FLARES FOR MIXING AND BURNING MULTIPLE GASSES

Abstract

Gas flares configured to mix and burn multiple gasses are disclosed. According to one aspect, a gas flare head includes a first and second conduit one inside the other to form an interior region between the conduits. The interior region between the conduits is partitioned into multiple channels by a dividing structure. Each channel is configured to route a gas from a source to a mixing chamber where the gasses are mixed and burned.

Claims

1. A gas flare head, comprising: a first conduit having a wall and a first conduit open end; and a second conduit disposed at least partially within the first conduit to form an interior region, the second conduit having a second conduit open end recessed within the first conduit so that the wall and the first conduit open end extend beyond the second conduit open end to form a mixing chamber between the first conduit open end and the second conduit open end, an interior of the second conduit being configured to channel a mixing fluid to the mixing chamber through the second conduit open end; and at least one divider positioned in the interior region between the first and second conduits to divide the interior region into at least a first channel and a second channel, the first channel being configured to route a first gas to the mixing chamber and the second channel being configured to route a second gas to the mixing chamber.

2. The gas flare head of claim 1, wherein the first conduit and the second conduit are disposed at least in part as concentric pipes.

3. The gas flare head of claim 2, wherein the at least one divider divides the interior region into angular sectors.

4. The gas flare head of claim 1, wherein the at least one divider is configured to withstand a highest pressure of the first and second gasses.

5. The gas flare head of claim 1, wherein the at least one divider divides the interior region into more than two channels, each channel being configured to separately route a gas to the mixing chamber.

6. The gas flare head of claim 1, wherein the second conduit is configured to route a liquid to the mixing chamber.

7. The gas flare head of claim 1, wherein the wall of the first conduit is configured with at least a first opening and a second opening, each of the first and second openings configured to receive a different gas.

8. The gas flare head of claim 7, wherein a first gas line is coupled to the first conduit at the first opening and a second gas line is coupled to the first conduit at the second opening.

9. A method of manufacture of a gas flare head, the method comprising: positioning a dividing structure on a first length of a first pipe, the dividing structure having at least two fins adjoined to a base at one end of the fins, the base configured to surround the first pipe, the dividing structure being positioned on the first length of the first pipe so that each fin extends from the base to a point in proximity to an open end of the first pipe; and positioning a second pipe over at least a part of the first pipe and over at least the fins of the dividing structure to form at least two channels, each channel bounded by at least two fins, by the base, and by walls of the first and second pipes, the second pipe having a second length at least as long as a distance from the base to the open end of the first pipe.

10. The method of claim 9, further comprising: prior to positioning the second pipe, cutting at least two slots in the second pipe, each slot corresponding to a different fin and being at least as long as a corresponding fin; binding each of the at least two fins to the second pipe along a corresponding slot; and sealing the second pipe to the base to prevent gas from escaping around the base.

11. The method of claim 10, wherein the binding is by welding.

12. The method of claim 10, wherein the binding is by a paste configured to harden over time.

13. The method of claim 9, further comprising, prior to positioning the second pipe over at least the part of the first pipe, binding the dividing structure to the first pipe.

14. The method of claim 9, further comprising, prior to positioning the second pipe over at least the part of the first pipe, making at least two openings in the second pipe, each opening configured to receive a gas into a separate one of the at least two channels.

15. The method of claim 14, further comprising positioning the second pipe so that an open end of the second pipe extends beyond the open end of the first pipe to form a mixing chamber to receive a gas from each of the at least two channels.

16. A gas flare head, comprising: an outer pipe; an inner pipe being at least partially disposed within the outer pipe, the inner pipe having an inner pipe open end that is recessed within the outer pipe to form a mixing chamber that extends at least from the inner pipe open end to an outer pipe open end, the inner pipe configured to route a fluid to the mixing chamber; and a partitioning structure to partition a region between the inner pipe and the outer pipe into channels, each channel configured by the partitioning structure to route a gas from a different source to the mixing chamber.

17. The gas flare head of claim 16, wherein the outer pipe is configured with an opening for each channel, each opening configured to receive a gas from a different source into a respective channel.

18. The gas flare head of claim 16, wherein the partitioning structure has at least two fins having ends affixed to a base, the base configured to surround the inner pipe, the partitioning structure being positioned so that each of the at least two fins extends from the base to the inner pipe open end.

19. The gas flare head of claim 18, wherein the at least two fins are compressible.

20. The gas flare head of claim 16, wherein the inner pipe is configured to route a liquid to the mixing chamber.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] A more complete understanding of the present invention, and the attendant advantages and features thereof, will be more readily understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:

[0014] FIG. 1 is a first conventional gas flare head;

[0015] FIG. 2 is a second conventional gas flare head;

[0016] FIG. 3 is a first example embodiment of a gas flare head constructed in accordance with principles disclosed herein;

[0017] FIG. 4 is a second example embodiment of a gas flare head constructed in accordance with principles disclosed herein;

[0018] FIG. 5 is a third example embodiment of a gas flare head constructed in accordance with principles disclosed herein;

[0019] FIG. 6 is a fourth example embodiment of a gas flare head constructed in accordance with principles disclosed herein;

[0020] FIG. 7 illustrates a partially unassembled gas flare head according to principles disclosed herein; and

[0021] FIG. 8 is an example flowchart of an exemplary process of assembly of a gas flare head according to principles disclosed herein.

DETAILED DESCRIPTION

[0022] Gas flares configured to mix and burn multiple gasses are disclosed. According to one aspect, a gas flare head includes a first and second conduit one inside the other to form an interior region between the conduits. The interior region between the conduits is partitioned into multiple channels by a dividing structure. Each channel is configured to route a gas from a source to a mixing chamber where the gasses are mixed and burned.

[0023] Referring again to the drawing figures, there are shown in FIGS. 3-6 various embodiments of multi-channel gas flare heads, referred herein collectively as gas flare heads 52, that are constructed according to principles disclosed herein. FIG. 3 depicts one example embodiment of a multi-channel gas flare head 52-A. The gas flare head 52-A has an inner pipe 54 and an outer pipe 56. A dividing structure 58 has divider walls 58-1 and 58-2 that partition the interior region between the inner pipe 54 and the outer pipe 56 into channels 60 and 62. Note that in some embodiments, the divider walls may be referred to as fins 58-1 and 58-2. In the example of FIG. 3, the interior region is divided into angular sectors. For example, one channel 60 may occupy an angular sector of 90 degrees and the other channel 62 may occupy an angular sector of 270 degrees. As will be explained further below, the divider walls 58-1 and 58-2 may be attached to a base 58-b which encircles the inner pipe 54 or is at least concentric with the inner pipe 54. The base 58-b may therefore be part of the dividing structure 58. In some embodiments, the dividing structure 58 is made of one continuous single piece of metal or plastic, for example. In some embodiments, the inner pipe 54 and the outer pipe 56 may be of dissimilar materials. For example, one of the two pipes may be aluminum and the other of the two pipes may be steel. Further, in some embodiments, the dividing structure 58 may include a compressible material such as a rubber or plastic compound that is compressed between the inner pipe 54 and the outer pipe 56 when the gas flare head 52 is assembled.

[0024] The channel 60 receives a first gas from the first gas line 48 through a first opening 64. Similarly, channel 62 receives a second gas from the second gas line 50 through a second opening 66. Each gas may be under a different pressure or the same pressure. The divider walls 58-1, 58-2 and base 58-b may be configured to withstand the highest pressure of either the first gas or the second gas. The channel 60 routes the first gas from the first gas line 48 to a mixing chamber 68. The channel 62 routes the second gas from the second gas line 50 to the mixing chamber 68. The inner pipe 54 routes a fluid such as air or steam, for example, from the inlet 72 of the inner pipe 54 to the mixing chamber 68 through the open end 74 of the inner pipe 54.

[0025] The fluid routed by the inner pipe 54 to the mixing chamber 68 may be pumped through the inner pipe 54 at a constant pressure or a controllable or non-controllable varying pressure. The fluid may serve one or more purposes that may include providing increased combustion efficiency by mixing the first and second gasses more efficiently, ensuring that the flow of burning gases remains directed toward the open end 76 of the outer pipe 56, and/or blowing the flame from the burning gasses out of the mixing chamber into the surrounding atmosphere. Other purposes may be served by the fluid routed to the mixing chamber 68 by the inner pipe 54. Varying degrees of mixing of the gasses and the fluid may be achieved by, for example, shaping the wall of the outer pipe 56 at or near the distal end of the outer pipe 56.

[0026] The first and second gasses are mixed and ignited in the mixing chamber 68. The burning gasses exit the mixing chamber through the open end 76 of the outer pipe 56, the burning gasses being accelerated in the direction of the open end 76 by the fluid routed to the mixing chamber 68 by the inner pipe 54. The source of the fluid may be an air blower or steam injector, for example. For convenience, the source is not shown. Persons having ordinary skill in the art will readily recognize different sources of fluid and how to route such sources to the inner pipe 54 of the gas flare head 52. Note that the distance L2 from the nearest inlet receiving gas to the open end 28 of the outermost pipe 36 may be any suitable distance or may be chosen to optimize performance for a particular application. Similarly, the chamber height L3 of the mixing chamber 68 may be chosen to optimize performance. For example, optimum performance may be an optimum efficiency of combustion of the received gasses. In some embodiments, the gas lines 48 and 50 and openings 64 and 66 may be located remote from the open end 74 of the inner pipe. For example, the gas lines may be joined to the channels 60 and 62 near the bottom of the stack, away from the open end 74 located near the top of the stack.

[0027] FIG. 4 shows another example embodiment of a gas flare head 52-B constructed according to principles disclosed herein. There are at least two differences between the gas flare heads 52-A and 52-B. Unlike the divider walls 58-1 and 58-2 of the gas flare head 52-A, the divider walls 78-1 and 78-2 of the gas flare head 52-B divide the region between the inner pipe 54 and the outer pipe 56 into two channels occupying equal angular sectors of 180 degrees. The dividing structure 78 includes the divider walls 78-1 and 78-2 and the base 78-b. Also, height L4 of a divider wall 78-1 and/or 78-2 may be such that the upper edge 78-e of the divider wall is below the height of the open end 74 of the inner pipe 54. This configuration may provide better mixing in the mixing chamber 68. In this embodiment, the chamber height L3 may be measured from the upper edge 78-e to the open end 76 of the outer pipe 56. In some embodiments, the height L4 of the divider walls 78-1 and 78-2 may be such that the upper edge 78-e of the divider wall is above the height of open end 74 of the inner pipe 54.

[0028] FIG. 5 shows another example embodiment of a gas flare head 52-C constructed according to principles disclosed herein. In the gas flare head 52-C, the gas lines 48 and 50 are connected at the base 80 of the dividing structure 58 between the divider walls 58-1 and 58-2. Thus, a first gas is routed by the gas line 48 into the channel 60 via a first opening 82 in the base 80 of the dividing structure 58. Similarly, a second gas is routed by the second gas line 50 into the channel 62 via a second opening 84 in the base 80 of the dividing structure 58. Note that the size of the openings 82 and 84

[0029] FIG. 6 shows a top view of another example gas flare head 52-D with a dividing structure 86 that divides the interior region into three channels 88-1, 88-2 and 88-3. Each channel occupies one of three angular sectors, in this example. Each channel 88-1, 88-2, 88-3 receives a gas from a different opening 90-1, 90-2, 90-3, respectively.

[0030] Note that a dividing structure can be configured to partition the interior region between the inner pipe 54 and the outer pipe 56 into more than three channels, in some embodiments. Note also that the openings 90-1, 90-2 and 90-3 can be the same size or can be different sizes. Further, the inner pipe 54 and the outer pipe 56 may be non-circular in cross section. For example, the inner pipe 54 and the outer pipe 56 may be elliptical or rectangular in cross section. In some embodiments, the inner pipe 54 is not concentric with the outer pipe 56.

[0031] Note that various parts of the gas flare heads 52-A through 52D can be pre-assembled and shipped to a site or plant where the gas flare is to be installed. For example, a pre-assembled subassembly may include the inner pipe 54, the outer pipe 56, and the dividing structure 58, 78. This subassembly may be shipped to a site where it is installed on a stack and connected to first and second gas lines 48 and 50, and possibly more gas lines. In some embodiments, for some gas flare applications, the subassembly is installed on a stack before shipping the combination of the subassembly and stack to the site where it is to be connected to gas lines 48 and 50, or even more than two gas lines, as discussed above.

[0032] FIG. 7 shows a partially unassembled gas flare head 52-E, which may be assembled to achieve the embodiments depicted in FIGS. 3, 4 and 6. Assembly of the gas flare head 52-E to achieve the embodiment depicted in FIG. 5, is similar and may differ only in where the gas lines 48 and 50 are coupled to the gas flare head 52. In one step of assembly of the gas flare head 52-E, the dividing structure 58, which includes the divider walls 58-1, 58-2 and the divider base 58-b, is preassembled by, for example, welding the divider walls 58-1 and 58-2 to the base 58-b. The dividing structure 58 may be constructed prior to sliding the dividing structure 58 over the inner pipe 54. The dividing structure 58 may be positioned over the inner pipe 54 so that the upper edge 58-e of a divider wall 58-1 is even with the open end 74 of the inner pipe 54. The dividing structure 58 may be bonded and/or placed in sealing engagement with the inner pipe 54 by, for example, welding and/or applying a binding/sealing paste along gaps where the dividing structure 58 meets the inner pipe 54.

[0033] Corresponding to each divider wall 58-1 and 58-1, there is a slot 92-1, 92-2 cut into the outer pipe 56. To assemble the gas flare head 52-E, the outer pipe 56 is oriented so that the slots 92-1 and 92-2 receive their respective divider walls 58-1, 58-2 as the outer pipe 56 is slid over the structure that includes the dividing structure 58 and the inner pipe 54. After the outer pipe 56 is positioned over the dividing structure 58 and the inner pipe 54, a sealing bead may be welded along the length of each slot 92-1 and 92-2 to seal the joint formed by a divider wall 58-1, 58-2 and the corresponding slot 92-1, 92-2, and to bind the divider wall 58-1, 58-2 to the outer pipe 56. As an alternative to welding a sealing bead, an adhesive paste configured to bond the divider wall 58-1, 58-2 to the outer pipe 56 may be applied along the slots 92-1 and 91-2, the adhesive paste being pliable when applied, yet hardening over time. In addition to bonding the divider walls 58-1 and 58-2 to the outer pipe 56 along the slots 92-1 and 92-2, the base 58-b of the dividing structure 58 may be bonded and sealed to the outer pipe 56 by welding or applying an adhesive paste, for example, to the joints formed between the base 58-b and the outer pipe 56. Once, the outer pipe 56 is placed in position over the inner pipe 54 and over the dividing structure 58, the gas lines 48 and 50 may be attached to the outer pipe 56 at openings 64 and 66.

[0034] In some embodiments, the divider walls 58-1 and/or 58-2 may be made of the same material as the inner pipe 54 and/or the outer pipe 56. In some embodiments, the divider walls 58-1 and/or 58-2 may be made of a compressible material that compresses against both the inner pipe 54 and the outer pipe 56 when the outer pipe 56 is slid over the subassembly comprising the dividing structure 58 and inner pipe 54.

[0035] FIG. 8 is a flowchart of an example process of assembly of a gas flare head according to principles disclosed herein. The process includes positioning a dividing structure on a first length of a first pipe, the dividing structure having at least two fins adjoined to a base at one end of the fins, the base configured to surround the first pipe, the dividing structure being positioned on the first length of the first pipe so that each fin extends from the base to a point in proximity to an open end of the first pipe (Block S100). The process also includes positioning a second pipe over at least a part of the first pipe and over at least the fins of the dividing structure to form at least two channels, each channel bounded by at least two fins, by the base, and by walls of the first and second pipes, the second pipe having a second length at least as long as a distance from the base to the open end of the first pipe (Block S102).

[0036] Thus, some embodiments include gas flares and gas flare heads 52 configured to route gasses from multiple sources to a mixing chamber 68 for mixing and burning of the multiple gasses. In some embodiments, a gas flare head 52 includes an inner pipe or conduit 54 and an outer pipe or conduit 56 oriented to form an inner region in between the inner pipe or conduit 54 and the outer pipe or conduit 56. In some embodiments, the inner region is partitioned into channels 60, 62, 88, by a dividing structure 58, 78, 86, and the channels are configured to route the multiple gasses to the mixing chamber 68. Note that certain conventional components, such as conduit coupling devices to couple the gas lines 48 and 50 to the gas flare head 52, are not shown in the figures for simplicity.

[0037] It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described herein above. In addition, unless mention was made above to the contrary, it should be noted that all of the accompanying drawings are not to scale. A variety of modifications and variations are possible in light of the above teachings without departing from the scope of the following claims.