Gas-Assisted
When steam or electric is not available on-site, our high pressure gas-assisted smokeless technologies are viable options to achieve smokeless capacity. This technology can also be used to retrofit an existing flare stack that is experiencing smoke formation and outside of the environmental compliance regulations
Shown are pictures of an application where gas plant began to handle heavier feed gas, causing their flare to smoke. HERO Process Solutions retrofitted an existing flare stack with a new high pressure gas-assisted flare tip to achieve 100% smokeless performance.
Gas-Assisted Flares and Smokeless Flare Tip Retrofits
What Is a Gas-Assisted Flare and How Does It Work?
A gas-assisted flare uses high-pressure fuel gas, injected through nozzles at the flare tip, to create the turbulence and air mixing that burns waste gas without smoke. It is the smokeless option to reach for when steam or electric power for a blower is not available on site, common at remote and unmanned locations.
Unlike simply diluting the waste stream with fuel gas, a high-pressure injection tip pulls air into the flame far more efficiently, so it holds smokeless performance with less assist gas. The result is clean combustion and EPA compliance without the cost of a steam system or an air-assist blower. Tell us your available fuel gas pressure and we will confirm whether gas-assist is the right fit.
When to Choose Gas-Assist vs Air-Assist or Steam
The right assist medium depends on what you have on site. Gas-assist is the practical choice when you have high-pressure fuel gas available but no steam and no electric power for a blower, often the case at remote sites. Air-assist suits sites with electric power but low gas pressure, using a blower to supply mixing air. Sonic flares offer another high-pressure gas option with no blower required.
Gas-assist is also a low-cost way to bring an existing non-assisted flare into smokeless compliance for flow rates under 200,000 SCFD. Send us your utilities and flow rates and we will recommend gas-assist, air-assist, or another option.
Retrofit a Smoking Flare with a Gas-Assisted Tip
If your existing flare has started to smoke or has drifted out of compliance, you usually do not need a whole new stack, just a better tip. Hero retrofits existing flare stacks with a new high-pressure gas-assisted flare tip custom designed to fit your current connections.
Our installation goal is lift-and-bolt: the new tip is engineered to your existing flange so the swap is fast and field welds are minimized. This is exactly what we did for a gas plant whose flare began smoking after it started handling heavier feed gas; the retrofit tip restored 100% smokeless performance. In many retrofit cases a new permit application is not required. Send us photos or drawings of your current tip and we will scope a lift-and-bolt retrofit.
Signs You Need a Retrofit Tip
A few clear signals tell you a flare tip retrofit is worth a call:
Visible Smoke
Visible smoke from the flare, especially after a change in feed gas composition or flow rate.
Compliance Failure
A Method 22 reading that puts you out of smokeless compliance with 40 CFR 60.18 or state rules.
Poor Flame Stability
Poor flame stability or frequent pilot outages that reduce combustion reliability.
Heavier Gas Stream
A heavier or richer gas stream than the flare was originally designed for, a common cause of smoking after process changes.
Aging Tip
Corrosion, sagging, or a tip near the end of its service life that affects performance and safety.
If any of these sound familiar, send us your flare details and we will tell you whether a gas-assisted tip retrofit solves it.
Compliance and Destruction Efficiency
A gas-assisted flare keeps you compliant without the cost of steam or a blower. Hero high-pressure gas-assist flares meet EPA and state regulations and are designed to 40 CFR 60.18 Method 22, the federal smokeless standard, with a guaranteed 98% or better hydrocarbon destruction efficiency.
Because most retrofits reuse the existing stack and connections, many projects do not require a new permit application, saving time and cost. We provide compliance documentation, structural calculations, API datasheets, and thermal radiation profiles for your records. For more on the current rules, see our OOOOb/c overview, then contact us for the documents you need.
Is Your Flare Smoking or Out of Compliance?
Send us photos or drawings of your current flare tip and our engineers will scope a lift-and-bolt gas-assisted retrofit to get you back to 100% smokeless.
Related Flare Systems and Resources
If gas-assist is not the right match for your site, Hero builds the full range of flare systems and supports retrofits across the line.
Air-Assist Flares
Blower-driven smokeless flaring when you have electric power but limited gas pressure.
Sonic Flares
Smokeless flaring with no blower required when high gas pressure is available.
Utility & Emergency Flares
Economical flaring for relief, emergency, and upset flow events.
Portable Flares
Trailer-mounted units for temporary operations and rental jobs.
Aftermarket & Retrofit
Tip swaps, upgrades, and field service for existing flare systems.
Typical Applications
High Pressure Gas or Air Assist flares are a low-cost solution to comply with EPA standards 40 CFR 60.18 Method 22 to achieve smokeless compliance as well as ensure the surrounding community is put at ease with a clean burning flame. Typical applications for this flare include:
Specific Features & Benefits
High Stability Flare Tip – These flare tips are suitable for all hydrocarbon vapors. Stainless steel construction ensures a long tip life.
Meets EPA Regulations – Meets EPA and state regulations. We guarantee 98% or better hydrocarbon destruction efficiency. Often, this retrofit does not require a new permit application.
Easy to Retrofit – The new tip is custom designed to fit the existing flare stack connections. “Lift and bolt” is our installation goal
New Pilot Ignition System – While we can reuse existing pilots and ignition systems, most retrofit projects include spark ignited pilots and control panels. Shop tested to work the first time. Why not solve two problems at once?
Engineering Assistance – Use our engineering staff for specialized technical assistance on flare design and operation. Structural calculations, API datasheets, and thermal radiation profiles are available.
Frequently Asked Questions
A gas‑assisted flare system uses high‑pressure gas‑assist technology to achieve smokeless capacity when steam or electric power is not available on site. Hero Process Solutions also applies this technology to retrofit existing flare stacks that are smoking or out of environmental compliance. Share your site utilities and smoking issues so we can confirm if gas‑assist is the right solution.
Hero Process Solutions retrofits existing flare stacks with new high‑pressure gas‑assisted flare tips that provide the extra mixing energy needed to achieve 100% smokeless performance. This approach has been used, for example, when a gas plant began handling heavier feed gas and its existing flare started to smoke. Contact us with your current flare design and gas changes so we can review a retrofit option.
Hero Process Solutions notes that high‑pressure gas or air‑assist flares are ideal low‑cost solutions when electricity is not available on site and smokeless performance is still required. They are also suited for upgrading existing non‑assisted flares for smokeless operation at flow rates less than 200,000 SCFD. Share your available utilities and flow rates so we can recommend whether gas‑assist, air‑assist, or another option fits best.
Typical applications include sites where electricity is not available, upgrades of existing non‑assisted flares to achieve 100% smokeless performance, and applications that require smokeless performance for flow rates below 200,000 SCFD. These use cases help facilities comply with environmental regulations while managing capital cost. If you describe your application briefly, we can confirm whether it matches these typical cases.
Hero Process Solutions states that its high‑pressure gas‑assist flares meet EPA and state regulations and are designed to comply with 40 CFR 60.18 Method 22 smokeless standards. They guarantee 98% or better hydrocarbon destruction efficiency, and in many retrofit cases a new permit application is not required. Contact us if you need help tying gas‑assist performance to your site’s specific regulatory requirements.
The high‑stability gas‑assisted flare tip from Hero Process Solutions is suitable for all hydrocarbon vapors and uses stainless steel construction to ensure long tip life. It is custom designed to fit existing flare stack connections so the retrofit is as straightforward as possible. Share your existing stack drawings and connections so we can review a custom tip design.
Hero Process Solutions describes its gas‑assisted tip retrofit as “easy to retrofit” because the new tip is custom designed to match the existing flare stack connections. Their installation goal is a simple “lift and bolt” approach, minimizing field modifications. If you send photos or drawings of your current tip, we can discuss how a lift‑and‑bolt retrofit would work for you.
While Hero Process Solutions can reuse existing pilots and ignition systems, most retrofit projects include new spark‑ignited pilots and control panels that are shop‑tested to work the first time. This means you can address both smokeless performance and ignition reliability in one upgrade. Tell us about any recurring pilot issues so we can factor that into your retrofit plan.
Hero Process Solutions offers engineering staff for specialized technical assistance on flare design and operation, including structural calculations, API datasheets, and thermal radiation profiles. This support helps ensure the gas‑assisted flare meets both process and safety requirements. Reach out with your preliminary data and we can outline the engineering deliverables available for your project.
The gas‑assist flares page from Hero Process Solutions includes a Request a Quote link and contact details, including phone, email, and address, so you can quickly start a project discussion. Engineers are on standby to assist with questions and upcoming projects. Send us your basic flow, pressure, and application details and we’ll help you move toward a formal quote.
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We have engineers on standby to assist with any questions or to support you with any upcoming projects. Contact us today!