Separation Function

Relief and blowdown streams contain condensed hydrocarbons and water from pressure reduction, cooling, or upset conditions. Liquid carryover damages flare tips, creates smoking and ground flaring, and violates air permits. Flare separators provide gravity separation removing liquids before vapor reaches flare header ensuring clean combustion and regulatory compliance.

Vessel Design

Horizontal or vertical knockout drum with inlet diverter reducing gas velocity. Wire mesh mist eliminator captures submicron droplets. Vapor outlet at top flows to flare header. Liquid boot section at bottom with drain connections. ERGIL sizes separators based on flare load, liquid carryover potential, and required separation efficiency.

Design Conditions

Operating pressure typically 5-50 psig matching flare header. Design pressure provides margin for upset conditions. Temperature ratings accommodate cold blowdown to ambient flare gas. Materials handle diverse relief streams including hydrocarbons, acids, and corrosive compounds. Relief valve protection against blocked outlet.

Material Selection

Carbon steel construction suitable for most flare service. Stainless steel for corrosive streams containing H₂S, chlorides, or acids. Materials per ASME Section VIII with corrosion allowances. Design accommodates thermal cycling during relief events.

Applications

Refinery flare systems collecting relief from process units, gas plant emergency depressurization, chemical facility pressure relief, offshore platform flare knockout, and any facility requiring safe vapor flaring. Protects flare infrastructure handling continuous purge, intermittent relief, and emergency blowdown operations.

Liquid Management

Level switches activate drain valves routing liquids to closed drain systems or recovery. High-level alarms prevent overflow into flare header. Seal drums on drain lines prevent backflow. Liquid routing to slop oil, treatment, or incineration depending on composition.

Control Features

Differential pressure monitoring indicates mist eliminator fouling. Level control manages liquid inventory preventing gas breakthrough. Integration with flare gas recovery systems optimizes vapor handling. Automated operation during normal and emergency conditions.

Performance Benefits

Prevents flare tip damage and smoking from liquid carryover. Enables compliant flaring meeting air permit limits. Protects ground areas from liquid raining hazards. Recovers valuable liquids reducing waste. Simple proven separation technology essential for safe flare operations.

Construction Standards

Design per API 521 flare system standards and ASME Section VIII. Materials suitable for combined relief streams. Relief sizing per API 520. Complete documentation with separation calculations and flare system hydraulics supporting permit compliance.

ERGIL flare separators deliver dependable liquid knockout ensuring safe compliant flaring and protecting flare infrastructure in emergency pressure relief systems.