Gas Processing

Flare & Combustion Systems for Gas Processing Facilities

NGL fractionation plants, glycol dehydrators, amine treating units, and compressor stations require combustion equipment engineered for rich hydrocarbon streams, BTEX vent gas, and sour gas service.

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Subpart HH / HHH Certified BTEX Combustion Designs API RP 521 / 537 Sour Gas Alloy Service Oklahoma-Based Since 2012
Subpart HH Compliance Glycol dehydrators above throughput thresholds must route still column vent gas to a 95% HAP control device. Penalties up to $70,117/day per violation. HPS BTEX combustors ship compliance-documented. Review HAP control requirements →
BTEX
Rated Combustor Designs
>98%
HAP Combustion Efficiency
2″–36″
Sonic Flare Tip Range
3–8 wk
Standard Lead Time
H2S
Sour Gas Service Available
Engineering Challenges

What Makes Gas Processing Combustion Different

Each gas processing vent source (dehydrator stacks, NGL relief headers, amine regenerators, compressor blowdowns) has its own stream composition, BTU content, and permit requirement.

BTEX in Glycol Dehydrator Vents

TEG dehydrator still column vents concentrate benzene, toluene, ethylbenzene, and xylenes — all listed HAPs regulated under Subpart HH. Standard flare tips smoke on BTEX-rich streams and fail DRE requirements.

HPS Solution: Air-assist combustors sized to the actual still column vent composition, not a generic natural gas assumption.

Rich Hydrocarbon Streams from NGL Plants

NGL fractionation plant relief vents carry high-molecular-weight fractions (propane, butanes, pentanes) with high smoking tendency. Flare tip sizing must follow API RP 521 for high-MW streams, not standard gas assumptions.

HPS Solution: Steam-assist or air-assist tip designs sized for actual NGL stream molecular weight and relief load per API RP 521.

Sour Gas from Amine Treating Units

Acid gas vent streams from amine regenerators carry H2S and CO2 with low BTU content that requires supplemental fuel for stable combustion. Flameout events produce SO2 odor and downwind hazards.

HPS Solution: Sour-service alloy pilot and burner packages with supplemental fuel injection for low-BTU acid gas. SO2 dispersion calculations included.

Variable Flow at Compressor Stations

Compressor station blowdown and relief vent flows vary widely between normal operations and emergency events. Equipment must handle peak blowdown rate without flame instability or structural overload.

HPS Solution: Staged tip designs or multi-tip headers for flow range management. Sonic flares for high-pressure blowdown where conventional tips exceed velocity limits.

Remote Location and Minimal Utilities

Many gas processing and midstream facilities are in remote locations with no instrument air, no steam utility, and limited electrical power. Combustion equipment must operate unattended on minimal infrastructure.

HPS Solution: Self-contained packages with propane pilot, solar ignition, and air-only utility requirements. No steam dependency for BTEX combustion.
Product Lineup

Combustion Systems for Gas Processing

Purpose-built for midstream oil and gas, from glycol dehydrator BTEX control to NGL plant relief headers and compressor station blowdown.

HPS air-assist flare and BTEX combustor for glycol dehydrator still column vent gas
Glycol Dehydrator / BTEX / HAP Control

Air-Assist Flares & BTEX Combustors

Air-assist combustors and flare tips for glycol dehydrator still column vent gas. Sized to actual BTEX vent stream composition with 95% or 98% HAP DRE. No steam utilities required.

HAP DRE95% or 98%
BTEX StreamsYes, sized to comp.
Flow Range5 to 500 scfm
UtilitiesAir only; no steam
Design Std40 CFR 63.11(b)
Lead Time3 to 6 weeks
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HPS sonic flare for NGL plant relief headers and compressor station blowdown
NGL Plants / Compressor Stations

Sonic Flares

Pressure-assisted sonic flare tips for NGL fractionation plant relief headers and compressor station blowdown where high-pressure, high-velocity streams exceed conventional elevated tip limits.

CE / DRE>98%
Tip Sizes2″ to 36″
Operating ModePressure-assist
Design StdAPI RP 521 / 537
H2S ServiceAlloy available
Lead Time4 to 8 weeks
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HPS enclosed combustor for storage vessel vents and small process vent streams at gas processing plants
Storage Vessel / Small Vent Streams

Enclosed Combustors

For storage vessel vent streams, pump seal vents, and small process vent streams at gas processing plants where a permit requires no visible flame and DRE documentation.

DRE>95% / 98%
Flame VisibilityNone
Flow Range5 to 2,000 scfm
Min. Combustion Temp1,600 to 2,000°F
MonitoringBFMS + Temp Logger
Lead Time8 to 16 weeks
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Regulatory Compliance

Key Standards for Gas Processing Combustion Equipment

StandardApplicabilityKey RequirementHPS ProductsStatus
40 CFR Part 63, Subpart HH
NESHAP: Oil & Gas Production		 Storage vessels and glycol dehydrators at oil and natural gas production facilities with major or area source HAP emissions above thresholds. 95% HAP reduction or outlet below 20 ppmv; dehydrator vent gas must be routed to a combustion device meeting Subpart HH performance requirements. Air-Assist Flares, BTEX Combustors COMPLIANT
40 CFR Part 63, Subpart HHH
NESHAP: Natural Gas Transmission		 Glycol dehydrators at natural gas transmission, distribution, and storage facilities with major source HAP emissions above applicable thresholds. 95% HAP reduction; dehydration unit vent gas routed to control device; no emissions averaging allowed. Air-Assist Flares, Enclosed Combustors COMPLIANT
EPA 40 CFR Part 60, Subpart OOOOb
NSPS: Oil & Gas (after Dec 6, 2022)		 New, modified, and reconstructed storage vessels, compressor wet seals, and other sources at gas processing plants affected after December 6, 2022. 95% or 98% VOC/HAP reduction depending on source type; combustion device performance monitoring and recordkeeping required. Enclosed Combustors, Air-Assist Flares COMPLIANT
40 CFR 60.18(c)
General Combustion Device Standards		 All flares and combustion devices used to comply with any NSPS or NESHAP rule at gas processing facilities. Net heating value at or above 300 BTU/scf; continuous pilot; no visible emissions except in specified circumstances. All HPS combustion products COMPLIANT
State Air Permits
Title V / Minor Source Permits		 Facility-specific permit conditions that may set operating parameter limits, monitoring requirements, and DRE minimums above federal thresholds. Varies; HPS documentation supports permit application and permit compliance recordkeeping. All products SITE-SPECIFIC
Engineer FAQ

Technical Questions on Gas Processing Combustion Systems

What DRE is required for a glycol dehydrator combustor under Subpart HH?

40 CFR Part 63 Subpart HH requires 95% HAP reduction from glycol dehydrators at oil and natural gas production facilities, or an outlet concentration below 20 ppmv. HPS air-assist combustors are certified to 95% or 98% DRE with vent stream composition documentation included at delivery.

Can one combustor handle multiple dehydrator still column vents at one facility?

Yes: a vapor manifold can collect vent gas from multiple still column vents and route it to a single air-assist combustor. HPS sizes the unit for the combined peak vent rate and determines the manifold configuration based on dehydrator layout and local regulatory requirements.

Our acid gas from the amine regenerator has very low BTU content. Can you combust it?

Yes. Amine regenerator acid gas with high CO2 dilution can have a net heating value well below the 300 BTU/scf minimum for stable unaided combustion. HPS designs supplemental fuel injection systems to achieve stable combustion across the full vent rate range with NACE MR0175 alloy options for H2S service.

What H2S levels require special materials in the combustion device?

Material selection for H2S service follows NACE MR0175/ISO 15156. HPS specifies 316L SS wetted surfaces above 200 ppmv H2S; Incoloy 825 for pilot tube and burner internals above 500 ppmv; Hastelloy C-276 for high-H2S acid gas service above 2,000 ppmv or where liquid H2S condensate is possible.

Does OOOOb apply to storage vessels at our gas processing plant?

Yes. EPA 40 CFR 60 Subpart OOOOb (2024 rule) requires storage vessels at oil and natural gas facilities after December 6, 2022 to achieve 95% VOC emission reduction if throughput exceeds specified thresholds. The control device must be a combustion device or vapor recovery unit meeting performance requirements, with pilot monitoring and recordkeeping. HPS provides the PE-stamped design calculation and monitoring plan at delivery.

What lead time should we plan for a BTEX combustor replacement?

Standard air-assist combustors for glycol dehydrator still column vent gas ship in 3 to 6 weeks from order. Larger units or those with H2S-service alloy packages run 5 to 8 weeks. Contact HPS with your vent stream composition and peak flow rate for a firm delivery estimate. Call (918) 941-2166.
BTEX
Rated Combustor Designs
OOOOb
Compliant Equipment
>95%
Minimum HAP DRE
H2S
Sour Service Material Options

Gas processing vent streams are not natural gas. A glycol dehydrator still column vent is a BTEX-rich mixture that will smoke on a standard flare tip and fail its DRE requirement within the first inspection period.

Craig Rosencutter, President, Hero Process Solutions
Resources

Technical Reference for Gas Processing Applications

Data Sheets

Combustor & Flare Spec Sheets

Dimensional and performance data for HPS air-assist combustors, sonic flares, and enclosed combustors for gas processing service.

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Product Page

Air-Assist Flares & BTEX Combustors

BTEX-rated combustion systems for glycol dehydrator and amine treating unit vent streams. Subpart HH / HHH compliant.

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Product Page

Sonic Flares for NGL & Compressor Service

Pressure-assisted sonic tips for NGL plant relief headers and compressor station blowdown. API RP 521 / 537 designed.

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Product Page

Enclosed Vapor Combustors

No-visible-flame control for storage vessel vent streams and small process vents. OOOOb-certified with monitoring plan.

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Compliance Guide

Subpart HH / HHH / OOOOb Compliance Guide

HAP control requirements for glycol dehydrators, storage vessels, and compressor wet seals at gas processing facilities.

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Engineering Support

Talk to an HPS Engineer

Send us your vent stream composition, flow rate, and permit conditions. We confirm equipment type and lead time within 48 hours.

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Get a Quote

Gas Processing Combustion Equipment Quote

Send us your vent stream composition, flow rate, operating pressure, and permit requirements. We confirm equipment type and DRE compliance basis within 48 hours.

  • ✓ BTEX combustor and air-assist flare sizing
  • ✓ HAP DRE compliance documentation included
  • ✓ Sour gas alloy selection for H2S service
  • ✓ Sonic flare sizing for high-pressure blowdown

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Ready to Specify Your Gas Processing Combustion System?

Send us your vent stream composition, flow rate, and permit conditions. We confirm equipment type and lead time within 48 hours.

Request a Quote → Call +1 (918) 408-7608

Hero Process Solutions, 14842 Maple Dr, Kellyville, OK 74039