High Reliability Elevated Flare System

Safety and Explosion-Proof Design for Complex Industrial Conditions

Overview

The Elevated Flare System is an essential safety device designed for the controlled combustion of excess hydrocarbon gases in petrochemical, refinery, and chemical plants. Utilizing advanced combustion control and monitoring technologies, it ensures safe disposal of volatile gases while minimizing environmental impact.
The system features intelligent ignition control, real-time flame monitoring, and high-temperature resistant materials, providing long-term operational stability even under harsh environmental conditions such as high wind, corrosive atmospheres, or extreme temperature fluctuations.
Its high combustion efficiency and low emission performance have made it widely used across industries including petrochemical, natural gas processing, metallurgy, and waste treatment, serving as a reliable safety barrier for industrial emissions management.

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The system is used for the safe combustion of emergency vented gases and continuous low-pressure hydrocarbon streams, ensuring compliance with national and local emission standards while maintaining high safety and reliability under fluctuating process loads.

To achieve both environmental compliance and operational economy, Ruiding designed a pressure-assisted elevated flare integrating automatic control of air-fuel ratio, pilot flame stability, and combustion intensity. The system achieves 99.5% combustion efficiency and visible smoke-free operation, effectively eliminating volatile organic compounds (VOCs), CO, and hydrocarbons from vent streams.

Theory

The Elevated Flare System operates based on the principle of thermal oxidation, where combustible gases are mixed with air and burned at the flare tip.

1. Waste gas is collected from the process vent system and passed through a knock-out drum to remove liquid droplets.

2. The dry gas is conveyed to the flare stack, where pilot burners ensure ignition reliability even under low flow or adverse weather conditions.

3. The flare tip is designed to enhance mixing and combustion efficiency, ensuring complete oxidation of hydrocarbons into CO₂ and H₂O.

4. Auxiliary systems such as steam or air assist are used to minimize smoke and stabilize the flame.

5. The system operates automatically through PLC and DCS integration, with real-time temperature, pressure, and flame monitoring for safe, continuous operation.

The flare system’s design complies with API 521, API 537, and NFPA 30/59A standards, ensuring operational reliability and safety in demanding industrial environments.

Advantages

1. High Safety and Explosion-Proof Design:
   The system adopts intrinsically safe ignition circuits and explosion-proof equipment to ensure safe operation in hazardous gas zones. Flame monitoring and auto-shutdown mechanisms guarantee reliable protection.

2. Stable Combustion and High Efficiency:
   Optimized flare tip structure and steam/air-assisted design achieve complete combustion with a thermal efficiency exceeding 98%, ensuring no visible smoke and minimal carbon deposition.

3. Smart Control and Automation:
   Equipped with a Programmable Logic Controller (PLC) and intelligent monitoring software, the system enables real-time diagnostics, remote operation, and automatic ignition/flameout control.

4. Corrosion and Weather Resistance:
   Constructed with stainless steel or Inconel alloys, the flare tip and riser resist corrosion and deformation, extending service life even under high-temperature and high-wind conditions.

5. Energy Recovery Options:
   Integration with waste heat recovery units and steam generation systems allows the reuse of combustion heat for process heating, thereby reducing energy costs.

6. Ease of Maintenance:
   Modular design and quick-connect pilot assemblies facilitate easy inspection and replacement, reducing downtime and maintenance cost.

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R&D and Production:

Ruiding has established the jiangsu province clean incineration resource engineering technology center and the key laboratory of the JICUI-Ruidings joint innovation center.

This laboratory is equipped with advanced detection equipment such as ICP inductively coupled plasma emission spectrometry, atomic absorption spectrophotometry, atomic fluorescence spectrophotometry, high-temperature combustion ion chromatography analyzer, high-temperature combustion rate analyzer, and rapid equilibrium flash point tester. it possesses capabilities for heavy metal analysis, elemental analysis, off-gas calorific value analysis, ash melting point detection, incineration boiler water quality testing, sewage analysis, and volatile waste analysis, etc.

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Company Introduction:

Ruiding is expertized in the engineering, fabrication, construction, commissioning service of industrial waste combustion treatment system including thermal oxidizer (also referred to as incinerator), heat recovery system (boiler), pressurized vessel, flue gas treatment system (DeSOX, DeNOx) and plate heat exchanger, etc.

Ruiding has been authorized with the Environmental Protection Engineering Class 2 (waste gas, waste liquid, waste solid treatment) EPC certificate, ASME Certificate, Class A boiler manufacturing license, Class A boiler installation and Revamping & Maintenance certificate, A2 designing and manufacturing certificate for press vessel, GC1, GC2 press pipeline designing & construction certificate.

Ruiding covers a building area of over 250,000 square meters and has nearly 300 professional and technical staffs. We have completed over 500 engineering projects, spread across various domestic and international industries, with a significant market share in the petrochemical industry.

Faq:

1. What is the company's main business? ‌
Focus on the R&D, design, production, installation and commissioning of industrial three wastes (waste gas/waste liquid/solid waste) incineration treatment equipment and special boilers, and provide supporting equipment (such as heat exchangers, sludge dryers, etc.) ‌.
2. Do you have industry qualification certification? ‌
The company has now passed the quality, environment, occupational health, and occupational hygiene and safety management system certifications, and has the second-level qualification for environmental protection engineering contracting, Class B special environmental engineering design, Class A boiler manufacturing qualification, Class A boiler installation, inspection and maintenance certificate, A2 pressure vessel design and manufacturing certificate, GC1, GC2 pressure pipeline design and installation certificate, and Class A environmental pollution control (waste, waste gas, waste liquid) qualification certificate.
‌3. What are the core products? ‌
(1) Waste gas incinerator:
Regenerative thermal oxidation furnace (RTO), regenerative catalytic oxidation furnace (RC0), catalytic oxidation furnace (C0), high temperature thermal incinerator (T0), catalytic denitrification furnace (SCR)
(2) Waste liquid incinerator:
Organic waste liquid incinerator, salt-containing waste liquid incinerator, heavy component residue incinerator
(3) Solid incinerator:
Combined rotary kiln incinerator, gas-controlled pyrolysis incinerator, fluidized bed incinerator, step-type incinerator
(4) A-level boiler:
Modular waste heat boiler, tunnel waste heat boiler, furnace-boiler integrated incineration boiler, large cavity membrane wall boiler, fire tube boiler
(5) Plate heat exchanger:
Fully welded pressure plate heat exchanger, high-efficiency vortex tube heat exchanger, high-efficiency spiral tube heat exchanger
(6) Incineration auxiliary machine:
Sludge dryer, customized burner, solid waste crusher, VOC catalyst ‌
4. In what aspects are the technical advantages reflected? Have you ever had experience in cross-border cooperation?

We have 29 patented technologies, covering the fields of incinerator structure optimization, heat recovery, etc. The company has a first-class design team in China, which has mastered the incinerator technology and is familiar with the operation of incinerators. The designers have a solid theoretical foundation and rich design and practical experience. During the design process, they combine the operation of advanced devices at home and abroad to carry out process and structural design. The design response is fast, and the plan can be modified in time according to the buyer's requirements, and optimization suggestions can be made according to the buyer's data and processes.
5. What does the service scope include?
We provide full-process services from project consultation, scheme design, equipment manufacturing to installation and commissioning, and support pressure pipeline and boiler renovation.
6. Are there any successful cases for reference?
It has served multiple industries including petroleum, chemical, pharmaceutical, and solid waste disposal. Typical cases include organic waste gas RTO system, chemical waste liquid incineration project, etc.
7. How to obtain cooperation or quotation?
You can submit your needs through the official website online form, or contact directly:
Tel: +86 15606162805 ; +86 0510-87418884
Email: ruiding@rdee.com.cn
Address: Xinzhuang Industrial Concentration Zone, Yixing City, Jiangsu Province, China.
8. Is there any international business cooperation? ‌
Holding the independent import and export rights, we can provide equipment export and technical solution customization services for overseas customers.

Jiangsu Ruiding Environmental Engineering Co., Ltd. (abbreviated as "Jiangsu Ruiding") is a leading enterprise in China's energy conservation and environmental protection industry, specializing in comprehensive VOCs treatment solutions including research, design, manufacturing, installation, commissioning and engineering services. The company's core products encompass waste incinerators for gaseous, liquid and solid wastes, Class A boilers, and plate heat exchangers. With over 60 national patents, Jiangsu Ruiding has established strategic partnerships with prominent domestic and international corporations and engineering companies across key sectors including petroleum, chemical, pharmaceutical and coal chemical industries.

With a proven track record of excellence, Jiangsu Ruiding Environmental Engineering has successfully delivered over 550 environmental projects throughout China, Southeast Asia, the Middle East, and Africa. As an ASME S and U certified manufacturer, we have led the compilation of China’s chemical industry standards, titled “Design Code for Waste Incineration Disposal Engineering of Chemical Construction Projects (HG20706)”. Furthermore, our technical expertise has been recognized through our participation as a key contributor to China’s Synthetic Resin Industrial Pollutant Emission Standards. Significantly, we were honored to be selected among the inaugural co-construction units for the National Technical Standard Innovation Base (Water Environment Technology and Equipment), where we continue to drive innovation in water environment standardization.

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