Integrated Burner Management System & Enclosed Ground Flare for Pyrolysis Off-Gas
Single-package BMS, burner and enclosed flare engineered for a highly variable pyrolysis vapour stream.
CRA is engineering, manufacturing, and supplying an integrated Burner Management System, main combustion burner, and enclosed ground flare for a biocarbon pyrolysis facility in Egypt, delivered as one engineered package under a single point of project responsibility. The raw pyrolysis vapour is a highly variable process stream, with water vapour, carbon monoxide, and hydrogen content each swinging across a wide range, which called for a first principles approach to burner and BMS design rather than a standard catalogue configuration.
Engineering Combustion Control for a Highly Variable Pyrolysis Vapour Stream
The facility’s raw pyrolysis vapour presented a wide compositional envelope that made a standard burner and safety system configuration impractical. Key constraints included:
- Water vapour content ranging from 18% to 45% of the raw stream
- Carbon monoxide content ranging from 10% to 30%
- Hydrogen content ranging from 2% to 22%
- A requirement for a single point of project responsibility across the burner, BMS, and enclosed flare
- ATEX compliant instrumentation across the full combustion and emergency flare paths
This range of vapour compositions called for a first principles burner and BMS design rather than a standard catalogue configuration.
One Engineered Package Spanning Burner, BMS, and Enclosed Flare
CRA is delivering a fully integrated combustion package engineered specifically for the facility’s pyrolysis vapour composition.
Core Scope Includes:
- Main combustion burner sized for the facility’s process vapour duty
- Enclosed ground flare pairing a molecular seal against flashback and air ingress with a nitrogen assisted ejector burner for the low pressure emergency path
- Redundant PLC governing combustion, flame supervision, and vapour routing across the combustion chamber and emergency flare paths
- ATEX compliant instrumentation across the full scope
Installation and Commissioning
CRA’s own crew is carrying out the on site refractory installation and commissioning, keeping fabrication, installation, and start up responsibility within a single team.
Designed Around the Full Range of Process Conditions
The system is engineered to hold stable combustion and flame supervision across the facility’s full process envelope:
- Vapour duty of 4,800 kg/hr (4,480 Nm³/hr) at the burner inlet
- Vapour temperatures of 500°C to 700°C entering the combustion system
- Steady state combustion temperature of 1,100°C
- Enclosed flare stack sized at 11 to 15 m for smokeless operation
A Single Point of Responsibility for Complex Pyrolysis Combustion
This project reflects CRA’s ability to take on complete combustion scope, from burner management system design through main burner and enclosed flare delivery, for process streams that fall well outside standard combustion envelopes. Taking on the burner, BMS, and enclosed flare as one engineered package, with CRA’s own crew handling on site refractory work and commissioning, gives the client a single point of accountability for a highly variable pyrolysis vapour stream.
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