Flare Gas Recovery Units (FGRU)

What Is a Flare Gas Recovery Unit?

A flare gas recovery unit (FGRU) is a system that captures flare gases and redirects them back into production workflows for reuse as fuel gas. This process helps to reduce routine flaring and emissions while saving operators on long-term production costs.  

How Does a Zeeco Flare Gas Recovery Unit Work?

The flare gas recovery process is made up of several steps. To begin, gases are redirected from the flare header to the FGRU. Gases pass through a compressor and then go to a separator to remove any liquids. The gases then leave the separator, are cooled, and go to a knockout drum to remove any condensates before heading back to the plant or facility for reuse. If, at any point, an upset occurs that requires a flaring event, the flare gas recovery process is stopped so that waste gases can be safely destroyed by the facility's flare.

Typical FGRU Sizing:

• • Flowrate ranges: 0.1 to 10MM SCFD (11,100 NM3/hr)
  • Pressure ranges: 35 to 300 psig (20.7 barg)

Pair Your FGRU With a Liquid Seal Drum

Zeeco recommends using a liquid seal drum to prevent the compressor in the FGRU from pulling a vacuum on the flare header. The water in the liquid seal drum helps to maintain consistent backpressure to the FGRU system while still allowing flare gases to go to the flare if an upset occurs or if there is more gas than the FGRU can recover. Some operators may choose to use a quick open valve with a buckling pin around it for safety to maintain back pressure, though the size of the valve needed often comes at a price much higher than that of a liquid seal drum. 

Why Should You Choose Zeeco for Your FGRU Project?

As the industry leader in advanced combustion technologies and environmental solutions, Zeeco has an intricate understanding of flare systems and their ancillary equipment. When you order an FGRU from Zeeco, you're not working with a team that just installs the system but rather a team that ensures your FGRU and ancillary equipment are designed for your specific process conditions so that you get the most out of your new equipment.

Services Offered:

• • Engineered studies: Let us help you determine if an FGRU system is right for your facility. Our engineers will recommend system sizing, compressor technology, and any necessary ancillary equipment. They will develop the cost estimate and evaluate the payback period to help you decide the economic feasibility of an FGRU system.
  • Engineering, design, fabrication, supply, installation, and startup of FGRU packages.
  • Field Support after equipment startup.