【Ten Years of Rapid Development in Chemical Processing Equipment】Successful first ignition of the world’s largest single-unit open-air flare from 2011 to 2019

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Safety first. Prevention first – let’s give praise and support to the achievements made in China’s chemical engineering technology and equipment. **********************【Ten Years of Great Development in Chemical Engineering Equipment】A continuously updated summary post is available; feel free to join the discussions at https://bbs.hcbbs.com/thread-3576046-1-1.html (Source: Haichuan Chemical Engineering Forum) ***************** On April 18, 2019, the world’s largest open-air ground torch, constructed by the 711 Institute, was successfully ignited for the first time. 　　Zhejiang Petrochemical’s open-type surface flares represent the largest flare turnkey project ever undertaken by 711 Institute, encompassing chemical industry surface flares, ethylene surface flares, styrene surface flares, and PX surface flares; it is the largest flare system built in a single batch in the world. 　　During startup/shutdown, normal operation, and emergency conditions, the production units of petrochemical enterprises generate large amounts of combustible gases that cannot be recycled. To ensure safe production and meet environmental protection requirements, these flammable gases must be treated by combustion through flare systems. 　　Early torch facilities were mainly elevated torches. In 2003, building on years of experience in torch technology and operation, 711 developed an open-type ground torch to address the shortcomings of overhead torches, such as large land occupation, incomplete combustion, black smoke emission, severe light pollution, and high noise levels. This new torch offers significant advantages in terms of safety and reliability, environmental protection, and land conservation. 　　An open-air ground torch disperses large amounts of flammable exhaust gases to numerous burners located on the ground for treatment. A metal fence is installed around the burner to shield against the effects of heat radiation, noise, and flames on the outside environment. Through research on key technologies such as multi-stage combustion open-air flare combustion technology, hierarchical control technology, backfire prevention technology, ignition technology, and thermal radiation assessment, the aforementioned problems associated with elevated flares have been resolved, enabling the safe combustion of combustible waste gases and meeting environmental protection requirements. 　　The 711 Institute has also achieved numerous technical innovations: it developed a plum-blossom shaped burner with a special design suitable for use in open-air flares. This burner combines pressure induction technology with steam smoke suppression technology to ensure smoke-free combustion across the entire operating pressure range ； A pressure-stage combustion control technology was developed, ensuring smoke-free and stable combustion of exhaust gases across the entire flow range, thereby significantly reducing the amount of steam required for smoke suppression ； A continuous water seal technology was developed to ensure effective isolation between the flare system and the production units, prevent backflow, and achieve intrinsically safe operations. 　　Through the joint efforts of the project team and all participating units, Institute 711 completed the construction of four torches in just 7 months. The project achieved a successful first ignition, laying a solid foundation for the subsequent successful operation of the torch.