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E. A. Emam/Petroleum & Coal 57(5) 532-555, 2015 546 gas was recovered by using FGRS in oil refining plant in Dushanzi-China. FGRS including LRC is a skid-mounted packaged system located downstream of the knock-out drum since all the flare gases are available at this single point. The results of using FGRS showed that, the plant prevented annually about 32.5, 176.8 and 67,000 metric tons of NOx, CO and CO2 from being emitted to the atmosphere, respectively. Additionally, thermal radiation from the flames was greatly reduced which resulted in an increase in overall safety of the plant. Light and noise were also greatly reduced. Furthermore, the FGRS installation allows substantial cost savings because the recovered gases can be used as fuel or process feedstock. Assuming a fuel gas cost of $ 5.00/MMBTU the plant will save more than $ 5,000,000 per year on fuel gas costs if the FGRS operate at full capacity. With an expected operating cost of $ 300,000 per year, the cost of the FGRS could be recovered in less than 9 months. FGRS including LRC for reducing about 163,000 tCO2e/year of baseline emissions from Suez oil refinery company in Egypt was presented [3,72]. For about 94 % of gas emissions will be decreased [3] and a payback period of about 2 years [72]. Another FGRS in Farashband gas refinery in Iran, using piston compressors operate to recover about 4.176 MMSCFD of flared gas, provides a compressed natural gas with 129 bar pressure for injection to the refi- nery pipelines [16]. In Uran plant [4] (205 Km from the Mumbai High offshore field), FGRS was used to recycle all of the flare gases and process them to recover and utilize valuable hydrocarbon of about 30,000 - 150,000 SCMD from gas processing in order to achieve technical zero flaring. Screw compressor (oil flooded) was used in this FGRS and designed to capable of handling gases of molecular weight between 19.5 - 36.2 (flare gas molecular weight varies as per flaring from different plant and sources). FGRS has significantly reduced the CO2 emissions released into the environments. The total estimated reduction about 977,405 tCO2e from 2007 - 2008 to 2016 - 2017 considering the avoidance of 44 MMSCM of gas per year. Another FGRS at Hazira plant (232 Kms from the Mumbai offshore oil field) was designed to recover and utilize the tail gas of about 14,000 - 73,000 SCMD from gas processing plant in order to achieve technical zero flaring [4]. Zadakbar et. al. [64] presented the results of two case studies of reducing, recovering and reusing flare gases from the Tabriz Petroleum Refinery and Shahid Hashemi-Nejad (Khangiran) Natural Gas Refinery in Iran, including eleven plants of petroleum refineries, natural gas refi- neries and petrochemical plants. In the Tabriz petroleum refinery, the recommended FGRS includes two LRC, two horizontal 3-phase separators, two water coolers, piping and instruments. For about 630 kg/hr flare gas will be used as fuel gas by $ 0.7 million capital investment corresponds to a payback period of about 20 months, and also 85 % of gas emissions will be decreased. In the Shahid Hashemi-Nejad (Khangiran) gas recovery, three LRC, three horizontal 3-phase separators, three water coolers, piping and instruments, proposed FGRS. For about 25000 m3/hr flare gas will be used as fuel gas by $ 1.4 million capital investment corresponds to a payback period of about 4 months, and 70 % of gas emissions will be decreased. Sangsaraki and Anajafi [6] studied the design criteria of FGRS and steady sate and dynamic simulation of the FGRS. The recovery of 5916 normal m3/hr of sweet natural gas, 24 ton/hr of gas condensates and production of 297 m3/hr of acid gas would be possible, according to steady state simulation results. Also, the changes in the temperature of the gases sent to the flare during total shutdown of the refinery as well as the impact it had on FGRS behavior was studied. It is obvious that the efficiency of the compressor is reduced due to the increase in the temperature of the gas sent to the flare network; therefore, the value of separation in two and three-phase separator shows a drastic change. 5.2 Gas-to-liquid technology Gas-to-liquid (GTL) technology is one of the best methods for reducing gas flaring in the application of environmentally friendly technologies. It is one of the most promising topics in the energy industry by the conversion of flare gas to hydrocarbons due to economic utilization of control waste gas to environmentally clean fuels. Another environmental issue is the regu-PDF Image | GAS FLARING IN INDUSTRY
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