a report by

J o h n Z i n k , a d i v i s i o n o f K o c h C h em i c a l T e c h n o l o g y G r o up L t d

The KMI flare tip is a hybrid of the highlysuccessful John Zink Hydra and Kaldair

Indair technology. The concept of multiple Indairtips being located in an array is not new; however,John Zink have developed the concept into asingle-point tip with multiple Indair nozzles. Thisnot only provides the multi-arm advantages of theHydra by increasing the flare gas surface areaexposed to the air, but also employs the infiniteturndown features of the variable slot Indair.

Each KMI arm terminates with a variable slotIndair nozzle. The Indair nozzle utilises theCoanda effect to entrain and mix air into thehydrocarbon gas stream. High-pressure gas isejected radially from the annular slot at the base ofthe Indair tulip. Instead of continuing horizontally,the gas adheres to the Coanda profile and isdiverted through 90 degrees, forming a thin filmover the tulip surface and entraining up to 20 timesits own volume of air in the process.

Ad v a n t a g e s o f t h e KM I

S m o k e l e s s O p e r a t i o n

Due to its unique pre-mixed turbulent flame, highair entrainment rate and thin film combustiontechnique, the KMI flare tip provides smokelessflaring of most hydrocarbon gas stream.

L o w R a d i a t i o n

The KMI flare tip produces a highly aeratedturbulent diffusion flame that radiates far less heatthan any other flare tip of its type

P u r g e R a t e s / b u r n - b a c k

Unlike other sonic flares, the KMI does not sufferfrom burn-back and requires a fraction of the purgegas needed for conventional sonic flare tips.

F l a m e L e n g t h

The flame length produced by a single Indair is lessthan half that produced by a conventional API-type

pipe flare. The KMI flame is even shorter.

F l a m e S t a b i l i t y

The KMI flare produces a stiff flame with a highdirectional stability that is not easily distorted by cross-winds. The unique geometry and stiff directional flameallow the KMI to be mounted at an angle withoutdetrimental effect to tip operation or life. In offshoreapplications the flame can be angled away from theplatform or floating production storage and offload(FPSO) vessel, reducing deck radiation.

A Super Son ic So lu t ion

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Figure 1: The Coanda Principle

Figure 2: KMI Systems Offshore West Africa

L i q u i d H a n d l i n g

The KMI flare is capable of burning 25% by weightof liquid carry-over without any fall-out or smokeproduction whatsoever. This feature means that, inmany cases, the flare may be operated without aliquid knockout drum in the HP flare line.

H i g h - p r e s s u r e O p e r a t i o n

Since the KMI flare operates at elevated pressurewhen burning HP gas (rather than near atmospheric

pressure as with a conventional flare), significantsavings in header size and knock-out vessel size maybe made.

E f f i c i e n t A i r E n t r a i n m e n t a n d

M i x i n g

Multi-point designs improve the efficiency bysplitting the flow between smaller, separatedcylinders of hydrocarbon gases, allowing efficient airentrainment into the flame. The unique KMI flaretip, based on the Coanda effect, forms a thin film ofhydrocarbon that entrains and pre-mixes air prior tocombustion. The KMI flare, in most cases, producescombustion efficiencies in excess of 99.9%.

T i p l i f e

The small Indair tulips used in the KMI are of aninvestment cast, highly robust single part constructionthat, combined with the multi-nozzle design, providesextended operational life compared with other flaretips on the market.

M a i n t e n a n c e

As the KMI tulips are very small they are easily man-handled. Therefore, in the event that any tulips requirechanging, it can be done without the use of a crane. Inaddition, the replacement of an investment cast smalltulip is not expensive whereas the manufacturing costof a large tulip is relatively high.

F l e x i b i l i t y

Turndown flexibility can be enhanced further byvarying the spring rates on the individual nozzlessuch that the flare tip can act as a staged system initself. Thus, the tip can be set up to bring nozzlesonline in turn, such that at low flows only one ortwo nozzles will have their slots open while all theothers are closed. As the pressure and flow increasethen slots can open in sequence until at full flow allslots are fully open

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Figure 4: 2 Million Kg/hr KMI tip supplied to Kazakhstan

Figure 3: KMI Demonstrates Clean Stable

Directional Flame