Sustainable process solutions for a smarter, cleaner future
At Hero Process Solutions (formerly Hero Flare), we design and deliver cutting-edge combustion and process equipment for the oil & natural gas industry, balancing performance, compliance, and environmental stewardship.
A lean, expert team solving complex challenges
We’re a team of engineers, project managers, and service professionals passionate about solving complex challenges in a clear, practical way. Our in-house capabilities span design, fabrication, installation, and field support, ensuring systems that perform reliably over the long term.
From Hero Flare to Hero Process Solutions
In 2020, Hero Flare acquired select assets from Tri-Point Oil & Gas Production Systems, including the Leed Fabrication, Superior Fabrication (SFI), and Edge Manufacturing & Technology brands. In 2024, we rebranded to Hero Process Solutions to reflect our expanded capabilities: vapor recovery, enclosed combustion, turnkey process packages, rentals, and aftermarket support.
Built on expertise, proof, and partnership
End-to-end expertise
From engineering and fabrication to installation, rentals, and aftermarket support; one accountable partner across the full lifecycle.
Proven products
EPA-certified technologies, including Quad O combustors, to reinforce our promise of optimal destruction efficiency and compliance.
Customer-first ethos
We collaborate closely to understand your specific needs, constraints, and goals, leading to better system design, faster delivery, and performance you can trust.
Engineering and Technology Leadership
Hero Process Solutions invests continuously in combustion engineering built around the real-world compliance challenges operators face: variable gas flows, unattended remote sites, high-wind installations, and the continuous monitoring obligations of EPA OOOOb.
VFD Air-Assist Blowers
Variable frequency drive-controlled blowers deliver proportional combustion air management matched to actual gas flow rates, eliminating the over-air and under-air conditions that drive visible emissions and incomplete combustion at low-throughput wellsites.
Smart Pilot Systems
Automatic electronic reignition pilot systems maintain continuous flame without manual intervention at unattended remote sites. Flame detection and reignition sequencing are integrated into the control panel, eliminating the compliance risk of an undetected pilot outage.
Coanda-Effect Sonic Tips
Sonic tip geometry using the Coanda effect produces crosswind-stable smokeless combustion without steam or air injection at low wind speeds. HPS sonic tips are engineered for the exit velocity and tip diameter required to maintain smokeless performance under the operating conditions specified for each project.
PLC-Based OOOOb Monitoring
Control panels log pilot flame status, combustion air pressure, gas flow parameters, and alarm events continuously in formats compatible with EPA OOOOb recordkeeping requirements. Monitoring packages are engineered and assembled by HPS in Kellyville, Oklahoma; not sourced from third-party suppliers.
These capabilities are built into HPS equipment by the engineering team in Kellyville, Oklahoma; not sourced from third parties or offered as aftermarket add-ons. Learn more about HPS flare system technology specifications.
Standards and Certifications
Hero Process Solutions designs and fabricates flare and combustor equipment to the following industry standards and regulatory requirements.
| Standard | Scope | HPS Application |
|---|---|---|
| API RP 521 | Pressure-relieving and depressuring systems: flare system sizing, thermal radiation, knockout drum design | Engineering design basis for all HPS flare system projects |
| API Std 537 | Flare details for refinery and petrochemical service: tip design, pilot, ignition, purge | Tip selection, exit velocity calculations, pilot specifications |
| EPA 40 CFR 60.18 | General control device performance standard: DRE presumption conditions, visible emissions, continuous pilot | Operating parameter design basis for all HPS combustion control equipment |
| EPA OOOOb | Oil and natural gas NSPS: 98% control efficiency, continuous parameter monitoring, recordkeeping | Control panel monitoring packages, OOOOb compliance documentation |
| NFPA 85 | Boiler and combustion systems hazards: burner management for enclosed combustion | Enclosed combustor burner management system design |
| NFPA 86 | Ovens and furnaces: temperature limits, purge requirements for enclosed combustion systems | Enclosed combustor operating procedure and safety interlock design |
We partner with you to deliver process solutions that support operational excellence and environmental responsibility
As regulations shift and technologies evolve, Hero Process Solutions ensures your system remains compliant, competitive, and efficient.
Let’s talk about your project
We have engineers on standby to assist with any questions or support you with upcoming projects. Reach out today.
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