximately 60-100%. The results from the new method showed a strong agreement with the extractive methods (r2=0.9856 and average difference in CE measurement=0.5%).  Implications: Because industrial flares are operated in the open atmosphere, direct measurement of flare combustion efficiency (CE) has been a long-standing technological challenge. Currently flare operators do not have feedback in terms of flare CE and smoke level, and it is extremely difficult for them to optimize flare performance and reduce emissions. The new method reported in this paper could provide flare operators with real-time data for CE and smoke level so that flare operations can be optimized. In light of EPA’s focus on flare emissions and its new rules to reduce emissions from flares, this policy-relevant development in flare CE monitoring is brought to the attention of both the regulating and regulated communities.