Accurate and reliable flare testing methods

Recently the Texas Commission on Environmental Quality (TCEQ), through The University of Texas (UT) initiated a project utilizing John Zink facilities to better understand the operating envelope of varying flare technologies across various process conditions. A large scale flare testing environment was necessary to obtain accurate data, specifically with regard to emissions and combustion performance. The results of this testing offer objective data that may be used to improve and understand flare operation within the entire industry. For many years flare system performance predictions have been based on historical results from a few limited test points, as well as theory. This basis has also been used to define regulatory operation envelopes. As additional industry scrutiny calls for more controlled and defined limits of operation, the need for accurate and proven test results grows. Flare testing has always been difficult to conduct due to the unique challenges full-scale systems pose with their wide range of process conditions at intermittent durations, high flow-rates, and elevated position of operation. This paper will describe the recent UT/TCEQ testing of large-scale flares and the methods used to obtain reliable data for air-assisted, steam-assisted, and high-pressure flares.