Sonic Flares : Reliable, Smokeless Flare Solutions (Variable Slot Orifice)
Also known as a Coanda flare, this state-of-the-art flare tip automatically adjusts the flare tip opening as the flow increases and decreases. At low flow, the variable orifice is almost completely closed. As the flow and backpressure increase, the flare tip orifice opens. This variable orifice technology allows the tip to maintain a high exit velocity at low flow rates as well as high flow rates to achieve maximum air mixing to achieve 100% smokeless performance.
The variable orifice sonic tip is a economical solution to other smokeless technologies such as air-assisted flares when a minimum of 30 psig waste gas pressure is available.
Advantages of Variable Slot Orifice
Sonic Flares (Fixed Orifice Flare)
A sonic flare uses the flare gas pressure to eliminate smoke, lower flame radiation, and shorten the flame length. Typically, sonic flare waste gas pressure will range from 15-100 psig pressure depending on the flare gas composition.
Sonic flares are a good economical solution to traditional air-assisted flares since they reduce the overall stack complexity and alleviates the need for air assist blowers.
Advantages of Sonic Flares
Frequently Asked Questions
A sonic flare uses the flare gas pressure itself to eliminate smoke, lower flame radiation, and shorten flame length. In Hero Process Solutions designs, typical waste gas pressure ranges from 15–100 psig depending on gas composition, and this pressure drives high exit velocity for strong air mixing and smokeless performance. Share your available flare gas pressure so we can confirm if a sonic flare fits your application.
Also known as a Coanda flare, Hero Process Solutions’ variable slot orifice tip automatically adjusts the flare tip opening as flow increases and decreases. At low flow the orifice is almost closed, and as flow and backpressure rise it opens, maintaining high exit velocity at both low and high flows for maximum air mixing and 100% smokeless performance. If your flows fluctuate widely, we can help you evaluate whether the variable orifice sonic tip is the best fit.
Hero Process Solutions notes that the variable orifice sonic tip is an economical alternative to air‑assisted flares when a minimum of 30 psig waste gas pressure is available. Sonic flares reduce overall stack complexity and remove the need for air‑assist blowers, making them a cost‑effective option where sufficient gas pressure exists. Send us your available flare header pressure and we can advise whether sonic or air‑assist is more appropriate.
Both Hero Process Solutions variable slot orifice and fixed‑orifice sonic flares are designed to achieve 100% smokeless operation without the need for a blower. High exit velocity created by the gas pressure provides the mixing energy required to minimize smoke. If blower‑free operation is important at your site, our team can confirm smokeless performance against your gas and pressure conditions.
Hero Process Solutions states that both the variable slot orifice sonic flare and the fixed‑orifice sonic flare are fully EPA compliant. They also provide proven, reliable performance to achieve 98% Destruction Rate Efficiency (DRE). Contact us if you need compliance language or performance data for your permitting package.
Hero Process Solutions lists several advantages: 100% smokeless operation without a blower, higher turndown smokeless capacity compared to traditional sonic flares, full EPA compliance, lower cost than traditional air‑assist flares, and proven performance to achieve 98% DRE. This makes the variable slot orifice design a strong choice where you need wide turndown and low complexity. Share your turndown range and budget targets and we can see if this design aligns with your project.
Hero Process Solutions fixed‑orifice sonic flares use gas pressure to eliminate smoke, lower flame radiation, and shorten flame length while remaining 100% smokeless without a blower. They are fully EPA compliant, offer lower cost than traditional air‑assist flares, and provide proven reliable performance to achieve 98% DRE. If you are considering a simpler fixed‑orifice design, we can help compare it to variable orifice options for your case.
For fixed‑orifice sonic flares, Hero Process Solutions indicates typical waste gas pressures from 15–100 psig depending on the flare gas composition. For the variable slot orifice sonic tip, a minimum of about 30 psig waste gas pressure is noted as the threshold for an economical alternative to air‑assist flares. If you share your gas composition and pressure, we can quickly check suitability for a sonic flare.
Hero Process Solutions highlights that both the variable slot orifice sonic tip and the fixed‑orifice sonic flare are lower cost options compared to traditional air‑assist flares. They also reduce stack complexity and eliminate the need for air‑assist blowers, which can lower both capital and operating costs. Send us your project requirements and we can provide a side‑by‑side cost and complexity comparison.
Hero Process Solutions notes that engineers are on standby to help with questions and upcoming projects for sonic flares. They can review your waste‑gas pressure, composition, and flow to determine whether a variable slot or fixed‑orifice sonic flare is the best solution. Call or email the team with your basic design data and they can recommend and size an appropriate sonic flare system.
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