Industrial plants that process oil, gas, and chemicals depend on flare stacks as essential safety devices. When excess hydrocarbons build up in a process, facilities need a reliable way to dispose of them. The flare stack provides that safeguard. By burning off gases under controlled conditions, flare stacks prevent dangerous pressure buildups and uncontrolled releases that could lead to explosions, fires, or toxic leaks. In short, flares protect workers, equipment, and surrounding communities.
The operating principle is straightforward yet crucial. Excess gases travel through a flare system to a tall stack where a continuous pilot flame ignites them. The combustion process breaks down volatile organic compounds into less harmful byproducts such as carbon dioxide and water vapor. Steam or air assist systems often mix with the gas stream to ensure complete combustion and minimize smoke. While flaring is never the first choice, it remains a necessary last line of defense in industrial operations.
That said, flaring carries environmental concerns. Even when properly managed, flare stacks emit greenhouse gases and, if not optimized, can produce soot and unburned hydrocarbons. Regulators, investors, and communities demand that operators minimize flaring, prove high combustion efficiency, and show commitment to sustainability. For plants, the challenge lies in achieving both safety and environmental compliance while keeping operating costs in check.
This is where technology has begun to transform flare management. Baker Hughes, through its Panametrics division, has developed the flare.IQ flare management control system, a solution designed specifically to address inefficiencies in traditional flare operations. Historically, operators had little real-time visibility into flare combustion efficiency. Adjustments to steam or air assist often relied on manual estimates, leading to wasted energy and suboptimal destruction efficiency.
Flare.IQ closes that gap with advanced monitoring and automated control. The system continuously measures flow, temperature, and gas composition, then applies real-time algorithms to calculate combustion efficiency. With those insights, flare.IQ automatically adjusts steam or air assist to maintain ideal conditions. This not only ensures regulatory compliance and higher destruction efficiency but also reduces unnecessary steam consumption, delivering significant energy and cost savings.
Plants that implement flare.IQ reports greater confidence in meeting environmental requirements, improved reliability, and lower operating costs. Instead of treating flare systems as a compliance burden, operators can now view them as optimized, intelligent assets that support both safety and sustainability.
For companies in the Mountain West, Front Range, and Southwest regions, having a local partner to implement and support this advanced technology makes all the difference. Process Technology, Inc. of Salt Lake City stands as the trusted resource in the region for Baker Hughes Panametrics solutions, including flare.IQ. With deep technical expertise, hands-on support, and a commitment to customer success, Process Technology, Inc. helps industrial operators integrate smarter flare management into their facilities. By partnering with Process Technology, Inc., plants not only meet safety and environmental demands but also unlock new levels of efficiency and performance.
