Air-Assist Flares for Emergency and Standard Applications
Smokeless flare technologies utilize steam, gas-assist, or air-assist to produce mixing energy for the waste gas and air at the tip exit to achieve smokeless performance. When steam or gas-assist is not available, air-assist flare technology is the ideal choice for applications requiring a smokeless flare. The blower is mounted at the base of the flare stack and can range from 1 horsepower up to 250 horsepower depending on the flow rate and smokeless requirements. The Hero air-assisted technology ensures that the blower combustion air and waste gas stream are isolated from each other throughout the flare system and are combined at the flare tip exit to generate turbulence to achieve a reliable smokeless performance. The Hero air-assisted flare tip technology is proven technology that evenly distributes the waste gas stream throughout the tip to maximize the waste gas surface area as it comes in contact with the air to ensure a reliable smokeless performance throughout the operation of the flare.
emergency flares
Air-assisted flares are commonly used for handling emergency releases from safety valves, blow-down systems, and depressuring systems. The Hero air-assisted flare technology is utilized to safely burn and destroy large volumes of waste gas during unplanned situations, such as power outages or emergency conditions. While primarily designed for emergency releases, emergency air-assisted flares are typically designed to handle smaller flow rate day-to-day vent streams from various process operations during non-routine events that requires 100% smokeless capacity.
Our in-house engineering team can custom design an emergency flare to meet your specific needs for flow rates of to 400 MMSCFD.
A+ series tank battery flares
Hero offers a complete line of standard size tank battery flare systems that can be provided with a single inlet, or dual inlet (i.e. high pressure / low pressure). Our A+ Series air-assisted flares consist of a standard turnkey package that includes everything that is required for installation. All of our A+ Series flare systems comes equipped with a blower VFD in order to achieve OOOOb/c compliance by ensuring the blower speed is adjusted based on tank vapor flow rate to achieve 98% or greater Destruction Efficiency (DRE).
These standard flare systems are typically in stock for immediate shipment.
| Model | LP Capacity | HP Capacity |
|---|
| G201A133 | 140 MSCFD | 1 MMSCFD |
| G30A566 | 350 MSCFD | 5 MMSCFD |
| G40A766 | 450 MSCFD | 10 MMSCFD |
| G60A968 | 550 MSCFD | 20 MMSCFD |
| G60A1168 | 700 MSCFD | 25 MMSCFD |
| T40VT8 | 2.5 MMSCFD | 20 MMSCFD |
| T60VT8 | 2.5 MMSCFD | 30 MMSCFD |
| T60LH810 | 2.5 MMSCFD | 60 MMSCFD |
air-assisted liquid flares
Flare systems are designed to handle waste gas streams that are in vapor phase. When vapor phase is not obtainable, the flare system must be specifically designed to handle liquid waste gas streams. The Hero liquid air-assisted flare technology utilizes our proprietary tip design that provides maximum liquid atomization to achieve a safe and reliable operation at all times. When flaring liquid, pressures in the range of 30 to 70 psig are needed to utilize the pressure drop across the flare tip to achieve reliable atomization.
HERO Advantages
Frequently Asked Questions
Hero Process Solutions uses a blower at the base of the stack to provide the required combustion air, keeping air and gas isolated until they mix at the flare tip exit for strong turbulence and smokeless burning. The exact air rate is engineered per application so the blower and tip together achieve reliable smokeless performance over your operating range. Share your flow rates and gas data so our team can size the blower air correctly for your system.
Smokeless flare technologies can rely on steam, gas‑assist, or air‑assist for mixing energy at the tip, and when steam or gas‑assist are not available, air‑assist is the ideal solution for smokeless operation. Hero Process Solutions’ air‑assisted flare technology is designed specifically for these no‑steam, no‑gas‑assist environments. If you’re missing steam or assist gas, we can confirm if an air‑assist design is the right fit for your site.
Hero Process Solutions emergency air‑assisted flares are commonly used to handle emergency releases from safety valves, blow‑down systems, and depressuring systems during unplanned events such as power outages. They are also typically designed to handle smaller day‑to‑day vent streams that require 100% smokeless capacity. Send us your routine and emergency scenarios so we can confirm if one system can cover both.
Hero Process Solutions’ air‑assisted flare tip technology evenly distributes the waste gas throughout the tip, maximizing the surface area as it contacts combustion air. This proven design supports reliable, smokeless combustion performance and high destruction efficiency when operated within design limits. If you provide basic gas composition and flow ranges, we can evaluate how this design fits your emissions goals.
Hero Process Solutions air‑assist flares meet 40 CFR 60.18 EPA requirements and are fully OOOOa/b/c compliant. The blower VFD is used to maximize Destruction Rate Efficiency (DRE) and support regulatory performance across changing tank vapor flows. Contact us if you need compliance statements or documentation for permits and audits.
The air‑assisted flare tip technology from Hero Process Solutions is proven to evenly distribute the waste gas stream throughout the tip and maximize the surface area as it contacts combustion air. This configuration supports reliable smokeless performance throughout operation of the flare. Share your gas composition and expected operating range so we can review tip performance for your conditions.
When vapor phase is not obtainable, Hero Process Solutions offers liquid air‑assisted flare technology specifically designed for liquid waste gas streams. These systems use a proprietary tip design that provides maximum liquid atomization, typically with pressures in the 30–70 psig range used across the tip for reliable atomization and safe operation. If you have liquid streams, send us your pressure and fluid details so we can confirm a liquid air‑assist solution.
The A+ Series from Hero Process Solutions is a complete line of standard size tank battery flare systems offered with single or dual inlets (high pressure / low pressure) as a turnkey package that includes everything required for installation. Each A+ Series flare comes equipped with a blower VFD that adjusts blower speed based on tank vapor flow rate to achieve 98% or greater Destruction Efficiency (DRE) and OOOOb/c compliance. Share your LP and HP volumes and we’ll recommend the right A+ Series configuration.
Hero Process Solutions keeps dual LP/HP air‑assist flares in stock, including standard models such as G201A133, G30A566, G40A766, G60A968, G60A1168, T40VT8, T60VT8, and T60LH810 for a wide range of tank battery applications. LP capacities span from 140 MSCFD up to 2.5 MMSCFD and HP capacities from 1 MMSCFD up to 60 MMSCFD, depending on the model. Tell us your expected LP/HP flows and timeline so we can confirm which in‑stock unit fits your project.
Hero Process Solutions equips all A+ Series flares with a blower VFD that adjusts blower speed based on tank vapor flow rate. This dynamic control helps keep Destruction Efficiency at or above 98% and supports OOOOb/c smokeless performance even as vent loads change. If you share your typical and peak vent profiles, we can review how the VFD control will track those changes.
Contact us
We have engineers on standby to assist with any questions or to support you with any upcoming projects. Contact us today!