What Is a Utility Flare and How Does It Work?
A utility flare is an unassisted, open-tip flare that burns waste gas using flame stabilization at the tip and a constantly burning pilot, with no steam, air, or assist gas. It is the economical choice when the gas does not need smokeless treatment, either because smokeless capacity is not required or because the gas burns clean on its own.
A stable flame across the full flow range, from a large emergency release down to purge flow, is what keeps a utility flare safe and compliant. Because there is no blower or steam system, the utility flare has the lowest capital cost and simplest operation of any flare type. Tell us your gas composition and we will confirm whether a utility flare is enough.
When to Choose a Utility Flare vs a Smokeless Flare
If the stream is light and burns clean on its own, or your permit does not require smokeless capacity, a utility flare is the most economical option. If the gas is heavy and would smoke, you need a smokeless design such as an air-assist, sonic, or gas-assist flare.
Many sites use a utility flare as the emergency backup alongside a smokeless flare for routine duty. Send us your routine and emergency cases and we will tell you which combination fits.
Design and Construction
Hero utility flares are built for long life and easy service in the field, so your emergency flare is ready when an upset hits.
Stocked to 20 MMSCFD
Standard utility flares in stock for fast deployment when you need an emergency flare quickly.
Stainless Steel Pilots
Maximum life in high-heat service with stainless steel construction on pilots and tip.
Retractable Pilot System
Service the pilot from grade level — no elevated work required for maintenance.
Guy-Wire or Self-Supported
Flexible stack options to match your site footprint and structural requirements.
Single-Point Lift
Eliminates field welds at height for safer, faster installation.
EPA 40 CFR 60.18
Meets the federal flare performance standard most permits reference.
Pilots and Ignition Reliability
Hero uses stainless steel pilots for long life and a retractable pilot system that lets your crew service the pilot from grade instead of working at height. That means faster maintenance, safer service, and high ignition reliability when it matters most.
Applications and Industries Served
Common uses include emergency shutdowns, compressor blowdowns, pigging operations, well-head testing, and pipeline maintenance. Operators in the Permian Basin, Oklahoma, Marcellus, and Haynesville plays rely on utility flares as a dependable backup. For liquid streams, pair with a knockout system. View all markets.
Compliance and Safe Disposal
Hero utility flares meet 40 CFR 60.18 EPA requirements. We can reflect this in your permitting documentation. See our OOOOb/c overview. Need a unit fast? Check flare rentals.
Need an Emergency Flare You Can Deploy Fast?
Hero stocks utility flares up to 20 MMSCFD. Send your emergency flow rate and gas data and we will confirm the right unit.
Why Choose Hero Utility Flares
EPA 40 CFR 60.18
Meets federal standards so emergency flaring stays compliant.
Stocked to 20 MMSCFD
In stock for fast deployment on emergency applications.
Stainless Steel Pilots
Long-life pilots with retractable system serviceable from grade.
Flexible Stacks
Guy-wire or self-supported to match your site.
Single-Point Lift
No field welds at height — safer, faster installation.
Lowest Cost Solution
No blower or steam — lowest capital cost of any flare.
Ready to Get Started?
Spec Your Emergency Flare System Today
Our engineers size every emergency and utility flare to your relief flow rate, back-pressure, and site requirements. Get a detailed quote in 24 hours.
Kellyville, OK 74039 Midland 2714 East County Road 147
Midland, TX 79706
What Makes a High-Quality Emergency and Utility Flare System
Emergency and utility flares handle pressure relief gas, blowdown events, and process upset flows — flow conditions that are infrequent but must combust safely and compliantly on demand. Five factors differentiate equipment that performs reliably during these high-stakes events from equipment that fails precisely when needed.
Rated capacity matched to the maximum relief scenario. The flare tip and knockout drum must be sized for the worst-case simultaneous relief scenario, not the average operating flow. Undersized emergency flares create backpressure on relief valves, which can compromise vessel protection. Request confirmation that the flare system is sized per the facility’s maximum credible release event.
Auto-ignition reliability. Emergency flares must ignite instantly when a relief event begins, without operator intervention. High-quality systems use continuously burning pilots with high-energy electronic ignition backup and thermocouple-confirmed flame status sent to the control room. Gravity-feed or pressure-activated ignition systems that require manual reset are not acceptable for unattended or remote facilities.
Low-flow pilot stability between events. Emergency flares spend most of their life in standby mode with only the pilot burning. Pilot designs that cannot maintain a stable flame at low-flow standby conditions will extinguish between events, leaving the system unlit at the onset of the next relief. Specify a pilot burner rated for continuous stable combustion independent of the main flare flow.
Knockout drum sizing and liquid drainage. Relief events often carry liquid slugs that can extinguish a flare tip or create a liquid projectile hazard. The knockout drum upstream of the flare tip must be sized to separate liquid from the vapor stream at the maximum relief flow rate, with an automatic liquid drain or pump-out to prevent liquid accumulation.
Thermal radiation setback documentation. Emergency flares operating at maximum relief flow produce significant thermal radiation. Manufacturers should provide site-specific thermal radiation calculations (API 521 methodology) confirming safe setback distances for personnel and equipment at the rated capacity.
What Makes a High-Quality Emergency and Utility Flare System
Emergency and utility flares handle pressure relief gas, blowdown events, and process upset flows — flow conditions that are infrequent but must combust safely and compliantly on demand. Five factors differentiate equipment that performs reliably during these high-stakes events from equipment that fails precisely when needed.
Rated capacity matched to the maximum relief scenario. The flare tip and knockout drum must be sized for the worst-case simultaneous relief scenario, not the average operating flow. Undersized emergency flares create backpressure on relief valves, which can compromise vessel protection. Request confirmation that the flare system is sized per the facility’s maximum credible release event.
Auto-ignition reliability. Emergency flares must ignite instantly when a relief event begins, without operator intervention. High-quality systems use continuously burning pilots with high-energy electronic ignition backup and thermocouple-confirmed flame status sent to the control room. Gravity-feed or pressure-activated ignition systems that require manual reset are not acceptable for unattended or remote facilities.
Low-flow pilot stability between events. Emergency flares spend most of their life in standby mode with only the pilot burning. Pilot designs that cannot maintain a stable flame at low-flow standby conditions will extinguish between events, leaving the system unlit at the onset of the next relief. Specify a pilot burner rated for continuous stable combustion independent of the main flare flow.
Knockout drum sizing and liquid drainage. Relief events often carry liquid slugs that can extinguish a flare tip or create a liquid projectile hazard. The knockout drum upstream of the flare tip must be sized to separate liquid from the vapor stream at the maximum relief flow rate, with an automatic liquid drain or pump-out to prevent liquid accumulation.
Thermal radiation setback documentation. Emergency flares operating at maximum relief flow produce significant thermal radiation. Manufacturers should provide site-specific thermal radiation calculations (API 521 methodology) confirming safe setback distances for personnel and equipment at the rated capacity.
Why Engineers Choose Hero Process Solutions
| What You Need | How Hero Process Solutions Delivers It |
|---|---|
| 98% DRE documentation for permit compliance | In-house combustion engineers provide site-specific performance certifications backed by tip-specific test data |
| Equipment on-site before the compliance deadline | Rental fleet deployable in 24 to 72 hours across the Permian Basin, Mid-Continent, Appalachia, and Rockies |
| Manufacturer that designs its own tips | All combustion tips designed, fabricated, and tested at Hero Process Solutions’ Kellyville, Oklahoma facility |
| Field service when equipment needs attention | Direct HPS field technicians — not third-party contractors — cover major producing regions |
| Equipment for multiple applications | Air-assist, sonic, gas-assist, low-flow, emergency, and portable flares plus vapor combustors and VRUs from one manufacturer |
Hero Process Solutions is a US-based manufacturer and rental provider serving upstream, midstream, pipeline, and industrial clients since the company’s founding under the Hero Flare brand. Contact (918) 941-2166 or email sales@hero-ps.com to discuss your application. Engineering specifications and rental availability are provided within one business day of inquiry.