For the vast majority of applications, the Hero Hotspot Ignition System is the recommended choice. It covers 99% of flare ignition scenarios, is kept in stock for immediate shipping, and uses the most reliable ignition probe technology available with thousands of units in service. The Flame Front Generator is reserved for rare situations such as flare stacks 200 feet or taller, offshore platforms exposed to salt and corrosive materials, or existing flares built around a specific FFG design. Request a quote at heroprocesssolutions.com/contact or call (918) 941-2166 to confirm the right system for your stack.

Hero Process Solutions offers two core flare pilot technologies: the Hotspot Ignition System for standard applications and the Flame Front Generator for tall or offshore flares. Both systems can be powered by AC electricity or solar and operate on either natural gas or propane fuel. Additionally, Hero offers retractable pilot systems that allow pilots to be raised and lowered at grade level using a manual winch, eliminating the need for man baskets or crane access to perform maintenance and inspections while the flare remains in service.

Pricing for Hero flare ignition systems depends on the technology selected, power configuration, fuel source, and whether a retractable pilot system is included. The Hotspot Ignition System is the most cost-effective option for the majority of installations and ships from stock with minimal lead time. Flame Front Generators carry additional engineering for specialized applications. Retractable systems add value by eliminating costly crane or man basket services for pilot maintenance over the life of the flare. Every Hero system is built for long-term reliability to minimize total cost of ownership.

Hero Hotspot Ignition Systems are kept in stock and ready for immediate shipping, making them one of the fastest pilot solutions available for new installations or emergency replacements. Installation on existing flare stacks is straightforward because the system is designed to bolt directly onto the stack structure with no welding required at elevation. Hero engineers are on standby to support sizing, selection, and field commissioning so your flare is reliably ignited as quickly as possible. Request a quote at heroprocesssolutions.com/contact or call (918) 941-2166 for lead time on your configuration.

The Hero Retractable Pilot System uses heavy-duty bearings and precision-machined subcomponents combined with stainless steel guide cables to ensure smooth, trouble-free travel from the base to the flare tip every time. Pilots are raised and lowered at grade level by cranking a manual winch, eliminating the need for man baskets or crane access. Unlike common Unistrut-based systems that rust, corrode, and hang up over time, the Hero design is engineered for long-term reliability in harsh field conditions and can be retrofitted onto existing flare stacks with minimal welding or field work.

Yes. The Hero retractable pilot system is specifically designed to be retrofitted onto existing flare stacks with minimal field work and no welding at high elevations. The system bolts directly onto the stack structure, meaning your flare can remain in service during installation. Once installed, periodic pilot maintenance and inspections are carried out at grade level while the flare continues operating normally. This eliminates shutdowns, hot work permits at height, and expensive crane or man basket rentals. Request a quote at heroprocesssolutions.com/contact or call (918) 941-2166 to discuss retrofit options for your stack.