For optimization and development of its products and/or processes, PREMATECNICA uses recognized last generation software tools such as ANSYS Fluent or FlareSim. Here are some examples of it:
Pilot burner optimization
We continue to improve the efficiency of our equipment with the new design of our pilot burner. This optimization process has been carried out thanks to the CFD (Computational Fluid Dynamics) analysis through ANSYS Fluent.
Hydrogen sulphide tail gas thermal oxidizer
In this case, hydrogen sulphide,H2S, combustion in a horizontal thermal oxidizer is studied. The geometry is iteratively changed in order to optimize the temperature distribution at the exit, improving the behavior and maximizing the tail gas conversion rates.
Sonic flare burner optimization
In this project the behavior of the gases are analyzed inside a sonic flare burner. After analyzing the results, the internals were modified to maximize the available pressure at the flare tip exit in order to improve the air-gas mixing and the combustion. Shock waves generated by the supersonic gases are displayed in the image.
Improvement of a vapor assisted flare
One of the solutions to enhance the combustion of the waste gases in a flare is to inject vapor inside the flare burner. Atmospheric air is dragged by the vapor and introduced inside the flare tip. The more air is induced, the greater the efficiency and the lower the emissions. The difference between the old and the optimized design is presented in the attached table. A 250% increment of air flow is reached.
Heavy gas burner design
Using CFD, we have been able to design a new concept of smokeless burner for ground flares. The gas pressure is used to generate a big turbulence (see image), generating eddies that improve the air-gas mixing.
Optimization of the burners’ distribution in a ground flare
During the ground flare design the situation of the burners should be defined. After a first design, we could check thanks to the CFD simulation that the temperature limits were reached at the refractory walls and that some gases were not correctly burnt. After several simulations where the situation of the burners was modified, the temperature limit was not reached and, also, the emission of unburnt gases was eliminated.