Engineering, Supply & Installation of a Biogas Flare System for GIDC Facility, Gujarat
Combustion Research Associates (CRA) executed the engineering, supply, and installa-tion of a biogas flare system for a GIDC industrial facility in Gujarat, supporting Toshiba Water Solutions Pvt. Ltd. The system was designed to safely dispose of excess and emer-gency biogas generated during wastewater treatment operations. Engineered for methane-rich biogas containing trace hydrogen sulphide, the flare system delivers high combustion efficiency, operational safety, and compliance with international flaring standards under both normal and upset conditions.
Ensuring Safe and Reliable Disposal of Biogas Under Normal and Upset Conditions
The GIDC facility required a robust flaring solution capable of handling variable biogas flows generated from wastewater treatment processes. Key challenges included:
• Safe disposal of methane-rich biogas during emergency and excess generation scenarios
• Prevention of flame flashback into upstream process equipment
• Reliable combustion performance despite fluctuations in gas composition and flow
• Compliance with international flaring and safety standards
• Long-term operational reliability in an industrial environment
The system had to ensure both process safety and environmental compliance without introducing excessive pressure losses or operational complexity.
Engineered Biogas Flare System with Integrated Flame Arrestor Protection
CRA engineered and supplied a complete biogas flare system designed to deliver stable combustion and enhanced safety through integrated flame arrestor technology. The solution focused on controlled ignition, flame stability, and upstream equipment protection.
Core Components Delivered
• Biogas flare stack engineered for methane-rich gas combustion
• High-efficiency flame arrestors installed upstream of the flare system
• Structural flare assembly designed for industrial installation
• Integrated safety provisions for emergency and upset operating scenarios
Engineering Design for Safe, Stable, and Compliant Biogas Combustion
• Flame arrestors engineered to prevent flame propagation during normal and upset conditions
• High-efficiency flame quenching elements designed to minimize pressure drop while ensuring rapid flame extinction
• Design suitable for variable gas compositions, flow rates, and ambient conditions
• Compliance with API 521 and API 537 flaring and safety standards
• Layout optimized for integration with wastewater treatment infrastructure
Manufacturing, Assembly, and On-Site System Integration
• Fabrication of flame arrestors and flare components using industrial-grade materials
• Supply of complete system with QA/QC documentation, drawings, and operating manuals
• Installation support aligned with site safety and operational requirements
• Design provisions to ensure ease of inspection and long-term maintainability
Proven Combustion Performance and Operational Reliability
Safe, Efficient, and Standards-Compliant Biogas Flaring Solution
• Reliable disposal of excess and emergency biogas streams
• Enhanced upstream process protection through integrated flame arrestors
• Stable combustion performance with >98% efficiency
• Compliance with international flaring and safety standards
• System engineered for long-term operation in an industrial GIDC facility
A Robust and Compliant Solution for Industrial Biogas Flaring
This project reinforces CRA’s capability to engineer and deliver biogas flare systems that balance combustion efficiency, operational safety, and regulatory compliance. By integrating high-performance flame arrestors with a standards-compliant flare design, CRA provided Toshiba Water Solutions Pvt. Ltd. with a robust solution for safe biogas disposal at the GIDC facility in Gujarat. The installation highlights CRA’s expertise in delivering reliable gas handling systems for industrial wastewater and biogas applications.
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