ITAS, THE EUROPEAN COMPANY LEADER IN …€¦ · FLARE SYSTEM DESIGN ELEVATED FLARES GROUND FLARES...

GENERAL CATALOG

PETROCHEMICALDIVISIONFLARE SYSTEM DESIGNELEVATED FLARESGROUND FLARESBIO-GAS FLARESFLARE TIPSBURN PITFLARE SYSTEM COMPONENTSVENT AND SNUFFING SYSTEMOFF-SHORE EQUIPMENTH2S AND/OR ACID GASCOMBUSTION EQUIPMENTBURNER SYSTEMPIPING ACCESSORIESSCRAPER TRAP STATIONS

ECOLOGYDIVISIONECOLOGY AND ENVIRONMENTEMISSION TREATMENTECOLOGY/SERVICESECOLOGY AND ENVIRONMENT

COMBUSTIONDIVISIONAIR HEATERSSYSTEMS

CONTROLDIVISIONSYSTEMS

www.itas.com [email protected] have the answer

ITAS, THE EUROPEAN COMPANYLEADER IN INDUSTRIAL COMBUSTION

ECOLOGY ANDENVIRONMENT

PRODUCTS AND SERVICES00 EMISSION TREATMENT:

VAPOURS, LIQUIDS AND GASES

EMISSIONTREATMENT01 HEAT RECUPERATING

OXIDISING UNITS02 CATALYTIC OXIDISING UNITS03 HEAT REGENERATING

OXIDISING UNITS04 HEAT REGENERATING AND

CATALYTIC OXIDISING UNITS05 WET REMOVAL06 SOLVENT RECOVERY

WITH ACTIVATED CARBONS07 ROTATING CONCENTRATORS

ECOLOGY/SERVICES08 COLLECTION SYSTEMS AND

EMISSION OPTIMISATION

ECOLOGY ANDENVIRONMENT09 CONTROL SYSTEM AND SERVICES

ECOLOGY DIV IS ION

HEAD OFFICEITAS spa Italy via Metauro, 5 20052 Monza (MI)Tel. +39.039.2733.1 Fax +39.039.745077

INTERNATIONAL OFFICESITAS Germany Brönnerstraße 17 60313 FrankfurtTel. +49.(0)69.2193570 Fax +49.(0)69.21935757 e-mail: [email protected]

ITAS United Kingdom New Barn Farm - Tadlow Road Tadlow SG8 0EPTel. +44.(0)1767.631188 Fax +44.(0)1767.631651 e-mail: [email protected]

ITAS Spain Via Augusta, 13-15 5ª, Izq.da Edificio Ederra Augusta 08006 BarcelonaTel. +34 932187454 Fax +34 932188382

ITAS Belgium Porte de Batisseur, 20 7730 EstaimpuisTel. +39.039.2733.1 Fax +39.039.745077 www.itas.com [email protected]

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I TA S S p A I TA LY v i a M e t a u r o , 5 2 0 0 5 2 M o n z a ( M i ) - I TA LY Te l . + 3 9 . 0 3 9 . 2 7 3 3 . 1 F a x + 3 9 . 0 3 9 . 7 4 5 0 7 7 w w w. i t a s . c o m

EMISSION TREATMENT(VAPOURS, LIQUIDS AND GASES)01 Heat recuperating oxidising units02 Catalytic oxidising units03 Heat regenerating oxidising units04 Heat regenerating and catalytic

oxidising units05 Wet removal06 Solvent recuperation by

activated carbon07 Rotating concentrators08 Denox systems

RECUPERATING SYSTEMS01 Shell and tube heat exchangers02 Shell and heat exchanger with

floating head03 Plate-type heat exchangers04 Aircoolers and condensers

CONTROL SYSTEMS01 Programmable Logic Control panels 02 Control systems (PC, PLC, DCS)03 Remote supervision systems

(Tele service)

SERVICES01 Combustion analysis02 Emission analysis03 Optimisation of existing plants04 Thermodynamic process analysis

by means of CFD Software05 Feasibility studies with environmental

impact analysis06 Emission collection and

optimisation systems07 Support for preparing the necessary

documentation for public authorities08 Integrated technical assistance09 Training of Customer’s engineers10 Maintenance contracts ecology division

E C O L O G Y D I V I S I O N

E C O L O G Y A N D E N V I R O N M E N T PRODUCTS AND SERVICES

ITAS proposes ecological solutions foremissions treatment tailored for everysituation. They are the result of the mostadvanced research into industrial combus-tion technology. Moreover they considerall parameters in order to obtain the per-fect balance between investment, andoperating costs. ITAS ecology division isspecialised in emission treatment by VOCoxidising; this process may be carried out

thermally through regenerating, heatrecuperating and catalytic thermal oxidis-ing units . This divis ion designes andrealises activated carbon systems for sol-vent recovery and wet removal plantswith washing towers and scrubbers. ITAStypically conceives its plants on the basisof operation efficiency and economy. Thedesign takes into account the pay back,and other relevant benefits.

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such technology and plants as to provide a sufficientremoval of pulluting substances. The major part ofthese, in any form (gas, vapours, powders, liquids)consists of organic compounds mainly containing car-bon, hydrogen and oxygen, bound in very complexmolecules. The task of ecology oriented technologiesis to “split” such molecules and reduce their com-plexity, so that the free atoms may form other mole-cules such as water (H2O), oxygen (O2), carbon diox-ide (CO2), carbon monoxide (CO) and nitrogenoxides (NOx). The development of these technolo-gies is part of ITAS‘s “mission”, that references ofplants installed since 1978 (Pirelli - Milan, recentlyenlarged). With over 20-year experience, ITAS hasfaced the most varied needs. This is why remainscommitted to the idea of “tailor made”, i. e. of meet-ing every Customer’s requirements, through the useof various technologies, in order to supply the mostsuitable plants into the existing production processesto fulfil not only ecology, but also energy and econo-my needs of every industrial reality.

E C O L O G Y D I V I S I O N 00

E C O L O G Y A N D E N V I R O N M E N T EMISSION TREATMENT: (VA-POURS, LIQUIDS AND GASES)

Every production process is subject to rulesthat must prevent environmental pollutionfrom the emission of substances aboveestablished concentration levels. In Europe,the community directives dictate the levels

that each member country must acknowl-edge and put into practice. According tothis, the industrial processes, that generateVOC and odorous emissions above the limitsstated by the directives, must be reduced by

TREATMENT PROCESSES FOR VOLATILE ORGANIC SUBSTANCES (VOC)PROCESSES OXIDATION TREATMENT ADSORPTION ABSORPTION CONDENSATION

BIOLOGICon activated

Thermal Catalytic Biofilters carbonsRecuperative Regenerative Recuperative Regenerative

Concentration 5 to 20 g/Nm3 < 10 g/Nm3 < 15 g/Nm3 up to 1 g/Nm3 1 to 50 g/Nm3 2 to 50 g/Nm3 > 15 to 20 g/Nm3

Thermal self sust. 8 to 10 g/Nm3 2 to 3 g/Nm3 2 to 4 g/Nm3 0,7 to 1 g/Nm3

Delivery < 30 000 1000 to 300 000 100 to 20 000 up to 100 000 up to 150 000 1000 to 100000 1000 to 100000 up to 2000Nm3/h Nm3/h Nm3/h Nm3/h Nm3/h Nm3/h Nm3/h Nm3/h

Performance HCT (1) < 20 HCT < 20 mg/Nm3 HCNM (2) < 20 mg/Nm3 HCT < 150 < 100 to 150 < 150 mg/Nm3

mg/Nm3 CO < 20 mg/Nm3 NOx < thermal oxidation mg/Nm3 mg/Nm3

CO < 100 mg/Nm3 NOx < 50 mg/Nm3 chlorinated < 20NOx< 100 mg/Nm3 mg/Nm3

Low Presence of chlorinated, Presence of powders, heavy metals, elevated Selection of the Temperature, Cost. Associationconcentrations. sulphured or content of chlorinated or silicon derivatives. suited strain. low powder and Complexity. with anotherMissing of fluorinated products. Cold gases moisture content. technology.energy recovery Catalyst endurance. (20 to 40°C). Polymerizable

Limits capacity. Particles and compounds,of exploitation Presence of aerosol ketones.

chlorinated, < 20 mg/Nm3. Water mixedsulphured or Moisture rate solvent, complexfluorinated products. pH and nutrition separation, water

balance C, N, P, treatment.to be maintained. Activated carbon

endurance.

Printing shops, Same fields as those Offset printing, induction, paint driers Depurators, Degreasing Ketones, Degreasing,painting of aluminium, of heat recuperation chemical and pharmaceutical industry. breeding, (chlorinated), heavy products. hydrocarbonsinduction, oxidising units + agriculture and food industry, bad smelling slaughter dry cleaning, roto- Refineries, stocking,

Fields pre-lacquering, chemical and pharma- gas treatment. houses, gravure printing, petrochemical, petrochemical,of application paint driers, ceutical industry, printing shops publishing industry chemical, chemical, pharma-

hydrocarbons manufacture of chips agricultural and (toluene), chemical pharmaceutical ceutical industrystorage. boards, tiles and food industry, industry, pharma- industry, (operation in

bricks, foundries. chemical industry, ceutical industry... cokery, inert nitrogenfoundries. cold lamination atmosphere)

(1) Total hydrocarbons (2) Non methane hydrocarbons

04/2003


The Heat Recuperating oxidising Units allow therecovery of energy from the combustion of hydro-carbons without generating polluting emissions.

The oxidisation in a combustion chamber at tempera-ture between 700 and 1000 °C (and with residencetime between 0.6 and 2 seconds) is the most simplemethod to destroy polluting compounds.

This technology is used with high VOC concentrationsand where it is possible to recover useful energy.The recovery may involve hot water, steam, thermaloil or air.

Main advantages:- constant emissions- simple management- reduced erection times- energy recovery (heat)- maximum reliability also in the presenceof powders and liquids, and in case ofchanges of concentrationor pollutant types.


E M I S S I O N T R E A T M E N T HEAT RECUPERATINGOXIDISING UNITS

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The oxidising reactions, that take place in thermalplants at temperature above 700 °C, may beobtained at lower temperatures by means of a cat-alytic bed consisting of metal oxides or salts of pre-cious metals.Effectively, catalysts start the oxidising reactions attemperatures between 250 and 450 °C.

This technology is used where the utilisation of hotfluids such as oil, steam or air do not have a signifi-cant value and there is a lesser need for producedheat recovery. However, it is applicable where pollu-tant composition is well known and there is no com-ponent that covers or poisons the catalyst.

Main advantages.Reduction to minimum of support gas use for pre-heating and eventual oxidising reaction support.


E M I S S I O N T R E A T M E N T CATALYTIC OXIDISINGUNITS

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They are installed when there is no need of heatrecovery or when this need is not sufficient to justifya heat recuperating oxidising unit.

The main plant components are:- Fan- Heat accumulation towers with ceramicfiller (2 or 3 towers, also in multiplebattery, according to the needs)

- Combustion chamber- Compensating tower to control emissionlinearity (in the presence of 2 heataccumulation towers)

- Control and adjustment board with PLC,inverter, display panel, PC with severalpages screen.

Main advantages:- constant emissions- simple management- very reduced fuel consumption(the plant self sustains atlow pollutant concentration)

- utilisation of the energy contained bythe solvents in order to self sustain the plant

- polluting substance removingtechnology and efficiency that may becompared with the results of Heatrecuperating oxidising units for VOC

- reduced emissions of CO and NOx.

Advantages of ITAS technology:- process valves with both mechanicaland pneumatic sealing.


E M I S S I O N T R E A T M E N T HEAT REGENERATINGOXIDISING UNITS

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The Heat Regenerating and Catalytic oxidising unitsdistinguish themselves from the heat regeneratingtechnology, as the ceramic mass inside the reactorscontains the catalysts and therefore the self sustain-ing is obtained with low concentrations (0.7 to 1.5g/Nm3).

The use of ceramic masses containing the catalystsallows to transform existing plants type RTO into CTOwith the advantage of reducing the support gas con-sumption where low concentrations exist and thepoint of self sustaining is very far.


E M I S S I O N T R E A T M E N T HEAT REGENERATING ANDCATALYTIC OXIDISING UNITS

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The wet removal process utilises the physical phe-nomenon of VOC diffusion from gaseous phase to theliquid according to dissolving capacity of process liq-uid used and the different component concentrationin both fluids. The physical absorption into the sol-vent takes place until the conditions of balancebetween the phases are reached, according toHenry’s Law. As the absorption process takes placebetween a liquid phase and a gaseous phase, it aris-es that one among the fundamental parameters isthe available surface for the transfer. This is the rea-son why the most common plants that carry out theabsorption on an industry base are towers with pack-ing, towers with spray action or towers with plates,where a sensible increase of contact surface isobtained respectively by means of packing bodies, aforced liquid atomisation or gas scrubbing throughthe liquid in a condition of extreme turbulence.

Technology limits.- Gas purification through absorptiontowers takes to formation of solutions(generally aqueous) that contain VOC .These must be subjected to a treatmentor a distillation in order to separate thesolute from the solvent in view of thesubsequent recuperation.

- The VOC must be soluble into the liquidused for the absorption.


E M I S S I O N T R E A T M E N T WET REMOVAL

AIRINLET

AIROUTLET

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forces (Van Der Waals forces) or by adhesion forcesarising from capillarity phenomena.As it is a phenomenon of molecule migrationbetween a gaseous phase and a solid phase, a fun-damental feature of the adsorbing material is theactivated surface that allows the contact between thecomponents.Particularly, the extremely diffused presence ofmicro porosity in the activated carbon generates avery large surface development: just think that 1 kgof activated carbon may include a total surface oftwo millions of square meters.From the thermodynamic point of view, the adsorp-tion is always followed by heat development, arisingfrom the molecule settlement on a more energetical-ly stable state: effectively, we assist to a free energydecrease due to the formation of bonds within theadsorbed and the adsorber as well as an entropydecrease because of a lesser freedom degree of themolecules.


E M I S S I O N T R E A T M E N T SOLVENT RECOVERYWITH ACTIVATED CARBONS

The operation of activated carbon plants isbased on the adsorption process, i. e. on thephenomenon of molecular diffusionbetween components in gaseous phase,defined as adsorbed, and a solid, defined as

adsorber.The experimentation showed that gas mole-cules (VOC) adhere to solid surface andform one or more superposed layers of sub-stance, created by electrostatic attraction

GAS INLETTO DEPURATION

STEAMINLET

CHILLEDWATER

WATER TOTREATMENT

RECOVEREDSOLVENT

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In rotating concentrators, that use an adsorptionprocess, the VOC contained in a large air flow areconcentrated into a much lesser air flow.This is obtained by keeping the VOC on an adsorbingmaterial and then by releasing them by means of ahot air flow.Both operations are carried out continuously byusing a single drum that rotates at low speed. It isplaced in such a way to work in correspondence withtwo separated sections. In the first one, the pollutedair crosses the rotating drum containing the adsorb-ing material and then it may be directly dischargedinto the atmosphere, as it is adequately purified. Inthe second section the VOC are desorbed by meansof a hot air flow of much lesser flowrate comparedwith that being purified. Therefore in this secondflow the VOCs result at much higher concentration. Asa consequence, VOC recovery processes, where it isconvenient, or thermal destruction processes becomemore easy and economic.The adsorption is ensured by various materials,including activated carbon and zeolites, whilst theparts that form the rotating drum may be in a singleo different materials.All that allows ITAS to design and to manufacture theconcentrators according to the most varied require-ment, also in consideration of the fact that verylarge air flows may be treated by means of rotatingdrums set in parallel.


E M I S S I O N T R E A T M E N T ROTATING CONCENTRATORS

DESORPTION GAS WITHCONCENTRATED VOC

(TO OXIDISER)

PURIFIED PROCESSEXHAUST GAS

(TO STACK)

PROCESSEXHAUST GAS

INLET

COOL DOWN GAS

DESORPTION GAS

AUXILIARYHEATER

ROTATION

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Thanks to over 20-years experience acquiredthrough the installation of its hot air generating unitsfor paper, cellophane, PVC, synthetic fibre, clothes,etc. drying systems and its VOC removal systems,ITAS developed its technologies in the optimisationfield of air circuits containing VOC or water with theaim to reduce energy consumption and exhaust pol-luted air volumes along the process.

“Turn-Key” plants:- feasibility studies;- detection of flowrate and concentrationof VOC or H2O;

- design with investment cost andrelevant pay-back analysis;

- plant erection;- commissioning and start-up;- after sale service.Intervention features:- optimisation of circulation within theplant, by utilising adjustingequipercentage valves produced by ITAS;

- installation of suitable L.E.L. analyser;- replacement of indirect diathermic oil,steam or electrical heating systems,with its direct gas heating system;

- installation of IR burners in order toincrease drying capacity and productionmachine speed.

Advantages:- energy cost reduction per treatedproduct quantity;

- emission volume reduction with savingon the investment for the removal system;

- increase of VOC concentration, thatallows to reach the energy self sustenanceof thermal oxidising units and a betterefficiency of solvent recovery systems.

ITAS manufacturing factory is ISO 9001 certified andits production is carried out taking into consideration:- customer’s personnel safety and health;- plant production capacity andproduct quality;

-VOC concentration in air flows.


ECOLOGY / SERVICES COLLECTION SYSTEMSAND EMISSIONOPTIMISATION

04/2003


CONTROL SYSTEMS01 Programmable Logic Control panels 02 Control systems (PC, PLC, DCS)03 Remote supervision systems

(Tele service)

SERVICES01 Combustion analysis02 Emission analysis03 Optimisation of existing plants04 Thermodynamic process analysis

by means of CFD Software05 Feasibility studies with

environmental impact analysis06 Emission collection and

Optimisation systems07 Support for preparing the necessary

documentation for public authorities08 Complete technical assistance09 Training of Customer’s engineers10 Maintenance contracts

Main fields of application forITAS technologies (Ecology Division)

- printing shops- electronic industry- vehicle manufacture - floor coating production- smell elimination in food industry- production and manufacture of plastics- manufacture of paints- metal recycling- paper mills- pharmaceutical industry- production of Masonite boards- cloth ennobling industry- production of bricks and tiles.


E C O L O G Y A N D E N V I R O N M E N T CONTROL SYSTEMS ANDSERVICES

ITAS designs and manufactures all neces-sary equipment to manage and control theprocesses performed by its plants. ITAS car-ries out the whole design of control, adjust-ment and safety systems for each plant bymeans of CAE systems. Since 1979, ITAS hasused programmable logic in their mostadvanced states, such as nets, remoteperipherals and, first in Italy, PLC certified

as safety equipment, with central units con-nected in back-up. The Ecology divisionsince long time introduced the use ofPersonal Computers as interface betweenuser and process, through the PLC (displays,adjustments and actuation through thescreens, historical storing of process vari-ables, etc.).

TEST ROOMITAS possesses a Test Room that not onlyserves for inspections, tests and research-es on the systems being designed andmanufactured, but also can be put at dis-posal for tests to be carried out accordingto customer’s specifications.

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03/2003

PETROCHEMICAL D IV IS ION

FLARE SYSTEM DESIGN0/00 INTRODUCTION

ELEVATED FLARES1/00 INTRODUCTION1/01 GUY-WIRED SUPPORTED1/02 DERRICK SUPPORTED/CONSTANT

DERRICK GUY-WIRED SUPPORTED1/03 SELF SUPPORTED1/04 MULTI FLARES DEMOUNTABLE RISERS1/05 PORTABLE FLARES

GROUND FLARES2/00 INTRODUCTION2/01 TYPES OF GROUND FLARES

3/00 BIO-GAS FLARES

FLARE TIPS4/00 INTRODUCTION4/01 NON-SMOKELESS4/02 SMOKELESS STEAM4/03 AIR BLOWN4/04 STEAM/AIR SMOKELESS4/05 LOW BTU WASTE GAS

COKE OVEN GAS TIP4/06 ACID GAS (H2S) TIP4/07 AMMONIA (NH3) TIP

HYDROGEN (H2) TIP4/08 SONIC TIP4/09 SPECIAL DESIGN

5/00 BURN PITS

FLARE SYSTEM COMPONENTS6/00 INTRODUCTION6/01 VERTICAL/HORIZONTAL WATER SEAL6/02 VERTICAL/HORIZONTAL K.O. DRUM6/03 COMBINED WATER SEAL/K.O. DRUM6/04 AIR INFILTRATION PREVENTION DEVICE

DYNAMIC AND LABYRINTH SEALS6/05 PILOTS6/06 IGNITION AND CONTROL SYSTEMS6/07 OPTICAL INFRARED PILOT DETECTOR

SMOKELESS CONTROLS6/08 OTHER CONTROLS

7/00 VENT ANDSNUFFING SYSTEM

OFF-SHORE EQUIPMENT8/00 MAIN EQUIPMENT8/01 BOOM STRUCTURE

H2S AND/OR ACID GAS9/00 INTRODUCTION9/01 COMBUSTION EQUIPMENT

BURNER SYSTEM DESIGN10/01 COMBUSTION EQUIPMENT10/02 LOW NOx SHORT FLAME

BURNER TYPE IT-IS10/03 ULTRA LOW NOx BURNER TYPE IT-Q10/04 LOW NOx DOWN FIRING BURNER

TYPE IT-DFB/510/05 LOW NOx SIDE WALL FLAT FLAME

BURNER TYPE IT-FFB/510/06 INJECTION GAS BURNER TYPE IT-IGB10/07 DIRECT FIRED HEATER TYPE IT-DFH10/08 PILOT BURNER TYPE

IT VBP/ND/EI/IR/6010/09 LOW HEAT VALUE SPECIAL BURNER10/10 BURNERS FOR INDIRECT FIRED

HEATERS OR GLYCOL REGENERATORS

SCRAPER TRAP STATIONSAND PIPING ACCESSORIES 11/01 PRODUCT RANGE (1/2)11/02 PRODUCT RANGE (2/2)

www.itas.com [email protected] have the answer

THE FLARE IS THE MAIN AND MOSTCRITICAL PART OF AN EMERGENCYPROCESS RELIEF SYSTEM.The purpose of a flare system is to safely dispose ofwaste gases from a process and to oxidise them intoless harmful substances especially where the wastesare toxic or corrosive.

Flare types commonly available can be put into threemain groups:

ELEVATED FLARES

GROUND FLARES

BURN PITS

ITAS FLARE DESIGNFlares have to perform as safe, effective and effi-cient operating systems. All ITAS designed flaresoperate at optimised levels with regard to stringentinternational standards, safeguarding plant opera-tion, maximising destruction efficiencies and reduc-ing noise levels.

ITAS also has full range of equipment to complementthe flares available. This is particularly importantwith regard to controlled smokeless flares utilisingforced air, steam, water or gas pressure as we areable to offer complete systems on a turnkey basis.

In addition a wide range of instrumentation is avail-able to monitor safety interlocks, combustion effi-ciency, emissions and utility consumptions.

P E T R O C H E M I C A L D I V I S I O N 0/00

F L A R E S Y S T E M D E S I G N INTRODUCTION04/2003


ELEVATED FLARESThe term elevated flare is used to describe flareswhich comprise a single tube riser arranged verticallylike a chimney so that the flame at the top is wellabove ground level and does not constitute a hazardto personnel or plant. Elevated flares may vary inheight from as little as 3m to as much as 200m.

BENEFITSElevated flares are selected in preference to otherequipment primarily on economic grounds, having alarge capacity for a relatively small capital outlay.The use of elevated flares is particularly importantwhere toxic gases are burned and height is requiredto assist dispersion or where the radiation from theflare flame has to be kept within safe limits atground level.

TYPES OF STRUCTURESThe type of structure used for an elevated flaredepends on economic and structural design consider-ations rather than on process requirements.There are commonly three different designs used:

GUY SUPPORTED FLARES

SELF SUPPORTED FLARES

DERRICK SUPPORTED FLARES


E L E V A T E D F L A R E S INTRODUCTION04/2003


GUY SUPPORTED FLARESare usually the most economic choice.

For this type of flare the structural design is the mostcomplex but computer aided structural planning isavailable to solve the problems connected to differ-ences in stack and ambient temperature and also toforces generated by wind and/or earthquake.

The guy ropes add large damping forces and fre-quently overcome aerodynamic loading problems.

The major disadvantage associated with the use ofguy ropes is the land usage required to locate theanchor points as an allowance has to be made forthe deadman radius which is usually up to 55% ofthe lenght of the guy-supported stack. Three dead-men usually anchor up to five ropes from the stackand are designed to resist the horizontal and verticalcomponents of the tension in each rope. The horizon-tal load determines the concrete area to be usedagainst the frictional resistance of the ground andthe thickness of the block calculated against theallowable bearing pressure in the ground to counter-act the vertical load of the guys.

In order to reduce maintenance on the ropes, wirerope cores should be used rather than fibre andropes and fittings should be heavily galvanized. Ifpretensioned ropes are used retensioning after initialerection will be minimised.

Erection of guyed stacks relies heavily on the use oftall craning and this should be a consideration atdesign stage. Single piece lift using strongback tech-niques to stiffen the riser tube are also possible asare self build units using a climbing davit.


E L E V A T E D F L A R E S GUY-WIRED SUPPORTED04/2003


DERRICK SUPPORTED FLARES:comprise a simple riser tube housed within and sup-ported by a braced framework.

This design is particularly suited to taller flares whereguyed units are not practical and self supportedstacks are uneconomic. Generally these structuresare expensive to erect and maintain, but are suffi-ciently flexible to suit erection needs and may beassembled piecemeal where only limited craneage isavailable. To minimise maintenance the derrick struc-ture should be galvanised.

Foundations are probably simpler than with self sup-ported flares and the final design is usually adapt-able for subsequent changes to the stack or servicepiping.

For extreme temperature or corrosive service wherespecial materials may be needed, it is often prefer-able to use derrick support which allow the risers toeconomise on thickness or even to be replaced aspart of a scheduled maintenance programme.

Derrick supported flares permit the installation of amulti flare system with demountable flare stacksdivided in flanged sections. This system is advanta-geous for refineries and petrochemical plants wherethere is a limitation in locating several flares on theavailable plot plan and allow an easy maintenanceof a single flare while the others are in service.

CONSTANT DERRICK GUY-WIREDSUPPORTED FLARES:allow internal or external flare riser installation. Thisparticular flare structure is desirable when handlinghot waste gases.

Guy wires are not effected by expansion or contrac-tion of the flare gas riser as they are anchored to thestructure. The structure incorporates all required pip-ing, wiring, ladders and platforms.


E L E V A T E D F L A R E S - DERRICK SUPPORTED- CONSTANT DERRICKGUY-WIRED SUPPORTED

04/2003


SELF SUPPORTED FLARES:These are completely free-standing structures.Although designed to simple structural principles thistype of structure faces the biggest challenge withrespect to aerodynamics and seismic forces.

The self supported flare has the smallest footprintand is an attractive option when space is at a premi-um. However, for flare stacks of any appreciableheight it is likely to be the least favourable withregard to capital investment.

Design challenges of a self-supported flare includewind induced oscillations and stress reductions to pre-vent plate buckling. Most codes cover vortex shed-ding oscillations and seismic considerations.

The foundations for a self supported flare are usuallymore involved than other designs as the whole windload and bending moment must be carried by a sin-gle foundation.

Erection relies on available craning. However, thegreater stiffness of the self-supported design (overthe guyed type) facilitates lifting.


E L E V A T E D F L A R E S SELF SUPPORTED04/2003


MULTI FLARE DEMOUNTABLE RISERSON DERRICK STRUCTUREITAS Multi Flare Demountable Risers DerrickStructure has been designed in order to be able totake down or put up a stack without taking the otherflares out of service. It is advantageous forRefineries and Petrochemical Plants where there is alimitation in locating several flares on the availableplot plan.

The supporting structure can be a three or four legsteel tower, capable of bearing multiple flare stacks.The supporting structure is manufactured from pipeor rolled steel section (profiles).

On the vertical surface of the derrick, guide rails(two for each flare) are installed. Sufficient laddersand platforms are provided for the demountableoperation of the flare stack(s). For access to the ele-vated platforms caged ladders are installed.

A thermal radiation shield is provided above theworking platform as protection during change out offlare.

The flare stack(s) is divided in flanged sections of anapprox. length of 20 metres. All the utility lines(pilot gas, ignition and steam lines) are attached tothe stack sections and are likewise flanged. Each sec-tion of the stack(s) is provided with support armswith rollers that can turn along the guide rails. Thedistance between the top of the flare tip and the topof the supporting structure is about 10 metres.

The hoisting system for lowering and lifting the stacksections consists of electrical or hydraulic winches.The winches are equipped with automatically operat-ed brakes to prevent an accidental release of theload. Winches are mounted on a sub-frame so as toallow storage indoors.

ITAS Multi Flare Demountable Risers DerrickStructure can be utilised for flare systems up to 200metres high.


E L E V A T E D F L A R E S MULTI FLARESDEMOUNTABLE RISERS

04/2003


This type of flare is particularly useful for pipelineand maintenance operations or where a large sterilearea is available.

The ITAS portable flare consists of a flare tip mounteddirectly onto a base mounted molecular seal or K. O.drum. They are usually assembled on service vehicleand can be erected by one man in a few minutes.The flares include a stainless steel tip, and theignition system can be either electrical, with batteryback-up or piezo-electric.

The portable f lares can be equipped with agas/liquid separator.


E L E V A T E D F L A R E S PORTABLE FLARES04/2003


Ground flares vary in phisical size and shape but allconform to the general requirement that flaring anddisposal may take place at low level. In remote loca-tions low level open flaring has been employed. Inpopulated areas ground flares are now used to burngas without smoke and with no visible flame. Thishas led to the development of a range of equipmentbased on the furnace designs in which combustion isshielded from view thereby avoiding nuisance toneighbours.

The flared gases often contain hydrocarbons thatwould burn with a smoky flame without additionalenergy. For this reason, the ITAS staging system andthe burner design use the pressure in the waste gasat the burners (to inspire sufficient quantities of freeair for smoke suppression) and forced air or steamfor those conditions where the pressure falls too low.

Bottom fired or side-fired burners may be used andselected in accordance with the design and geometryof the ground flare, taking into account the qualityof the flared gases. The flare burners are manifoldedin grouped stages, with each stage containing therequired number of burners. The relief system hasan open first stage burner with no-automated valve.The burners are designed to fire into the combustionchamber, causing circulation and improved mixing.This gives a shorter flame and ensures even distribu-tion of the combustion in the chamber.


G R O U N D F L A R E S INTRODUCTION04/2003


Waste gas flow to all of the stages is controlled (openor closed) through fast-acting, high performancevalves. These “staging” valves are actuated by theStaging Control System consisting of flow or pressuretransmitters, which input to a programmable con-troller to ensure proper sequencing and coordination.The staging valve rack is located outside the wind-fence of the ground flare system.

Sufficient pilots are provided to ensure proper igni-tion. The ITAS burner design easily cross-lights fromone burner to the adjacent one horizontally or verti-cally. The pilot interlock logic is that at least one pilotmust be proven on each stage to allow the stages toopen. Additionally, the failure of any pilot wouldsound an alarm for operator intervention and lock-out any unused stage.

The enclosed ground flare is usually lined with one oftwo different types of refractory:- ceramic fibre;- refractory castable.Both systems are designed for a hot face tempera-ture of 1.200°C minimum.

The windfence is designed to diffuse any wind fromimpinging directly on the burner windows, and toassist in distributing air around the unit. The wind-fence is designed for a very low pressure drop, underthe full flow conditions. It also shields against radia-tion from the flare.

The windfence is internally lined with a high temper-ature ceramic fibre material to protect the surfacefrom the high radiation and also to attenuate thenoise from the combustion.

-TOTALLY INVISIBLE FLARING SYSTEM-HIGH PRESSURE MULTI TIPS FLARE-AIR INDUCED ENCLOSED FLARE-PRESSURE STEAMLESS GROUNDFLARE-STEAM ASSISTED GROUND FLARE-CONTROLLED COMBUSTION GROUND FLARE


G R O U N D F L A R E S TYPES OF GROUND FLARES04/2003


Bio-gas and Landfil l flares are flare systemsdesigned specifically to dispose of gases produced ina waste treatment or disposal system. The organicwaste produces methane gas and carbon dioxide gasin about equal quantities.

Two types of flares are typically employed:- ELEVATED FLARE- TOTALLY ENCLOSED GROUNDFLARE

Open flame units have been a standard design formany years. Combustion takes place on top of a spe-cially designed flare burner. Stacks must be sizedwith enough height to limit radiation level at grade.The elevated flare does not have the flexibility toallow temperature control, air control, or sampling ofcombustion products. However, it does provide stablecombustion in extreme climatic conditions. The ele-vated flare is normally the most cost-effective way ofsafely disposing of waste gases.

Enclosed ground flares are designed such that thewhole combustion takes place in a refractory-linedchamber. No flame should be visible outside the unit.These units are used when a visible fire is notallowed. Enclosed flares also offer more control ofthe combustion process in relation to combustiontemperature and residence time.

Complete flare systems are designed to give auto-matic flaring on demand.


B I O - G A S F L A R E S04/2003


A flare tip is used for the disposal of waste com-bustible gases and consists basically of a high gradealloy tube. Usually it is mounted on the top of a steelstack so that the heat of combustion and its productswill not cause danger to life and property on theground.The flare tip is provided with an ignition sourcecalled a pilot burner. The pilot burners supply a con-stant source of ignition to the root of the flame sothat even if there is a tendency for the flame to liftoff, the flaring gas is being constantly re-ignited. Thenumber of pilot burners installed around the flare tipis function of the flare tip diameter.The wind shield is made up of a series of deflectors andis one of the most important components of the flaretip. In addition the flare tip is provided with flameretention rings or flame stabilisers. On the deflectorside wich is exposed to the wind, an air compression,immediately upstream of the plates, will take placedue to the energy of the wind stream. After the airstream has passed the free vertical spaces between theplates, a through vortex is formed by the suddenincrease of the cross section, so that the wind energy iscompletely absorbed. Thus, no air pressure and accu-mulation will build up on the flare tip side exposed tothe wind, and no vacuum can form on the lee-side. Inview of the above, a down-deflection of the flame issafety prevented and long life of the tip is ensured.TYPICAL TYPES OF FLARE TIPS:- NON-SMOKELESS- SMOKELESS STEAM- AIR BLOWN- STEAM/AIR SMOKELESS- LOW BTU- COKE OVEN GAS- H2 (HYDROGEN)- ACID GAS (H2S)- NH3 (AMMONIA)- SONIC

FLARE TIP DESIGN CONSIDERATIONSA flare tip should be selected with the aim of:- improving combustion to reduce radiations and thequantity of unburned gases released to the atmosphere;

- reducing or eliminating smoke formation;- ensuring that the flared gases burn with a stableflame over the whole operating range;

- reducing to a minimum the maintenance requiredover its operating life;

- meeting permissible noise levels.


F L A R E T I P S INTRODUCTION04/2003


The ITAS RK Tip is a general purpose flare tip for usewhen smoke suppression is not required eitherbecause the gas to be flared is not an inherentsmoke producer, or enviromental conditions permitit. This type of flare tip is equipped with wind deflec-tor and retention ring to ensure complete flame sta-bility under the most severe weather conditions.


F L A R E T I P S NON-SMOKELESS04/2003


The ITAS DIK Tip is a smokeless flare tip designed foruse with a wide range of hydrocarbon gases. Thesteam is externally injected directly into the root ofthe flame, by means of several nozzles locatedaround the top of the tip. Thus, the steam jetmomentum draws-in the air in order to producefaster and clean combustion.This type of flare tip is normally supplied completewith wind deflectors, retention ring, central steamnozzle.


F L A R E T I P S SMOKELESS STEAM04/2003


The AIR BLOWN flare is designed with the followingfeatures:1. Top exit swirling.2. Low operational costs.3. Lower maintenance requirements.4. Elimination of steam lines and controls.5. Non-luminous combustion.6. Longer flare burner life.7. Low noise levels.8. Low emissions.9. Low pressure air for smoke suppression.10. Up to 100% smokeless combustion.

The ITAS DKC flare tip is suitable for smokeless burn-ing of hydrocarbon gas, using air from a blower. One benefit of the air blown flare is a longer tip life.The forced air continuously flows past the flare tipeliminating burn-back problems and cools the flaretip itself. This results in lower maintenance.


F L A R E T I P S AIR BLOWN04/2003


The ITAS DKCS flare tip is designed to provide widerange smokeless burning at lower noise levels andwith optimum steam usage.

This type of burner is provided with an externalsteam injecting system located at the top of the tip.This flare tip also has an internally installed steamand air injecting system which feeds the steam airmixture into the centre of the gas stream.The lower steam injectors are equipped with thesilencer.Centre steam is provided to handle low waste gasflows and to offer operating flexibility.

ITAS DKCS flare tip design advantages:- low noise emissions;- low luminousity;- wide smokeless range;- low steam consumption.


F L A R E T I P S STEAM/AIR SMOKELESS04/2003


The ITAS flare tip is designed for low pressure drop,which gives a correspondingly low exit velocity.

When the LHV of the flaring gas is below 1600KCAL/Nm3 support fuel gas should be added toensure good destruction efficiency.This support fuel gas is injected in the flaring gasthrough special nozzles located in the top of the flaretip.

The flare tip is equipped with special heat shieldinstalled at the top of the tip, in order to protect theroot of the flame from the wind.


F L A R E T I P S LOW BTU WASTE GASCOKE OVEN GAS TIP

04/2003


Usually a separate Acid Gas flare is required to burnthe acid gas stream. The flare stack is externallyinsulated in order to keep the acid gas stream wellabove the condensation point.

Acid streams may require support fuel gas in orderto complete the combustion. This is a function of allthe components of the flaring stream.

Depending on the composition of the acid stream aspecial heat shield and a support fuel gas burnermay be required.


F L A R E T I P S ACID GAS (H2S) TIP04/2003


ITAS has designed an Ammonia flare tip in which theroot of the ammonia flame is well stabilised at theexit.

This design, associated with a low ammonia exitvelocity, creates a combustion efficiency of over95%. The burning of ammonia in this way producesa relatively cool flame with a relatively low level ofNOx emissions.

To increase the combustion efficiency, support gasmust be added to the ammonia stream.


F L A R E T I P S AMMONIA (NH3) TIP04/2003


In flaring Hydrogen, precautions must be taken toinsure that system is completely sealed so as to pre-vent air entry. Increased purge rate will avoid airentry. A Molecular Seal is strongly reccomended.When pressure is available the flare tip should bedesigned for high exit velocity.

HYDROGEN (H2) TIP

If the gas to be flared is available at the tip at highpressure it is possible to produce smokeless and lowradiation combustion.

ITAS is able to supply three types of sonic tip whichutilise the gas pressure to inspirate combustion airthereby improving combustion and lowering radia-tion.

The preferred design is a multi-arm, multi nozzleburner. Each nozzle is designed for a sonic exit veloc-ity thereby maximising the amount of air that can beinspirated.

A possible alternative is to operate an open pipe atsonic velocity. This type of tip does not provide opti-mum conditions for combustion, has high noise lev-els, but is relatively low cost.Consequently it is suited to emergency relievingwhich will occur infrequently and under highlyexceptional circumstances.


F L A R E T I P S SONIC TIP04/2003


On particular client demands, ITAS designs and sup-plies special flare tips utilising:- Water ignition nozzles;- Coanda injection nozzles;- High Pressure gaz nozzles;- Radial arms nozzles.


F L A R E T I P S SPECIAL DESIGN04/2003


The main use of a burn pit is to dispose of liquid ormixed liquid/vapour reliefs generally as emergencyflows or an intermittent basis when blowing downpipelines or vessels.

The nature of the pit is simply a shallow depressionor hole in the ground which acts as a reservoir forthe burning liquid. The pit is normally lined withrefractory material (castable or bricks). The philoso-phy of burn pit flaring is essentially unsophisticated,and this technology is frequently employed where itmay be necessary to blow down a section of pipelinein some emergency situations.

The design of the pit should take into considerationthe maximum input rate of liquid and the rate atwhich this can burn. The most conservative and con-sequently the usual method of sizing is to assumethat it is required to burn the flammable liquid at thesame rate at which it is relieved to the pit.

The liquid in the pit burns and supports its own com-bustion by radiating heat back from the flame intothe liquid at the top of the pool which then vaporisesand heats up further before burning in the flare. Therate at which this vaporisation occurs is dependanton the thermal heat output of the flame and the sen-sible heat of vaporisation of the liquid at the top ofthe pool.

As the air for combustion of the liquid supportedflame is drawn only from around the outside of thepool the mixing of air is poor and the resulting flamewill almost certainly smoke heavily and could relieveuncombusted hydrocarbon together with the smokeplume.

Ignition of the flammable vapours is accomplishedby setting a number of continuously burning pilotsaround the outlet of the feed headers. At least twopilots should be used for each header.

ITAS designs and supplies:

BURN PITSPIT TIPS AND PILOTSIGNITION SYSTEMSREFRACTORIES


B U R N P I T S04/2003


ITAS, one of the world’s largest manufacturers offlare systems, offers complete flare control pack-ages. ITAS experience with hundreds of flare systemsensures well-designed and proven controls technolo-gy.

IGNITION SYSTEMThe most important piece of flare control equipmentis the pilot ignition system. ITAS ignition systemsoffer the following benefits:- Easily accessible control components.- Proven and reliable ignition.- Complete shop testing prior to shipment.- Meets all required electrical classifications.

ITAS provides ignition systems of the following types:Manual or Automatic Flame Front Generator (FFG),Self-inspirating FFG, electronic High Energy Ignition,and Pilot monitoring.In addititon to ignition systems, ITAS provides othercontrols necessary for proper flare operations.

PURGE CONTROLSFor molecular and velocity seals, purge controlsensure proper flow of purge gas to the flare systemand prevent air entering into the flare header.

PILOT MONITORPilots are monitored via Dual Thermocouples and/orInfrared Pilot Monitor, with relevant control paneland remote alarms.

STEAM CONTROLITAS offers a complete steam control package,including restriction orifices, mass-flow controls,valves, gauges and controllers, coordinated aroundand designed for use with the ITAS Optical System.

SPECIAL FLARE CONTROLSITAS can provide special flare controls, featuring:- Patented staging controls.- Knockout and liquid seal drum controls.- Blower controls for air induced flares.- Flame extinguishing systems.- Skidded, assembled, completely pre-piped and pre-wired control packages.


F L A R E S Y S T E M C O M P O N E N T S INTRODUCTION04/2003


The water seal drum is utilised to provide positivepressure on the flare header and to be a flamearrestor in the event a flashback occurs in the flareriser.

The internals of the water seal have a special designto insure a steady flow of gases and minimise pulsa-tions to the flare burner. Consequently, with the mini-mum amount of supplementary energy, it is possibleto optimise the smokeless capacity of the flare, andto reduce the noise.The water seal can be either horizontal or verticaland may be incorporated into the flare stack base.


F L A R E S Y S T E M C O M P O N E N T S VERTICAL/HORIZONTALWATER SEAL

04/2003


ITAS Knock-out Drums are designed to removeentrained liquid droplets from the waste gas.

Removal of the entrained liquid from a waste gasstream is important for two reasons. Primarily, thepresence of hydrocarbon liquid in the gases pro-motes intense smoking during flaring. Also, if the liq-uid particles pass through the flame envelope at theflare tip, they may bring about a safety problem bybeing ignited and rain fire into the terrain below.

The K.O. drum can be either horizontal or verticaland may be incorporated into the flare stack base.


F L A R E S Y S T E M C O M P O N E N T S VERTICAL/HORIZONTALK.O. DRUM

04/2003


When it is possible to combine a Water Seal and K.O.drum there is a significant saving in costs due to lessfoundations, interconnecting piping and installation.

The water seal drum is utilised to provide positivepressure on the flare header and to be a flamearrestor in the event a flashback occurs in the flareriser. The internals of the water seal have a design toinsure a steady flow of gases and minimise the pul-sations to the flare burner. Consequently, with theminimum amount of supplementary energy, it is pos-sible to optimise the smokeless capacity of the flare,and to reduce the noise.

ITAS Knock-out Drums are designed to removeentrained liquid droplets from the waste gas.Removal of the entrained liquid from a waste gasstream is important for two reasons. Primarily, thepresence of hydrocarbon liquid in the gases pro-motes intense smoking during flaring. Also, if the liq-uid particles pass through the flame envelope at theflare tip, they may bring about a safety problem bybeing ignited and rain fire into the terrain below.


F L A R E S Y S T E M C O M P O N E N T S COMBINED WATERSEAL/K.O. DRUM

04/2003


DYNAMIC SEALThe ITAS dynamic seal is of a Venturi type, designedas an integral part of the flare tip. The Venturi isdesigned to minimise air infiltration into the flarestack with significant purge gas savings. The sealrelies on a momentary increase in the gas velocity,creating a turbulent flow condition and preventingthe ingress of air into the stack.

MOLECULAR SEALThe molecular seal is installed just below the flaretip. The seal is flanged between the flare tip andstack. The molecular seal is designed to prevent airfrom infiltrating into the flare system. Even when thepurge gas is interrupted, the molecular seal providesprotection for an extended period of time. The ITAS MS is of a labyrinth type. The device can beused with seal gas lighter or heavier than air. Eitherin the top or in the bottom section of the seal thepurge gas forms a barrier to prevent the penetrationof the air into the flare stack. There are many factorsinfluencing air entrainment into the stack: wind,temperature, molecular diffusion of gases, and soon. In order to counteract this phenomenon a perma-nent flow of purge gas is required to maintain theeffect of the seal.


F L A R E S Y S T E M C O M P O N E N T S AIR INFILTRATION PREVEN-TION DEVICE DYNAMICAND LABYRINTH SEALS

04/2003


ITAS pilot and ignition systems are compatible withthe complete flare range. Reliability and stability isensured by careful selection at the flare designstage.

The specially shielded nozzle ensures a stable flameand reignition in wind velocity as high as 200 km/hr.A traditional ITAS pilot assembly consists of an inspi-rating pilot burner with a forced draught ignition sec-tion. Each pilot is nominally rated at 30.000 Kcal/hr,but on request low consumption pilot can be provid-ed.

If pilot flame failure indication is required, a thermo-couple is fitted internally to the pilot nozzle to pro-tect it from exposure to the main flame.

ITAS also supplies High Energy Ignition Systems. Toguarantee reliable ignition the H.E. plugs are inte-grated into the burner head. The ignition is basedupon the principle of capacitor discharge over a spe-cial discharge surface.

ITAS pilots can be self-inspirating or forced air supplyand are suitable for natural gas, propane, butane,bio-gas, Hydrogen, mix-hydrocarbons, off-gas mix-ture.


F L A R E S Y S T E M C O M P O N E N T S PILOTS04/2003


The principle of flame front ignition is fairly simple.A pipe is filled with a gas air mixture and an ignitionsource is applied on the mixing chamber. The result-ing flame travels until it reaches the end of the pipe,where it may itself act as ignition source for a gasstream or pilot burner.

The ITAS pilot ignition systems are suitable for use onall types of elevated flares, ground flares and burnpits.Reliable operation is guaranted in extreme weatherconditions.

Pilot flame monitoring is usually by thermocouple.

Those systems include:- AUTO/MANUAL IGNITION PANEL- NO-ELECTRICAL IGNITION PANEL- HIGH ENERGY IGNITION PANEL- FLAME FRONT IGNITION PANEL- SPLIT - IGNITION PANEL


F L A R E S Y S T E M C O M P O N E N T S IGNITION AND CONTROLSYSTEMS

04/2003


Unlike costly thermocouple systems, the ITAS PilotMonitoring System uses an infrared optical unit todetermine pilot flame status. Flame status is then con-tirnously transmitted as a linear signal. This versatilesignal can function as an alarm for flame-out, as atrigger for auto ignition system, as a regulator of fuelgas usage, and for recording/reporting purposes.

Infrared optical technology enables the PilotMonitoring System to operate in remote plant loca-tion, safely away from flarestacks. Installation issimple and quick.Expensive installation equipment is not needed. Unlikethermocouples, plant/flarestacks shutdown is unneces-sary for installation and subsequent maintenance,resulting in both immediate and long-term savings.

The optical sensing unit of the Pilot MonitoringSystem is in full compliance with EPA recommenda-tions for pilot flame monitoring and control.Developed from the successful ITAS Flare StackMonitoring System, the Pilot Monitoring System isfield-tested and backed with ITAS proven reputation.


F L A R E S Y S T E M C O M P O N E N T S OPTICAL INFRAREDPILOT DETECTOR

04/2003


OPTICAL SMOKELESS DETECTORITAS flare stack monitoring system contains a uniqueinfrared optical unit. It detects flux density changes in thehydrocarbon flames of flares. ITAS systems work day andnight, unaffected by fog, rain or clouds.

ITAS systems generate a continuous process variable signalfor control purposes. The signal is proportional to theamount of unburned carbon in the flare. Flare gas compo-sition, density, or flow rate does not hinder the accuracy ofthe system’s signal.

The ITAS monitor provides the process variable signal forsteam control, allowing only the steam necessary for com-plete and smokeless combustion. No more, no less. Steamis used efficiently and economically. Noise from excesssteam is eliminated.

MASS FLOW METERSITAS provides a unique design to control the steam for smoke-less combustion utilising thermal mass flow meter or ultra-sonic flow meter backed up with optical smokeless detector.

SMOKELESS CONTROLS

WATER SEAL CONTROLSLevel gauge, level transmitter, temperature transmit-ter, control valves.

K.O. DRUM CONTROLSLevel gauge, level transmitter, Hydrocarbon conden-sate pumps

PLC STAGING SYSTEMFlow transmitter, pressure trasmitter, control valves,rupture disk.

AIRCRAFT WARNING LIGHTSFixed and removable lights in accordance with allinternational codes.

FLAME ARRESTORSInline, end of line, detonation flame arrestors,designed and supplied in accordance to EN12874 orPTB, B.S., U.S. Coast Guard.


F L A R E S Y S T E M C O M P O N E N T S04/2003


ELEVATED VENTIn many situations, pressure-relief vapour streamsmay be safely discharged directly to the atmosphereif environmental regulations permit such discharges.

The decision to discharge hydrocarbons or otherflammable or hazardous vapours to the atmosphererequires careful attention to ensure that disposal canbe accomplished without creating a potential hazardor causing other problems, such as the formation offlammable mixtures at grade level or on elevatedstructures, exposure of personnel to toxic vapours orcorrosive chemicals, ignition of relief streams at thepoint of emission, excessive noise level, and air pol-lution.

High vent stacks are sized for an high exit velocity atthe maximum relief rate to provide excellent disper-sion.

AUTOMATIC INERTS SNUFFING SYS-TEMA remote controlled snuffing system should beinstalled on all cold vent stacks in order to avoid con-tinuous burning in the case of accidental ignition ofthe vented gases.

The snuffing medium may be nitrogen, carbon diox-ide or steam (if available); halon or other CFCs is notbe used due to their adverse effects on the environ-ment.

The snuffing system is operated from an auto/manu-al station. Once the flame is extinguished, the controlsystem ensures that metal temperatures at the tip ofthe vent fall sufficiently to prevent spontaneous igni-tion of gas and the danger of flash-back.

The snuffing facilities is sized to extinguish the stackat least three times in succession when it is burningand discharging at a rate corresponding to one per-cent of the maximum vent rate.


V E N T A N D S N U F F I N G S Y S T E M04/2003


Many different equipment may be provided for gasand liquid waste disposal on the off-shore platformsor rigs.

LIQUID/GAS MUD BURNERThe ITAS versatile burner is available in differentversions, using the same type of combustion headand standard swivel. Several atomizer nozzles arealso available to suit specific conditions.The burner is suitable for disposal of:- crude oil- oil-base mud and workover fluids.The ITAS Mud Burner comprises several combustionheads fitted on the same supporting frame. The mudburner is supplied with individual pilot and waterignition device. A supporting frame with two pivotsand swivel joints allows rotation of 75° on each sideof the boom center line.The special atomizing device ensures a perfectsmokeless combustion by direct water ignition intothe flame, thus resulting in no pollution and reducedheat radiation.

SPECIAL FLARE TIPSH.P./L..P. COMBINED FLARESONIC FLAREMULTI NOZZLE FLARESPECIAL ENCLOSED FLARE


O F F - S H O R E E Q U I P M E N T MAIN EQUIPMENT04/2003


SUPPORTING FRAMEIt supports the mud burner, piping, swivel and pilotlight system.SWIVEL JOINTFor complete safety, oil, air, gas and water are sup-plied through check valves to a vertical swivel jointdistributor which enables the burner to be orientedto suit the wind direction.ROTATION SYSTEMThe supporting frame is mounted on a rotating pivot,actuated by cable and a hand winch from the foot ofthe boom. An optional pneumatic rotation kit can besupplied for remote-control from the platform or rig.Maximum rotation: 150°.SUPPORTING BOOMIn addition to providing a support for the burner, theboom can be oriented and limits heat radiation onthe rig at an acceptable level.ITAS provides a standard supporting boom completewith an indipendent gas flare and the necessary pip-ing to feed the burner.The ITAS boom is manufactured in accordance withClient’s specifications and standards and is designedto withstand winds up to 240 km per hour. For easeof trasport and assembly, the boom is made up ofseveral lightweight corrosion resistant sections.Each structural member is of square tubular designto give the maximum possible strengh with the light-est weight.The U-shape facilitates safe and easy access to themud burner itself.The components of the boom are as follows:- A rotating pivot plate (horizontal and verticalrotation).

- A working platform around the burning heads.- A gangway equipped for safe circulation along theboom.

- Piping for oil, water, air, gas.- Gas/diesel oil pilot light.- Electric line for igniter.- Vertical guy ropes.- Two horizontal guy ropes ( boom orientation).- Gas flare.


O F F - S H O R E E Q U I P M E N T BOOM STRUCTURE04/2003


ITAS has more than 20 years of experience in thedesign and supply of combustion and process equip-ment.For the sulphur recovery process or others where anacid gas is involved ITAS can provide:

- ACID GAS BURNER- TAIL GAS BURNER- HIGH INTENSITY BURNER- IN-LINE REACTOR/BURNER- TAIL GAS/ACID GAS THERMALOXIDIZER

- REACTION FURNACE/WASTE HEATBOILER

- ACID GAS FLARE SYSTEM.


H 2S A N D / O R A C I D G A S INTRODUCTION04/2003


BURNERS

Tail gas and acid gas burners operation may be nat-ural draft, forced draft or pressurized.The burner design is effected case by case in functionof the specific quantity and components of the acid-gas stream and is suitable for operation in substoi-chiometric or stoichiometric or in excess of airdepending on the application required.Super alloys and heat/acid resistant refractory areused to withstand H2S corrosion.Burners are no-leak design, and are equipped withpermanent pilots or direct spark high energy igni-tion, IR/UV dual scanners, sight ports, purge connec-tions.

THERMAL OXIDISER

With air pollution laws becoming more stringent thethermal oxidiser (incinerator) is virtually mandatory.ITAS can provide natural draft or forced draft ther-mal oxidiser, complete with stack and controls.The unique design of the refractory lining ensureshigh efficiency and less maintenance.

REACTION FURNACE/W.H.B.

The refractory lined reaction chamber and fire-tubesboiler are manufactured according to all pressurevessels standards (ASME, TUV, BS, VRS/VSG, etc...).The unique design of the refractory lining and fer-rules ensures excellent performance and less mainte-nance.ITAS provides skid mounted packages, includingblowers, controls, valve trains.

ACID GAS FLARE

ITAS special design acid gas flare assures a destruc-tion efficiency greater than 99%.In the sulphur recovery process the acid flare isrequired in order to permit the operation of the plantin case of temporary shut-down of the sulphur recov-ery train.The flare is supplied complete with supporting struc-ture, ignition and control panel.


H 2S A N D / O R A C I D G A S COMBUSTION EQUIPMENT04/2003


ITAS S.p.A. is an engineering company designing andsupplying, amongst many other products, burnersand accessories for combustion systems as well asentire turn-key combustion plants.ITAS S.p.A. combustion equipment includes:1 - Industrial burners for chemical and petrochemical

processing heaters, gas and/or oil fired.2 - Boiler firing systems for thermal power plants

and steam raising units, gas and/or oil fired.3 - Special tailored burners according to clients

requirements, gas and/or oil fired.4 - Short flaming, high intensity heat radiating

burners, gas fired.5 - Complete direct firing air heater units including

combustion chambers.6 - Complete incinerator units for waste gas

and waste oil.7 - Ignition, flame monitoring and control systems,

locking and interlocking devices for theequipment described above.

Emission limiting execution of high standard (Low NOxand Ultra Low NOx construction) not only meeting but,in some respect, surpassing German Standards andRegulations (such as TA Luft, Bimsch, etc.) is available.In addition to the design and supply of burners andburner equipment for newly erected plants the applica-tion of ITAS S.p.A. burners and burner equipmentapplies to:• Limiting the flue gas emissions from existing boiler

plants and furnaces by replacing or modernisingoutdated or faulty burners.

• Increase of heating capacity based on the dimen-sioning of the furnace. Modification of burners incase of changing the firing media or composition.

• Preheating of air or flue gas in catalytic systems(start heaters).

• Destroying of gaseous and liquid waste(thermal oxidation)

• Up-dating of firing systems, providing orsupplementing them with ignition, monitoringand control systems.


B U R N E R S Y S T E M D E S I G N COMBUSTION EQUIPMENT04/2003


Special application for heaters with specific Short fur-nace or for rising of heater capacity protecting thefurnace convection zone against overheating.Available as either natural draft or forced draft burn-er, either as gas or combination gas oil burner. Thisburner can be installed either as side wall burner oras bottom burner. The NOx development is below200 mg/Nm3 independent of whether the burner isair staged operated or fuel staged. Our experience isbased on a capacity on 25 MW.Burners are available in the capacity range from 0,5to 50 KW; combustion air can be preheated up to100° C.


B U R N E R S Y S T E M D E S I G N LOW NOx SHORT FLAMEBURNER TYPE IT - IS

04/2003


gas jet, star type

air stage

swirler muffle

UV scanner

fuel gas inlet

pilot burner orignition rod

heater bottom

burnerhousing

secondaryair

primaryair

This burner is manufactured in two versions, eitheras gas burner or as a combination gas oil burner, tobe installed as bottom burner or as side wall burnerwith straight flame. Depending on the individualrequirement we supply this either as natural draft orforced draft. The operating capability of our stan-dardised burner type ranges between 0,5 - 25 MW.This burner distinguishes itself by its extreme lowNOx development which is below 50 mg/Nm3 in fluegas. At present the best measured value is 36mg/Nm3 burning refinery gas at a bridge wall tem-perature of 920°C and pre heating air with 350°C.


B U R N E R S Y S T E M D E S I G N ULTRA LOW NOxBURNER TYPE IT - Q

04/2003


primary zone

fuel gas inletdistributor

stagedgas

pilotburner

heaterbottom

burnerbody

com

bust

ion

air

inle

t

Especially suitable for reforming heaters. This burnerdistinguishes itself by its slim flame with a distinctsharp contour eliminating damage to the processtubes due to overheating. This type of burner can besupplied and is offered as natural draft burner aswell as forced draft with or whitout preheated air.The standard size ranges between 0,5 and 6 MW.Due to its staged fuel gas operation the NOx devel-opment remains below 150 mg/Nm3 in the fluegases.


B U R N E R S Y S T E M D E S I G N LOW NOx DOWN FIRINGBURNER TYPE IT - DFB / 5

04/2003


Fuel gas inlet

control

ignition

burnerhousing

airregulation

combustion air

fuel stage

This burner type is suitable for heaters where it isrequired to have a flat flame by the side of the wall.It produces a stable flat flame due to its special con-struction and the multiple drilled tube gas jet. Theburner muffle tile holds in a separate stainless steelhousing flanged onto the outer furnace steel wall.The burner housing can be flanged separately ontothe furnace housing. Our standardised burner sizes are available for acapacity between 0,5 and 4 MW either as naturaldraft burners or, depending on requirement, asforced draft burners with or without preheated air.The NOx development with this burner is below 200mg/Nm3 in the flue gases.


B U R N E R S Y S T E M D E S I G N LOW NOX SIDE WALL FLATFLAME BURNER TYPEIT - FFB / 5

04/2003


combustion air inlet(preheated)

multiple drillingraw gas tip

muffle heater wall burner body

fuel gasinlet

To be installed for the heating of heating pipes suit-able for the heating of gaseous or fluid medium.The internally placed injector can be utilised as pres-sure intensifier for the system. Therefore, it is suit-able for the application in areas without securedelectrical supply. This burner can be operated witheither gas or oil.The construction allows every mounting position.


B U R N E R S Y S T E M D E S I G N INJECTION GAS BURNERTYPE IT - IGB

04/2003


fuel gas inlet

injector

gas nozzle

primaryair inlet

secondaryair inlet

burnerhousing

star type jet

muffle

Applicable for the direct heating of gaseous fluids forexample for air pre heating at catalytic converters.This heater distinguishes itself by its compact design.To be operated either atmospheric or with overpres-sure also. Any mounting position is possible. Bychoice the ignition can be either by pilot burners orhigh energy ignition rods. UV-Scanners are common-ly used for the monitoring. The standardised heatersare supplied with an operative capacity between 1and 40 MW. Special constructions are also available.


B U R N E R S Y S T E M D E S I G N DIRECT FIRED HEATERTYPE IT - DFH

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heaterhousing

flamedetector

heated gaseousfluid outlet

burner muffle

gaseous fluidinlet

sight glass ignition device(retractable)

fuel

For safe ignition and supporting of main flamesburner. High flame stability by splitting of primarypremix and secondary zone. High capacity of 25 to70 KW. Firing all refinery and natural gases as wellas propane/butane. Inner guided and protected igni-tion and flame detection ionisation rods. Self-earth-ing robust connectors and cables for high voltage upto 15 kV. Easy handling of gas spud without removalof pilot body. Available with large volume air filteragainst dust and pollution.


B U R N E R S Y S T E M D E S I G N PILOT BURNER TYPEIT VBP / ND / EI / IR / 60

04/2003


pilot tip withelectrodes

pilot tube

main burner bottomflange

pilot holder

ionisationconnector

primary air

combustionair sieve

pilot gas inlet

ignitionconnector

Special application for heaters and/or thermal oxi-dizers where the gas to be burnt has both low heatvalue and/or low pressure. Operation may be natur-al draft, forced draft or pressurized.This burner can be either horizontal, vertical ordown-firing installed. Capacity of the burner canvary from 0,5 MW to 40 MW.


B U R N E R S Y S T E M D E S I G N LOW HEAT VALUESPECIAL BURNER

04/2003


The ITAS blow immersion burner (B.I.B.) is a forceddraft burner designed for low combustion air pres-sure and low fuel gas pressure. The burner producesa long luminous slow flame in order to obtain aneven heat distribution over almost the entire centralfire tube surface. Burners are available in the capaci-ty range between 100 - 300 KW. Burner is low noisetype (less than 75 db (A) at 1 meter distance). Theburner is suitable to meet the strictest emission regu-lations.

ITAS can also supply upon a request a natural draftself inspirating pre mix burner suitable to meet clientrequirement. Burners are available in the capacityrange between 0,2 to 600KW.


B U R N E R S Y S T E M D E S I G N BURNERS FOR INDIRECTFIRED HEATERS ORGLYCOL REGENERATORS

04/2003


SCRAPER TRAPS- Pig Launcher and- Receiver Stations

PIPELINE PIGS FOR- Batching and Displacement- Cleaning - Gauging

PIG PASSAGE INDICATOR- electric- visual- electronic

PIG LOCATORS- electronic

PIPING MATERIAL- Pipeline Casing Insulators - End Seals - Modular Wall Casing Seals


S C R A P E R T R A P S T A T I O N S & PRODUCT RANGE (1/2)04/2003


CASING INSULATOR CUTTING EQUIPMENT PIPE COUPLING

TANK SEAL

TANK MIXER

HEATING SYSTEM

STATIC MIXER

SCRAPERRECEIVINGSTATION

CRANE

CONTROL PANEL

TERMINAL BOXPIG SIGNALLER

PIG TRAP

PIG HANDLING

FLARE

PRESSUREREDUCINGSYSTEM


04/2003


P I P I N G A C C E S S O R I E SPLIDCO PIPING MAINTENANCE ANDREPAIR PRODUCTS- Couplings- Fittings

HEAT TRACING SYSTEMS- electric- steam

SIDE ENTRY TANK MIXERS- fixed type- swivel type

STATIC MIXERS- maintenance-free - no moving parts

TANK SEALS- floating roof type- fixed roof type

PRODUCT RANGE (2/2)

Heating System

Pipe Coupling

Scraper Pig

Pig Trap

Casing Seal

Casing Insulator

Cutting Equipment

COMBUSTION

AIR HEATERS1/00 STREAMING AIR GAS AND/OR

OIL AIR HEATERS2/00 INDIRECT EXCHANGE

AIR HEATERS

SYSTEMS3/00 FOR DRYERS4/00 FOR ATOMIZERS5/00 FOR TEXTILE MACHINES5/01 FOR TRANSFORMATIONS5/02 OPTIMIZATION6/00 FOR ROTARY MACHINES6/01 OPTIMIZATION OF PRINTING

MACHINES7/00 FOR PAPER INDUSTRY8/00 FOR CO-GENERATION9/00 DRY-CHARGE BATTERY OVENS10/00 FOR CERAMIC AND

BRICKS KILNS11/00 THERMAL TREATMENTS

COMBUSTION DIV IS ION






We have the answer

The streaming air heaters are widely used in diffe-rent drying processes in the following fields: paper,textile, ceramic, print, tannery, bricks, etc.

The main advantages are:

- high thermal efficiency- wide capacity regulating ratio

C O M B U S T I O N D I V I S I O N 1/00

A I R H E A T E R S STREAMING AIR GASAND/OR OIL AIR HEATERS

04/2003


The indirect exchange air heaters are used in theprocesses where hot air without any combustion pro-ducts is required, particularly in the fields of: foods,chemicals, surface treatments, etc.


A I R H E A T E R S INDIRECT EXCHANGEAIR HEATERS

04/2003


ITAS produces combustion systems for dryers usingeither commercial fuels or special fuels according tothe customer needs.

ITAS systems are built with all the safety equipments,according to the rules in force in the country of desti-nation.


S Y S T E M S FOR DRYERS04/2003


ITAS builds complete systems – turn key - with bur-ners that can be arranged for accepting the combu-stion products coming from turbines where cogenera-tion is foreseen.


S Y S T E M S FOR ATOMIZERS04/2003


ITAS has more than twenty years of experience inthe application of direct combustion systems onmachines such as: rameuse, dryers, vaporisers, print,calenders, etc.


S Y S T E M S FOR TEXTILE MACHINES04/2003


ITAS has more than twenty years experience in thetransformation from indirect to direct heating. In thisway ITAS has obtained a lot of advantages such as:

- REDUCED OPERATING COSTS- REDUCED MAINTENANCE COSTS- REDUCTION OF SPACES(REMOVAL OF THE BOILER ROOMS)


S Y S T E M S FOR TRANSFORMATIONS04/2003


ITAS is able to optimise existing plants, applying alsoinfrared gas burners, allowing the increase of pro-ductivity and reducing costs.


S Y S T E M S OPTIMIZATION04/2003


ITAS designs and realises heating systems on turnkey basis for drying or treatment of the air, usingrecycle systems that allow both consumptions andemission volumes reduction, with consequent increa-sing of VOC concentration. These systems permit thereduction of operating and investment costs for theplant installed for emission purification in atmosphe-re.


S Y S T E M S FOR ROTARY MACHINES04/2003


In order to achieve the best efficiency either underthe energetic profile or elimination of the environ-mental damages or also for increasing production, inthe printing machines optimisation field, ITAS offers:

- COST-PROFIT ANALYSIS- FEASIBILITY STUDIES- SPECIAL COMPONENTS- PRODUCTION OF TURN KEYSYSTEMS


S Y S T E M S OPTIMIZATION OFPRINTING MACHINES

04/2003


ITAS co-operates with the biggest groups in the paperfield, providing since 25 years direct exchange com-bustion systems and infrared ramps for continuousmachines and spreaders.


S Y S T E M S FOR PAPER INDUSTRY04/2003


Thanks to its more than twenty years experienceITAS can supply complete post-combustion systems,for cogeneration in various industrial and productivefields.


S Y S T E M S FOR CO-GENERATION04/2003


ITAS, through its experience, has designed a dryerthat allows to obtain the maximum of quality andsafety in this type of application. Among the advan-tages: high productivity, simplicity in load-adaptingto change of plate dimensions, pre-tested, compactand ready-to-use unit, very low energy consumptions(electricity, gas and water), cycle automatically PLCcontrolled, auto-diagnosis, CE mark, realised accor-ding to the rules in force in the country of destina-tion.


S Y S T E M S DRY-CHARGE BATTERYOVENS

04/2003


ITAS supplies complete systems using high andmedium velocity burners for fuels, gas and/or oil,both for continuous and intermittent ovens.Furthermore ITAS realises equipments for the optimi-sation and oil-to-gas transformation.


S Y S T E M S FOR CERAMIC ANDBRICKS KILNS

04/2003


ITAS supplies its combustion systems using burnerstype:

- HIGH VELOCITY- MEDIUM VELOCITY- PRE-HEATED AIR- RECOVERING- REGENERATION


S Y S T E M S THERMAL TREATMENTS04/2003


CONTROL

SYSTEMS1/00 ELECTRO-MECHANICAL PANELS2/00 PROGRAMMABLE LOGIC PANELS3/00 BMS FAIL SAFE4/00 TELESERVICE5/00 CONTINUOUS ADJUSTMENT OF

COMBUSTION PARAMETERS6/00 CONTROL SYSTEMS

CONTROL D IV IS ION






We have the answer

Electro-mechanical control panels to monitor all indu-strial processes - outdoor version included - and forexplosion proof classified areas.Panels are suitable for remote control.

C O N T R O L D I V I S I O N 1/00

S Y S T E M S ELECTRO-MECHANICALPANELS


04/2003

Control panels with programmable logics (PLC), com-plete with local and remote diagnostic functions. PLCnetworks for controll ing related processes.Programmable logics in fail-safe version and withback unit.


S Y S T E M S PROGRAMMABLELOGIC PANELS


04/2003

Burner Manager Systems, suitable for the control ofburners and multiburners realised and certified inaccordance with different industrial specifications.Systems are equipped with remote diagnostics forcontrol centres in unmanned plants.


S Y S T E M S BMS FAIL SAFE


04/2003

All our plants may be equipped with remote controland/or assistance systems anywhere in the worldthrough standard dedicated connection lines, therebyoffering a considerable advantage in terms of plantavailability.


S Y S T E M S TELESERVICE


04/2003

Systems for continuous adjustment of combustionparameters and/or emissions with guarantee andmonitoring of emissions.


S Y S T E M S CONTINUOUS ADJUSTMENTOF COMBUSTIONPARAMETERS


04/2003

Monitoring and control systems with MMI (ManMachine Interface) function for control of plants,complete with the following options:- Process data history.- Real-time process and production data distributionin LAN and on all DDE protocol applications(e.g. Microsoft Office TM).

- Digitalised image control and diagnostics alsofrom Web Cam.

- Remote access system with availability of alllocal functions and controls.

- Scheduled service option and emergencyremote assistance.

- System may be integrated into localcompany networks.


S Y S T E M S CONTROL SYSTEMS


04/2003

ITAS, THE EUROPEAN COMPANYLEADER IN INDUSTRIAL COMBUSTION

BENEFITS OF SELECTING ITAS

- Personnel expertise- Operational flexibility- 24h call service- Tailor made philosophy- Turn key plants- Testing facilities- In house components testing- Fast delivery guaranteed- Equipment supplied with law requirements- Low cost base- First class engineering skills- ISO 9001

AGENCIES:FRANCE

POLAND

EGYPT

SOUTH AFRICA

KUWAIT

OMAN

QATAR

UNITED ARAB EMIRATES

SAUDI ARABIA

IRAN

PAKISTAN

KOREA

TAIWAN

JAPAN

INDONESIA

VENEZUELA

ARGENTINA

BRAZIL

SERVICES

Project ManagementEngineering and Design Procurement

Field Erection and SupervisionCommissioning and Start-upOperation and Maintenance

Training of Clients' PersonnelWorkshop and Test Facilities

HEAD OFFICEITAS spa ITALY

via Metauro, 520052 Monza (MI)Tel. +39.039.2733.1Fax +39.039.745077

INTERNATIONAL OFFICES

ITAS GERMANY

Brönnerstraße 1760313 FrankfurtTel. +49.(0)69.2193570Fax +49.(0)69.21935757e-mail: [email protected]

ITAS UNITED KINGDOM

New Barn Farm - Tadlow RoadTadlow - Near Royston SG8 0EPTel. +44.(0)1767.631188Fax +44.(0)1767.631651e-mail: [email protected]

ITAS SPAIN

Via Augusta, 13-155ª, Izq.da Edificio Ederra Augusta08006 BarcelonaTel. +34 932187454Fax +34 932188382

ITAS BELGIUM

Porte de Batisseur, 207730 EstaimpuisTel. +39.039.2733.1Fax +39.039.745077

We have the answerwww.itas.com [email protected]

ITAS, THE EUROPEAN COMPANY LEADER IN …€¦ · FLARE SYSTEM DESIGN ELEVATED FLARES GROUND FLARES...

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Transcript of ITAS, THE EUROPEAN COMPANY LEADER IN …€¦ · FLARE SYSTEM DESIGN ELEVATED FLARES GROUND FLARES...