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.
What Is an Air-Assisted Flare?
An air-assisted flare is a smokeless flare that uses a motor-driven blower to push ambient air into the waste gas stream at the flare tip. The added air supplies the oxygen and mixing energy needed to burn heavy hydrocarbons without smoke. Operators choose air assist when steam or assist gas is not available or not economical, which is common at production sites, tank batteries, and remote facilities.
Unlike a steam-assisted flare that needs a steam supply, an air-assisted flare only needs power for the blower, so it fits locations where utilities are limited. The result is clean combustion that meets emissions rules while keeping the operating cost and the equipment footprint manageable. If you are weighing whether air assist fits your site, our engineers can confirm it against your gas and utility data in a short call.
How an Air-Assisted Flare Works
An air-assisted flare stack carries two separated paths: one riser for the waste gas and a path for the blower air, kept apart so the two streams never mix before the tip. The blower sits at the base and supplies low-pressure combustion air sized to the flow. At the flare tip exit, the air and gas combine and the turbulence pulls oxygen into the hydrocarbons for complete, smokeless burning.
The Hero air-assisted flare tip distributes the waste gas evenly across the tip to maximize the surface area meeting the air, which is what holds smokeless performance as flow changes. Keeping the streams isolated until the exit also limits heat transfer back into the system and supports reliable ignition. This is proven flare tip technology, not a one-off design, and it is the core of why our air-assist flares stay clean through real operating swings. Ask us to walk through the tip and blower sizing for your conditions.
Air-Assist vs Steam-Assist vs Gas-Assist: When to Choose Air
Smokeless flares rely on steam, gas-assist, or air-assist to add the mixing energy that burns waste gas at the tip. Each has a place. Steam assist suits large refinery flares with a steam supply on hand. Gas-assist works where high-pressure waste gas is already available. Air-assist is the practical choice when neither steam nor spare assist gas is available, because it needs only electrical power for the blower.
That makes it a strong fit for tank batteries, production pads, and midstream sites without utility steam. Air assist also gives a wide turndown range, so one system can stay smokeless from low routine vent rates up to peak releases. If you want a side-by-side breakdown, see our guide on air-assisted vs steam-assisted flares, then send us your site details and we will recommend the assist type that fits.
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.
Need a Smokeless Flare Sized for Your Site?
Send your flow rates and gas composition and our engineers will size the blower, tip, and stack, then check whether an in-stock A+ Series unit fits your timeline.
Smokeless Performance: What Makes a Gas Burn Clean
Not every waste gas smokes, and knowing which streams do helps size the assist air correctly. As a general rule, a gas with a carbon-to-hydrogen ratio under about 0.25 tends to burn smokeless, while a ratio above about 0.28 tends to smoke. Streams with a lower heating value under roughly 1,000 Btu/ft³ and a molecular weight under about 20 also favor clean burning.
Heavier, richer streams need more mixing energy, which is exactly what the blower and tip provide on an air-assisted flare. See also our vapor combustor systems for enclosed combustion. We use your gas composition and flow range to set the blower air so the flare stays smokeless across the operating window, not just at the design point.
Compliance and Destruction Efficiency
Staying legal is the whole point of flaring, so our air-assisted flares are built to the rules. Hero air-assist flares meet 40 CFR 60.18 EPA requirements and are fully OOOOa/b/c compliant. The blower VFD adjusts to changing tank vapor flow to hold 98% or greater destruction efficiency, the level most operators design to under 40 CFR 60.18, while NSPS OOOO and OOOOa set a minimum 95% control efficiency baseline that OOOOb/c tighten for new and existing sources.
We can provide compliance statements and documentation for permits and audits. For a deeper look at the rule, see our OOOOb/c compliance overview, then contact us for the records your site needs. Need a unit fast? Check our flare rental options. Need a unit fast? Check our flare rental options.
HERO Air-Assist Advantages
EPA 40 CFR 60.18 Compliant
Meets 40 CFR 60.18 EPA requirements, so your flare performance lines up with the standard most permits reference.
Fully OOOOa/b/c Compliant
Built for the current and tightening new-source rules, keeping your operation ahead of regulatory changes.
In-Stock LP/HP Flares
Dual LP/HP air-assist flares kept in stock for fast deployment on tank batteries and tight deadlines.
Blower VFD Control
VFD tracks vapor flow to hold 98%+ destruction efficiency across changing loads automatically.
Custom Engineering
In-house engineering sizes the blower and flare tip to your gas data, not a generic catalog spec.
Proven Tip Technology
Proven air-assisted flare tip holds smokeless performance through real operating swings.
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.
Applications and Industries Served
Air-assisted flares fit any site that needs smokeless combustion without a steam supply. Common uses include tank battery vapor control, emergency relief from safety valves and blow-down systems, routine process vents, and gas handling at production and midstream facilities.
Operators across upstream production — the Permian Basin, Oklahoma, Marcellus, and Haynesville plays — gas processing, and petrochemical sites use air assist to stay smokeless and compliant. If your application is not listed, it most likely still fits. Tell us the stream and the setting and our engineers will confirm the configuration. View all markets served.
Related Flare Systems and Resources
If air assist is not the right match, Hero builds the full range of flare systems. Explore a related product below, or browse all flares to compare options.
Gas-Assist Flares
Smokeless burning where high-pressure assist gas is available.
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