- Aromatics Flare Gas Recovery
The purpose of this project was to recover and treat all routine flared gas routed to an Aromatics Flare to comply with a consent decree. High-pressure gasses routed to the flare were alternately routed through four liquid ring compressors and reintroduced into the plant for reuse. The consent decree compliance deadline was Dec. 31, 2011. Our team started the final design in August 2010 and completed it in April 2011.
The key aspects of the Aromatics Flare Gas Recovery project front end planning (FEP) process were:
- Identify the proper gas composition from the myriad suppliers on the flare gas header
- Develop blunting strategies for minimizing the compressor capacity
- Select the most cost-efficient gas compressors
- Find a piping route to return the captured flare gas back into the plant
The final design and procurement activities began in August 2010, leaving 17 months for design, procurement and construction. Our team provided the engineering, procurement and expediting services and turned the project over to the owner's operations on Dec. 1, 2011. Startup proceeded without difficulties, and the Environmental Protection Agency approved the installation on Dec. 13, 2011.
The major equipment included four liquid ring compressors, four service liquid coolers, two separator drums and a 45,000 gallon seal vessel. One of the methods to expedite the project was to use modules for the equipment and pipe racks. Our team developed the modular drawings and followed up with in-shop inspection and oversight of the modular units. The project also included a 2,300-square-foot electrical building that was delivered in four modules, and two high-voltage and two medium-voltage transformers. A remote instrument enclosure (RIE) expansion was also part of the project, a single module nearly doubling the existing RIE facility.
We provided construction support services to facilitate proper installation and handle contractor questions expeditiously. Staff were placed on-site to smooth the commissioning and startup processes.
- Front end planning
- Procurement and expediting
- Construction support
- On-site staff for commissioning and startup