Extremely Low Btu Flare Tip Technology Breakthrough, A Crucial Step Toward Net-Zero in the Oil & Gas Industry

Abstract The oil and gas industry faces a significant challenge in reducing greenhouse gas (GHG) emissions to achieve net-zero ambitions. Existing lean gas or low BTU flare tip technologies have limitations in effectively minimizing emissions. To overcome these constraints, breakthrough innovations are essential. Conventional oil and gas production releases substantial GHG emissions. The gas sweetening process using membrane technology removes CO2 from feed gas but generates continuous flaring of low BTU flare gas (85–90% CO2, GHV 130–160 BTU per scf). Current low BTU flare tip technology depends on hydrocarbon (HC) content and gas velocity. When HC content is low, the flame may extinguish at heating values below 200-300 BTU per scf. To sustain combustion, 4–8 MMscfd of valuable HC gas is injected, raising GHV but increasing GHG emissions. The Extremely Low BTU Flare Tip invention addresses these limitations by leveraging fundamental principles of low heating value gas combustion, enhancing combustion efficiency, and ensuring safe offshore operation. The Extremely Low BTU Flare Tip invention project began in 2018. Progressing from initial concept to prototype development and field testing, this groundbreaking technology has been successfully installed on a gas processing platform in the Gulf of Thailand since July 2024, demonstrating its ability to significantly reduce GHG emissions while achieving cost savings. The RD&T research project underwent multiple iterations of prototype design, simulation, and testing, with various parameter adjustments to optimize performance. Prototype tests confirmed the effectiveness of the final design in terms of combustion completeness and mechanical integrity. The final design of the Extremely Low BTU flare tip prototype successfully combusted lower heating value flare gas, significantly outperforming existing technologies. Following rigorous prototype testing and design optimization, it was scaled up and first deployed offshore at Great Bongkot South in 2024. The successful field test validated its efficiency, with 40% higher combustion efficiency than existing technologies. This implementation has resulted in a maximum of 170,000 tCO2e emissions reduction annually, and cost savings per platform are estimated at USD15 million per year, depending on the lowest achieved heating value. These benefits were realized on a single production platform. Given the existence of over 100 membrane units currently in operation and the anticipated increase in units due to greenfield development projects with high CO2 reservoirs, the potential impact of this innovation is substantial. The adoption of the Extremely Low BTU Flare Tip offers a tremendous opportunity for reducing global emissions and improving efficiency within the oil and gas industry. Widespread implementation of this technology can drive significant progress in mitigating climate change while enhancing operational efficiency and economic viability. This groundbreaking invention