Figure 1.
Global gas flaring and oil production between 1996–2023 [
6].
Figure 1.
Global gas flaring and oil production between 1996–2023 [
6].
Figure 2.
Top ten flaring countries (2012–2023) [
6].
Figure 2.
Top ten flaring countries (2012–2023) [
6].
Figure 3.
The new air-assisted flare tip design: (a) side view, (b) cross-sectional view, (c) tip cross-sectional view, (d) top view.
Figure 3.
The new air-assisted flare tip design: (a) side view, (b) cross-sectional view, (c) tip cross-sectional view, (d) top view.
Figure 4.
CFD domain mesh and size; (a) utility flare case, (b) air-assisted flare case.
Figure 4.
CFD domain mesh and size; (a) utility flare case, (b) air-assisted flare case.
Figure 5.
Flare CFD model and mesh; (a) cross-sectional view, (b) model meshing, (c) tip meshing, (d) cold flow (air flow).
Figure 5.
Flare CFD model and mesh; (a) cross-sectional view, (b) model meshing, (c) tip meshing, (d) cold flow (air flow).
Figure 6.
Mesh independence study for air-assisted flare case (0.42 kg/min gas and 5.7 kg/min air) at the sampling location 0 m x-axis, 0 m y-axis, and 3.5 m z-axis.
Figure 6.
Mesh independence study for air-assisted flare case (0.42 kg/min gas and 5.7 kg/min air) at the sampling location 0 m x-axis, 0 m y-axis, and 3.5 m z-axis.
Figure 7.
Mesh independence study for utility flare case (0.42 kg/min gas) at the sampling location 0 m x-axis, 0 m y-axis, and 3.5 m z-axis.
Figure 7.
Mesh independence study for utility flare case (0.42 kg/min gas) at the sampling location 0 m x-axis, 0 m y-axis, and 3.5 m z-axis.
Figure 8.
Utility and air-assisted flare cases’ simulation stability.
Figure 8.
Utility and air-assisted flare cases’ simulation stability.
Figure 9.
Utility flare cases: (a) 0.3 kg/min gas, (b) 0.36 kg/min gas, (c) 0.42 kg/min gas.
Figure 9.
Utility flare cases: (a) 0.3 kg/min gas, (b) 0.36 kg/min gas, (c) 0.42 kg/min gas.
Figure 10.
Low flow utility flare operation and back flow issue: (a) 0.09 kg/min gas, (b) 0.162 kg/min gas, (c) 0.25 kg/min gas.
Figure 10.
Low flow utility flare operation and back flow issue: (a) 0.09 kg/min gas, (b) 0.162 kg/min gas, (c) 0.25 kg/min gas.
Figure 11.
Utility flare versus air-assisted flare operation: (a) 0.42 kg/min gas and 0 kg/min air, (b) 0.42 kg/min gas and 5.7 kg/min air, (c) 0.42 kg/min gas and 6.6 kg/min air, and (d) 0.42 kg/min gas and 8.2 kg/min air.
Figure 11.
Utility flare versus air-assisted flare operation: (a) 0.42 kg/min gas and 0 kg/min air, (b) 0.42 kg/min gas and 5.7 kg/min air, (c) 0.42 kg/min gas and 6.6 kg/min air, and (d) 0.42 kg/min gas and 8.2 kg/min air.
Figure 12.
Data sampling locations: (a) 0.42 kg/min gas and 0 kg/min air, (b) 0.42 kg/min gas and 5.7 kg/min air, (c) 0.42 kg/min gas and 6.6 kg/min air, and (d) 0.42 kg/min gas and 8.2 kg/min air.
Figure 12.
Data sampling locations: (a) 0.42 kg/min gas and 0 kg/min air, (b) 0.42 kg/min gas and 5.7 kg/min air, (c) 0.42 kg/min gas and 6.6 kg/min air, and (d) 0.42 kg/min gas and 8.2 kg/min air.
Figure 13.
Utility flare soot formation: (a) 0.3 kg/min gas, (b) 0.36 kg/min gas, (c) 0.42 kg/min gas.
Figure 13.
Utility flare soot formation: (a) 0.3 kg/min gas, (b) 0.36 kg/min gas, (c) 0.42 kg/min gas.
Figure 14.
Utility flare versus air-assisted flare soot formation: (a) 0.42 kg/min gas and 0 kg/min air, (b) 0.42 kg/min gas and 5.7 kg/min air, (c) 0.42 kg/min gas and 6.6 kg/min air, (d) 0.42 kg/min gas and 8.2 kg/min air.
Figure 14.
Utility flare versus air-assisted flare soot formation: (a) 0.42 kg/min gas and 0 kg/min air, (b) 0.42 kg/min gas and 5.7 kg/min air, (c) 0.42 kg/min gas and 6.6 kg/min air, (d) 0.42 kg/min gas and 8.2 kg/min air.
Figure 15.
Soot formation (mass %) of the utility and air-assisted cases at the sampling location 0 m x-axis, 0 m y-axis, and 3 m z-axis.
Figure 15.
Soot formation (mass %) of the utility and air-assisted cases at the sampling location 0 m x-axis, 0 m y-axis, and 3 m z-axis.
Figure 16.
Soot formation (mass %) of the utility and air-assisted cases at the sampling location 0 m x-axis, 0 m y-axis, and 3.5 m z-axis.
Figure 16.
Soot formation (mass %) of the utility and air-assisted cases at the sampling location 0 m x-axis, 0 m y-axis, and 3.5 m z-axis.
Figure 17.
DRE of the utility and air-assisted flare at the sampling location 0 m x-axis, 0 m y-axis, and 3 m z-axis.
Figure 17.
DRE of the utility and air-assisted flare at the sampling location 0 m x-axis, 0 m y-axis, and 3 m z-axis.
Figure 18.
DRE of the utility and air-assisted flare at the sampling location 0 m x-axis, 0 m y-axis, and 3.5 m z-axis.
Figure 18.
DRE of the utility and air-assisted flare at the sampling location 0 m x-axis, 0 m y-axis, and 3.5 m z-axis.
Figure 19.
DRECH4 of the utility and air-assisted flare at the sampling location 0 m x-axis, 0 m y-axis, and 3 m z-axis.
Figure 19.
DRECH4 of the utility and air-assisted flare at the sampling location 0 m x-axis, 0 m y-axis, and 3 m z-axis.
Figure 20.
DRECH4 of the utility and air-assisted flare at the sampling location 0 m x-axis, 0 m y-axis, and 3.5 m z-axis.
Figure 20.
DRECH4 of the utility and air-assisted flare at the sampling location 0 m x-axis, 0 m y-axis, and 3.5 m z-axis.
Figure 21.
CE of the utility and air-assisted flare at the sampling location 0 m x-axis, 0 m y-axis, and 3 m z-axis.
Figure 21.
CE of the utility and air-assisted flare at the sampling location 0 m x-axis, 0 m y-axis, and 3 m z-axis.
Figure 22.
CE of the utility and air-assisted flares at the sampling location 0 m x-axis, 0 m y-axis, and 3.5 m z-axis.
Figure 22.
CE of the utility and air-assisted flares at the sampling location 0 m x-axis, 0 m y-axis, and 3.5 m z-axis.
Table 1.
Flaring volume, intensity, and oil production between 2016–2023 in Iraq [
6].
Table 1.
Flaring volume, intensity, and oil production between 2016–2023 in Iraq [
6].
Years | Flaring Volume (Million m3/year) | Flare Intensity (m3 per Barrel of Oil Produced) | Oil Production (1000 Barrels per Day) |
---|
2016 | 17,551.51 | 10.82 | 4443.52 |
2017 | 17,843.04 | 10.98 | 4454.69 |
2018 | 17,767.14 | 10.55 | 4612.70 |
2019 | 17,914.22 | 10.35 | 4740.62 |
2020 | 17,373.79 | 11.64 | 4088.22 |
2021 | 17,891.97 | 12.00 | 4084.82 |
2022 | 17,902.88 | 10.96 | 4474.17 |
2023 | 17,689.50 | 11.16 | 4341.41 |
Table 2.
Case study gas composition.
Table 2.
Case study gas composition.
Basis = 100 kg mole |
---|
Components | Mole (%) | Mole (kg mole) | MWt (kg/kg mole) | Mass (kg) | Mass (%) |
---|
C1 | 83.34 | 83.34 | 16 | 1333.44 | 0.693 |
C2 | 9.501 | 9.501 | 30 | 285.03 | 0.148 |
C3 | 3.391 | 3.391 | 44 | 149.204 | 0.078 |
C6+ | 0.232 | 0.232 | 86 | 19.952 | 0.010 |
CO2 | 1.713 | 1.713 | 44 | 75.372 | 0.039 |
H2S | 1.816 | 1.816 | 34 | 61.744 | 0.032 |
N2 | 0.007 | 0.007 | 28 | 0.196 | 0.000 |
Total | 100 | 100.00 | | 1925 | 1 |
Table 3.
Utility flare cases average temp, CO, CO2, and soot at both sampling locations.
Table 3.
Utility flare cases average temp, CO, CO2, and soot at both sampling locations.
| x-Axis (m) | y-Axis (m) | z-Axis (m) | Radius (inch) | Temp (K) | CO (Mass%) | CO2 (Mass%) | Soot (Mass%) |
---|
Utility Flare (0.3 kg/min gas) | 0 | 0 | 3 | 3″ | 1.71 × 103 | 7.00 × 10−2 | 2.80 × 10−1 | 2.10 × 10−4 |
0 | 0 | 3.5 | 3″ | 1.68 × 103 | 5.00 × 10−2 | 2.60 × 10−1 | 1.70 × 10−4 |
Utility Flare (0.36 kg/min gas) | 0 | 0 | 3 | 3″ | 1.64 × 103 | 5.00 × 10−2 | 2.70 × 10−1 | 2.20 × 10−4 |
0 | 0 | 3.5 | 3″ | 1.63 × 103 | 6.00 × 10−2 | 2.50 × 10−1 | 3.10 × 10−4 |
Utility Flare (0.42 kg/min gas) | 0 | 0 | 3 | 3″ | 1.72 × 103 | 5.00 × 10−2 | 2.20 × 10−1 | 3.10 × 10−4 |
0 | 0 | 3.5 | 3″ | 1.61 × 103 | 3.00 × 10−2 | 2.40 × 10−1 | 4.20 × 10−4 |
Table 4.
Utility flare cases average C1, C2, C3, and C6+ at both sampling locations.
Table 4.
Utility flare cases average C1, C2, C3, and C6+ at both sampling locations.
| x-Axis (m) | y-Axis (m) | z-Axis (m) | Radius (inch) | C1 (Mass%) | C2 (Mass%) | C3 (Mass%) | C6+ (Mass%) |
---|
Utility Flare (0.3 kg/min gas) | 0 | 0 | 3 | 3″ | 3.10 × 10−2 | 9.10 × 10−3 | 4.70 × 10−3 | 6.00 × 10−4 |
0 | 0 | 3.5 | 3″ | 2.10 × 10−2 | 5.30 × 10−3 | 3.80 × 10−3 | 3.00 × 10−4 |
Utility Flare (0.36 kg/min gas) | 0 | 0 | 3 | 3″ | 2.80 × 10−2 | 7.40 × 10−3 | 3.90 × 10−3 | 5.00 × 10−4 |
0 | 0 | 3.5 | 3″ | 3.20 × 10−2 | 7.80 × 10−3 | 4.10 × 10−3 | 1.00 × 10−4 |
Utility Flare (0.42 kg/min gas) | 0 | 0 | 3 | 3″ | 2.50 × 10−2 | 7.10 × 10−3 | 3.60 × 10−3 | 5.00 × 10−4 |
0 | 0 | 3.5 | 3″ | 3.20 × 10−2 | 2.50 × 10−3 | 1.40 × 10−3 | 1.00 × 10−4 |
Table 5.
Utility and air-assisted flare average temp, CO, CO2, and soot at both sampling locations.
Table 5.
Utility and air-assisted flare average temp, CO, CO2, and soot at both sampling locations.
| x-Axis (m) | y-Axis (m) | z-Axis (m) | Radius (inch) | Temp (K) | CO (Mass%) | CO2 (Mass%) | Soot (Mass%) |
---|
Utility Flare (0.42 kg/min gas) | 0 | 0 | 3 | 3″ | 1.72 × 103 | 5.00 × 10−2 | 2.20 × 10−1 | 3.10 × 10−4 |
0 | 0 | 3.5 | 3″ | 1.61 × 103 | 3.00 × 10−2 | 2.40 × 10−1 | 4.20 × 10−4 |
Air-assisted Flare (0.42 kg/min gas and 5.7 kg/min air) | 0 | 0 | 3 | 3″ | 1.53 × 103 | 5.00 × 10−3 | 2.00 × 10−1 | 2.00 × 10−4 |
0 | 0 | 3.5 | 3″ | 1.50 × 103 | 4.00 × 10−3 | 2.30 × 10−1 | 2.00 × 10−5 |
Air-assisted Flare (0.42 kg/min gas and 6.6 kg/min air) | 0 | 0 | 3 | 3″ | 1.44 × 103 | 8.00 × 10−3 | 1.90 × 10−1 | 1.50 × 10−4 |
0 | 0 | 3.5 | 3″ | 1.50 × 103 | 1.00 × 10−3 | 2.40 × 10−1 | 1.90 × 10−5 |
Air-assisted Flare (0.42 kg/min gas and 8.2 kg/min air) | 0 | 0 | 3 | 3″ | 1.61 × 103 | 1.10 × 10−2 | 2.30 × 10−1 | 6.00 × 10−5 |
0 | 0 | 3.5 | 3″ | 1.07 × 103 | 3.00 × 10−3 | 1.50 × 10−1 | 2.70 × 10−5 |
Table 6.
Utility and air-assisted flare average C1, C2, C3, and C6+ at both sampling locations.
Table 6.
Utility and air-assisted flare average C1, C2, C3, and C6+ at both sampling locations.
| x-Axis (m) | y-Axis (m) | z-Axis (m) | Radius (inch) | C1 (Mass%) | C2 (Mass%) | C3 (Mass%) | C6+ (Mass%) |
---|
Utility Flare (0.42 kg/min gas) | 0 | 0 | 3 | 3″ | 2.50 × 10−2 | 7.10 × 10−3 | 3.60 × 10−3 | 5.00 × 10−4 |
0 | 0 | 3.5 | 3″ | 3.20 × 10−2 | 2.50 × 10−3 | 1.40 × 10−3 | 1.00 × 10−4 |
Air-assisted Flare (0.42 kg/min gas and 5.7 kg/min air) | 0 | 0 | 3 | 3″ | 1.10 × 10−3 | 4.00 × 10−4 | 2.00 × 10−4 | 4.00 × 10−5 |
0 | 0 | 3.5 | 3″ | 1.00 × 10−3 | 3.00 × 10−4 | 2.00 × 10−4 | 2.00 × 10−5 |
Air-assisted Flare (0.42 kg/min gas and 6.6 kg/min air) | 0 | 0 | 3 | 3″ | 1.10 × 10−3 | 4.00 × 10−4 | 2.00 × 10−4 | 3.00 × 10−5 |
0 | 0 | 3.5 | 3″ | 4.00 × 10−4 | 1.00 × 10−4 | 1.00 × 10−4 | 1.00 × 10−5 |
Air-assisted Flare (0.42 kg/min gas and 8.2 kg/min air) | 0 | 0 | 3 | 3″ | 2.20 × 10−3 | 7.20 × 10−4 | 3.70 × 10−4 | 4.50 × 10−5 |
0 | 0 | 3.5 | 3″ | 7.20 × 10−4 | 2.30 × 10−4 | 1.20 × 10−4 | 1.50 × 10−5 |
Table 7.
CE and DRE of the utility flare cases.
Table 7.
CE and DRE of the utility flare cases.
| x-Axis (m) | y-Axis (m) | z-Axis (m) | Radius (inch) | CE (%) | DRE (%) | DRECH4 (%) |
---|
Utility Flare (0.3 kg/min gas) | 0 | 0 | 3 | 3″ | 70.8% | 95.1% | 95.5% |
0 | 0 | 3.5 | 3″ | 76.6% | 96.8% | 97.0% |
Utility Flare (0.36 kg/min gas) | 0 | 0 | 3 | 3″ | 75.0% | 95.7% | 96.0% |
0 | 0 | 3.5 | 3″ | 70.6% | 95.3% | 95.4% |
Utility Flare (0.42 kg/min gas) | 0 | 0 | 3 | 3″ | 71.8% | 96.1% | 96.4% |
0 | 0 | 3.5 | 3″ | 78.3% | 96.1% | 95.4% |
Table 8.
CE and DRE of the utility and air-assisted flares.
Table 8.
CE and DRE of the utility and air-assisted flares.
| x-Axis (m) | y-Axis (m) | z-Axis (m) | Radius (inch) | CE (%) | DRE (%) | DRECH4 (%) |
---|
Utility Flare (0.42 kg/min gas) | 0 | 0 | 3 | 3″ | 71.8% | 96.1% | 96.4% |
0 | 0 | 3.5 | 3″ | 78.3% | 96.1% | 95.4% |
Air-assisted Flare (0.42 kg/min gas and 5.7 kg/min air) | 0 | 0 | 3 | 3″ | 96.6% | 99.8% | 99.84% |
0 | 0 | 3.5 | 3″ | 97.6% | 99.9% | 99.86% |
Air-assisted Flare (0.42 kg/min gas and 6.6 kg/min air) | 0 | 0 | 3 | 3″ | 95.1% | 99.8% | 99.84% |
0 | 0 | 3.5 | 3″ | 99.3% | 99.9% | 99.94% |
Air-assisted Flare (0.42 kg/min gas and 8.2 kg/min air) | 0 | 0 | 3 | 3″ | 94.1% | 99.7% | 99.68% |
0 | 0 | 3.5 | 3″ | 97.3% | 99.9% | 99.90% |
Table 9.
Soot formation and CE of the utility and air-assisted flares.
Table 9.
Soot formation and CE of the utility and air-assisted flares.
| x-Axis (m) | y-Axis (m) | z-Axis (m) | Radius (inch) | Soot (Mass%) | CE % |
---|
Utility Flare (0.42 kg/min gas) | 0 | 0 | 3 | 3″ | 3.10 × 10−4 | 71.8% |
0 | 0 | 3.5 | 3″ | 4.20 × 10−4 | 78.3% |
Air-assisted (0.42 kg/min gas and 5.7 kg/min air) | 0 | 0 | 3 | 3″ | 2.00 × 10−4 | 96.6% |
0 | 0 | 3.5 | 3″ | 2.00 × 10−5 | 97.6% |
Air-assisted (0.42 kg/min gas and 6.6 kg/min air) | 0 | 0 | 3 | 3″ | 1.50 × 10−4 | 95.1% |
0 | 0 | 3.5 | 3″ | 1.90 × 10−5 | 99.3% |
Air-assisted (0.42 kg/min gas and 8.2 kg/min air) | 0 | 0 | 3 | 3″ | 6.00 × 10−5 | 94.1% |
0 | 0 | 3.5 | 3″ | 2.70 × 10−5 | 97.3% |
Table 10.
Carbon balance study for the utility and air-assisted flares.
Table 10.
Carbon balance study for the utility and air-assisted flares.
| | | | | C1 (Mass%) | C2 (Mass%) | C3 (Mass%) | C6+ (Mass%) | Total (Mass%) | Removed Carbon (Mass%) |
---|
| | | | Fuel | |
---|
| | | | 6.93 × 10−1 | 1.48 × 10−1 | 7.80 × 10−2 | 1.00 × 10−2 | 9.29 × 10−1 |
---|
x-Axis (m) | y-Axis (m) | z-Axis (m) | Radius (inch) | Plume |
---|
Utility Flare (0.42 kg/min gas) | 0 | 0 | 3 | 3″ | 2.50 × 10−2 | 7.10 × 10−3 | 3.60 × 10−3 | 5.00 × 10−4 | 3.62 × 10−2 | 8.92 × 10−1 |
0 | 0 | 3.5 | 3″ | 3.20 × 10−2 | 2.50 × 10−3 | 1.40 × 10−3 | 1.00 × 10−4 | 3.60 × 10−2 | 8.93 × 10−1 |
Air-assisted Flare (0.42 kg/min gas and 5.7 kg/min air) | 0 | 0 | 3 | 3″ | 1.10 × 10−3 | 4.00 × 10−4 | 2.00 × 10−4 | 4.00 × 10−5 | 1.74 × 10−3 | 9.27 × 10−1 |
0 | 0 | 3.5 | 3″ | 1.00 × 10−3 | 3.00 × 10−4 | 2.00 × 10−4 | 2.00 × 10−5 | 1.52 × 10−3 | 9.27 × 10−1 |
Air-assisted Flare (0.42 kg/min gas and 6.6 kg/min air) | 0 | 0 | 3 | 3″ | 1.10 × 10−3 | 4.00 × 10−4 | 2.00 × 10−4 | 3.00 × 10−5 | 1.73 × 10−3 | 9.27 × 10−1 |
0 | 0 | 3.5 | 3″ | 4.00 × 10−4 | 1.00 × 10−4 | 1.00 × 10−4 | 1.00 × 10−5 | 6.10 × 10−4 | 9.28 × 10−1 |
Air-assisted Flare (0.42 kg/min gas and 8.2 kg/min air) | 0 | 0 | 3 | 3″ | 2.20 × 10−3 | 7.20 × 10−4 | 3.70 × 10−4 | 4.50 × 10−5 | 3.34 × 10−3 | 9.26 × 10−1 |
0 | 0 | 3.5 | 3″ | 7.20 × 10−4 | 2.30 × 10−4 | 1.20 × 10−4 | 1.50 × 10−5 | 1.09 × 10−3 | 9.28 × 10−1 |