Computational Fluid Dynamics Simulation of Combustion Efficiency for Full-Size Upstream Flare Experiments

Methane emissions from oil and gas production can occur throughout the value chain, but for many producers, one of the most significant sources is flaring. Understanding the influence of the operating conditions and the environmental factors the combustion efficiency and destruction and removal efficiency (CE/DRE) of flares is essential if their role in methane emissions, a potent but short-lived greenhouse gas, is to be better understood and mitigated. An industry-scale experimental study was focused on the emissions of un-assisted flares commonly encountered in upstream oil and gas production. This paper simulates two un-assisted flare tips combustions by using the commercial computational fluid dynamics (CFD) software package Fluent 21R2 to augment the physical experimental testing. Two three-dimensional (3D) flare tips models are built, and the k-omega SST turbulence model and flamelet generated manifold (FGM) combustion model are applied to simulate flaring combustion. The CFD model is first validated against full-scale industry flare tests that use extractive sampling of the combustion plume. CFD results are in good agreement with measured results when the vent gas net heating value (NHV) is greater than 300 BTU/SCF. Greater uncertainty exists for both CFD results and measured data if the NHV is less than 300 BTU/SCF. Then, the CFD model is extended to include high crosswind states up to 50 m/s that cannot be readily or safely examined empirically. The results emphasize the critical role of the vent gas net heating value (NHV) on flare combustion and crosswind in reducing the CE. The comparison helps pave the way for further use of CFD simulation to improve flare designs and modes of operation and supports the use of parametric models to track and report methane losses from flaring.