Understanding HP Flare and LO Flare in Industrial Applications
Introduction
In industrial plants especially oil refineries, petrochemical facilities, and gas processing units—
flare systems are critical for safe and efficient operations. Among the different types of flare
systems, High-Pressure (HP) flares and Low-pressure (LO) flares play distinct roles in managing
excess gases, ensuring safety, and minimizing environmental impact.
This article explores:
✔Flare System
✔ Flare Tips
✔What HP and LP flares are
✔Key differences between them
✔Design and operational considerations
✔Applications in industry
✔Environmental and safety regulations
1. What is a Flare System?
• A Flare System is an arrangement of piping and specialised equipment that
collects hydrocarbon releases from relief valves, blowdown valves, pressure
control valves and manual vents and disposes of them by combustion at a
remote and safe location
• A gas flare, or flare stack, is a gas combustion device used in industrial plants
such as petroleum refineries, chemical plants, natural gas processing plants, and
at oil or gas production sites with oil wells, offshore oil and gas rigs/platforms
and landfills.
2. Flare Tips - Smokeless Operation
The apparent density or opacity of smoke is defined as the Ringelmann number where 0 = clear
air and 5 =totally opaque. A low Ringelmann number is easier to achieve for a sonic or HP tip
and harder to achieve for a pipe type or LP tip. Most applications specify a Ringelmann number
of 0 or 1. This can be hard to achieve at low flare rates and therefore steam or air can be
injected to reduce the Smokiness.
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3. What Are HP Flare and LP Flare Systems?
High-Pressure (HP) Flare
Handles gases released at high pressures (typically above 5 barg).
Used for emergency releases, blowdowns, or process upsets.
Requires strong structural design to withstand high-velocity gas flow.
Often equipped with assisted combustion (steam or air injection) for smokeless burning.
Low-Pressure (LP) Flare
Manages gases released at near-atmospheric or low pressures (below 0.5 barg).
Typically used for continuous venting of low-pressure process gases.
May use passive diffusion or minimal assist systems for combustion.
Common in storage tanks, wastewater treatment, and small process vents.
4. Design Considerations for HP and LP Flares
HP Flare Design
✔ Material Selection – Stainless steel or high-grade alloys to resist corrosion and
thermal stress.
✔ Knockout Drum – Removes liquids to prevent flare flame instability.
✔ Pilot & Ignition System – Reliable ignition under high-pressure conditions.
✔ Noise & Radiation Control – Requires acoustic dampers and proper elevation.
LP Flare Design
✔ Low Backpressure – Ensures smooth venting without restricting flow.
✔ Vapor Recovery – May include gas recovery units (e.g., VRUs) to minimize flaring.
✔ Simple Combustion – Often uses passive burning without assist systems.
✔ Environmental Compliance – Focus on minimizing fugitive emissions.
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5. Key Differences Between HP and LO Flares
Feature HP Flare LP Flare
Pressure Range >5 barg <0.5 barg
Gas Velocity High (sonic or near-sonic) Low (subsonic)
Combustion Assist Steam/Air injection often Minimal or none
needed
Flare Tip Design High-efficiency, multi-point Simple, open pipe
Application Emergency blowdowns, Continuous venting, tank
process upsets emissions
Structural Strength Reinforced (stainless steel, Lighter construction
robust foundations)
6. Industrial Applications
HP Flare Uses
Refineries – Emergency depressurization during plant upsets.
Offshore Platforms – Safe disposal of high-pressure hydrocarbons.
Chemical Plants – Handling reactor overpressure scenarios.
LP Flare Uses
Storage Tanks – Venting of breathing losses.
Wastewater Treatment – Burning off low-pressure biogas.
Small Process Vents – Continuous disposal of non-critical gases.
7. Environmental & Safety Regulations
Flaring is heavily regulated due to emissions concerns:
EPA (USA), EU Industrial Emissions Directive – Limits SOx, NOx, and particulate
matter.
World Bank Zero Routine Flaring Initiative – Encourages flare gas recovery.
OSHA/API Standards – Mandate safe distances, flame detection, and emergency
shutdowns.
Modern trends favor flare gas recovery systems (FGRS) to reduce flaring and repurpose
waste gas.
Conclusion
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HP flares are essential for high-pressure emergency releases, requiring robust design
and smokeless combustion.
LP flares handle low-pressure venting with simpler, cost-effective systems.
Both systems must comply with strict environmental and safety standards, pushing
industries toward flare minimization and gas recovery solutions.
For optimal performance, companies must select the right flare type, ensure proper
maintenance, and adopt flare gas recovery technologies where feasible.
