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Operating the TCI Incinerator
General
The Total Combustion "TCI" unit is an
enclosed flare system that is designed to combust waste gases at high temperature so as to
achieve over 99% combustion efficiency. The system will burn solution gas, tank vapors,
BTEX emissions from glycol dehydrators and other waste gases. The system operating
temperature should be 900 degrees Celcius or higher and the flame should be contained
within the stack. This is very easy to operate with built-in bypass features for service
work or trouble shooting, without the need to shut in production.
Process Description
The combustion process starts with the delivery of
gas
from one or more flare lines into the TCI unit header system, which distributes the gas to
two or more burners. The number of burners are ignited by a standard piezo igniter unless
specific site parameters require flame failure and \or automatic shut-down systems. The
igniter can also act as a continuous live pilot if there is a constant fuel flow. The fuel
for the igniter can be slip-stream gas at least 1-5 psig or come from a propane bottle
that is refilled as required. The burners operate comfortably between 5 and 25 psi and
when sized properly, should contain the flame within the stack, so that there is no
visible flame from the outside. If there is a low pressure flare line (inches of
water), the gas on the low pressure line may be mixed, in the burn chamber, with the
higher pressure line I order to create the proper mixing and combustion conditions. At the
inlet to the incinerator there are enough valves pressure gauges to operate the unit under
varying conditions.
TCI's components
Our incinerator is made up of:
- lower body
- burner assemblies
- stack
- temperature thermocouple
- pressures gauge
- an array of ball valves
- inlet header
-
optional ACL 3500 ignition system and flame failure relight
- Kimray AOD regulator or
equivalent
- Optional wind skirting.
- There may also be an extra upper burner ring if required.
The system is designed to combust the gas vapors with 99%
plus combustion efficiency. Gas enters the unit through the header system and is mixed
with fuel gas inside the venturi burner system.
The number of valves (2 inch typically) opened is dependent
on the volume of the gas. If there is an upset condition and the pressure increases, the
ports on the regulator will open and a portion of the gas flow will bypass the main burner
system. Once the upset condition ends the regulator will close and the system will go back
to normal operation.
Safe Operation
The system has two safety features. The optional ACL 3500 ignition
system detects if there is no pilot and will spark for relight. The stack
may be equipped with an optional
temperature thermocouple which detects no or low stack temperature and goes to alarm
and/or operator notification.
Start-up
- Purge all inlet waste gas lines through the TCI header main
valve and flame arrestor.
- Start the ignition system and ensure that there is pilot
flame.
- Open the other ball valves as required to get the system
working at a reasonable pressure given your normal operating flows.
Shut down
- Close off inlet lines from waste gas flow source.
- Shut off pilot fuel at ACL ignition system.
- Turn off ACL ignition system.
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