350
Continuous Days · Zero Visible Flame
A new benchmark for refinery
combustion decarbonization.
Combined high-altitude and ground flare system EPC for Sinopec Zhenhai Refining & Chemical's ethylene complex. The 350-day continuous zero-flaring operation was achieved through three integrated technical strategies: (1) precision-engineered multi-tip burner array enabling smokeless combustion across the full molecular weight range; (2) optimised purge gas and pilot system design ensuring continuous flame stability and combustion efficiency; and (3) integrated DCS control coordinating relief management, plant-wide flow conditions and emergency response. This represents a directly transferable template for international petrochemical operators pursuing Scope 1 emission reductions.
Technical achievement: Multi-Tip Burner Array + Optimised Purge & Pilot Design + Integrated DCS Control
How We Achieved It
01Auxiliary Combustion Support Systems — continuous recovery of relief gas back to fuel gas system, eliminating routine flaring at source.
02Smokeless Multi-Stream Burner Design — proprietary low-radiation burner geometry with dynamic steam-assisted combustion control.
03Combined Elevated + Ground Architecture — relief loads dynamically routed between high-altitude and ground flare based on flow profile, enabling pilot-only operation under normal conditions.
04Integrated DCS Control Strategy — closed-loop monitoring of relief flow, fuel gas inventory, and pilot status enabling auto-shutdown when no relief is required.
Project ScopeCombined Elevated + Ground · EP
Plant Capacity1 MTPA Ethylene + POSM
Elevated Flare168.8m · 1,759 t/h Ethylene
Ground Flare(100+12) t/h × 2
Operation Year2010 onwards
Zero-Flaring Record350 Continuous Days