Flare Gas Recovery

Why flare gas recovery matters

Routine flaring leads to energy waste, increased emissions, and growing regulatory pressure. At the same time, flare gas presents challenging operating conditions, including low suction pressure, fluctuating flow rates, and variable gas composition.

Without a reliable recovery system, valuable hydrocarbons are simply lost.

GARO flare gas recovery systems are designed to operate continuously under demanding industrial conditions. Using liquid ring compressors, the system efficiently handles low inlet pressures and fluctuating gas composition while ensuring stable performance and long service life.

Recovered gas can be reused as fuel, sent for further processing, or utilized for power generation—turning emissions into value.

How a flare gas recovery system works

The gas (1) coming from the flare Process Unit enters the Liquid Ring Compressor (2) along with the process water (3).
After the compression phase, the gas, water and hydrocarbon mixture enters the separator (4) where the three elements are parted: the gas passes through a demister (5) to have minimum water and leaves the vessel from the top, while condensed hydrocarbons and water are separated by gravity due to lower gas speed.
The water is pushed back to the compressor, after being cooled again by a cooler (6).
Moreover, a continuous process water make up line (7) in the compressor suction line is provided to ensure a continuous water ring in the compressor.
The condensed hydrocarbons are discarded (8).
The gas exiting the separator finally heads to the Flare gas Amine Washing Unit (9) where it is amine treated to remove H2S.
The treated gas is then pushed to the Fuel Gas header to be used as fuel.

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Why liquid ring compressors are ideal for flare gas

GARO liquid ring compressors are the key-element of Flare Gas Recovery Units, providing safe and reliable compression of refineries’ potentially explosive and dirty gases. Liquid ring technology offers the advantage of low operating temperatures, thanks to near‑isothermal compression, and is largely insensitive to gas molecular weight, allowing it to handle wide variations in process gas composition. It can work with a variety of seal liquids, allowing for flexibility in treating toxic or corrosive compounds in the process gas.

Reliable operation at very low suction pressures

Tolerant to fluctuating gas flow and composition

Continuous-duty performance with minimal maintenance

Lower life-cycle costs compared to alternative technologies

FGR System provides several environmental and economic benefits to refineries, such as:

Lower Emissions: Recovering waste hydrocarbons allows refineries to reduce the number of toxic gasses, such as hydrogen sulfide (H2S), which are burned and released into the environment during the flaring process.
Reduced Operating Costs: Refineries can re-use recovered gasses, composed mainly of low molecular weight hydrocarbons (LPGs), resulting in a reduction in fuel gas cost for the facility. This is in addition to saving that could be made because of reduced Greenhouse Gas emissions, or through the sale of recovered gasses.
Social & Environmental Responsibility: Lowering CO2 emissions generated by facilities not only help organizations meet environmental regulations but also demonstrate an awareness and commitment to social responsibility and build goodwill within the surrounding community.