Combustion Technologies Developed to Meet Emission Requirements

G Squared develops combustion solutions using Honeywell UOP Callidus® flare systems. Known for quality and innovation, Callidus flares provide economical flaring with high destruction efficiency, high smokeless capacity, low noise and low radiation for a broad range of flare applications. Callidus flare systems are designed to provide stable, smokeless operation while meeting your process criteria and performance requirements.

G Squared is Your Gulf Coast Source for Flares

G Squared offers you the advantages of experience, proven ability to meet process specifications. We apply the highest quality standards in developing flare system solution with a broad selection of flare product to meet any requirement.

  • Solutions to meet EPA Refinery Sector Rule
  • Industry-leading drone inspection of flares
  • Flares engineered and constructed for long, reliable service

We work with an industry-leading manufacturer to offer the latest flare technologies, delivering smokeless operation over the whole operating range of the flare. EPA refinery sector rule requires that operators prove smokeless operation of their flares with recording and reporting system, and Callidus’ Flare Watch DVM [digital video monitoring] system meets these requirements today.

Callidus also offers industry-leading unmanned aerial drone flare survey and reports, with high-resolution video and expert support on flare performance.

Contact the G Squared team to discuss your project.

Tell Us About Your Project

  • Air Assisted Flares
  • Expert Flares
  • Hemisflare
  • Galaxy High Pressure Flares
  • MP4U High Pressure Flares
  • Pipe Flares
  • Pit Flares
  • Steam Assisted Flares
  • Stackable, Elevated Flares
  • Totally Enclosed Ground Flares
  • Multipoint Ground Flares

An effective alternative to steam-assisted smokeless flares, Honeywell UOP Callidus® Air Assisted Flares can help dramatically to reduce flare tip maintenance and lower operating costs.

Available in a variety of sizes and mixing geometries, air-assisted flare systems use blowers and a sophisticated flare tip mixing section to thoroughly mix air and waste gas within the combustion zone, resulting in smokeless combustion. The continual flow of forced draft air cools the tip and prevents flame pull down in high wind conditions.

Features:

  • No steam lines to run
  • High smokeless capacity
  • Plug welded brackets
  • Energy efficient pilots
  • Online maintenance of smoke suppression equipment (air blower)
  • Extremely stable pilot
  • Low noise design available

Benefits:

  • Low-cost smokeless flaring option for sites that do not have steam available or where steam is expensive
  • No high-frequency continuous steam injection noise
  • Low maintenance
  • Long service life
  • Low operating costs

Applications:

  • Applications where steam is unavailable due to site environmental conditions, available site utilities, or the high local cost of water
  • Upstream and midstream processing
  • Chemical/specialty processing

The Callidus Extended Perimeter Tip (Expert) is a unique multi-armed sonic flare tip with low emissivity, low noise levels, and a stable flame. Expert uses an investment cast flare nozzle to maximize the surface area for mixing between the waste gas and the surrounding air, ensuring smokeless, stable combustion at high velocity. This results in a well-aerated, low radiation flame with reduced susceptibility to wind-induced flame lean. The casting shape breaks up the sonic shockwave at the casting exit to reduce sonic jet noise.

Features:

  • High velocity, low radiation flame
  • No steam injection or air assist required for offshore applications
  • Low weight

Benefits:

  • Stable, smokeless combustion
  • Less susceptible to flame lean
  • Lower noise
  • Reduced utility cost
  • Improved offshore personnel safety

Applications:

  • Upstream and midstream processing

A breakthrough in modern flare technology, the Honeywell UOP Callidus® Hemisflare (HF) smokeless flare system produces high smokeless flow rates and excellent turndown performance.

Callidus Hemisflare systems use a patented Coanda design with enhanced ridges to increase flare gas and air mixing while enabling longer tip lifespan. The variable orifice design maximizes the waste gas velocity throughout the operating range, reducing radiation and maintaining the flare tip cool.

Features:

  • No steam injection or air assist required
  • Additional surface area to increase contact between air and flare gas
  • High-velocity operation
  • Variable exit model has no welds in a combustion zone
  • Increased mixing efficiency
  • Greater steam efficiency for Hemisflare with Steam Assist

Benefits:

  • Reduced utility cost
  • Smokeless combustion at a wide range of flows
  • Improved smokeless efficiency
  • Reduced radiation at grade for a shorter, less expensive flare stack
  • Reduced flare steam consumption
  • Simplified steam control system

Applications:

  • Upstream and midstream processing

The Callidus Galaxy multipoint flare burner is a high performance, low-cost system created with cutting-edge design and analysis tools and extensive physical testing. These flares have improved cross-lighting capabilities, shorter flames in both single and multiple burner applications, and has a robust design for use under high flow conditions.

These features combine to provide a more valuable system design which has reduced noise during lighting events, fewer components to purchase and maintain, a shorter flare fence and reduced foundation requirements.

Features:

  • Shorter flames
  • Cast high alloy steel construction
  • Single piece design with no welds in heat affected zone
  • Pre-tested in accordance with previous EPA AMEL requirements

Benefits:

  • Increased smokeless turndown capacity
  • Quieter operation
  • Lower capital and operating costs
  • Improved cross-lighting capabilities
  • Reduced foundation requirements

Applications:

  • Upstream, midstream and downstream processing
  • Petrochemical processing
  • Chemical/specialty processing

With thousands of installations globally, the Honeywell UOP Callidus MP4U multipoint flare burner is a proven design offering excellent flame stability and cross lighting capabilities. The proprietary single piece casting lengthens burner life for cost savings.

Features:

  • Burner center hub and burner castings may be a single piece casting or be a welded assembly
  • Various types of stainless steel available
  • Custom drilled for each application

Benefits:

  • A single piece casting increases the burner life
  • Excellent flame stability and cross-lighting characteristics

Applications:

  • Upstream, midstream and downstream processing
  • Petrochemical processing
  • Chemical/specialty processing

The Callidus Pipe Flare (CAL-PF), also called a utility flare system, is the most economical elevated flare solution. The long-life, simple-to-operate design is perfect for waste gasses that don’t smoke or where smokeless operation is not required. Pipe Flares come with a high stability flame retention system for stable burning during all types of weather conditions. This allows you to use smaller flares, increasing flare life while decreasing operating costs.

Features:

  • High stability flame retention system
  • Extremely stable pilots
  • Reliable pilot ignition systems
  • Plug welded brackets

Benefits:

  • Lowest initial capital cost and operating cost of any elevated flare system
  • Dependable, long service life
  • Simple to install and operate
  • Stable burning in all types of weather

Applications:

  • Upstream and midstream processing
  • Excellent choice for low BTU waste gas that does not smoke, such as ammonia
  • Applications where smokeless operation is not required

Callidus® pit flares offer a safe and easy way to dispose of liquid wastes. Pit flares are designed to lengthen flare tip life to reduce costs and include proven Callidus ignition systems for operation. Pits can be designed using state-of-the-art Computational Fluid Dynamic (CFD) modeling to ensure complete destruction of the waste liquid and proven operation under all wind conditions.

Features:

  • Proven Callidus ignition systems
  • CFD modeling ensures complete destruction of the waste liquid and operation under all wind conditions

Benefits:

  • Efficient liquid waste disposal
  • Longer flare tip life
  • Proven operation

Applications:

  • Upstream processing

Callidus Upper Steam Assist Flares  – With a high efficiency, low noise steam injection ring, the flare tip provides smokeless burning with quieter operation than traditional steam injection systems. Features:

  • Low noise steam ring
  • Plug welded brackets
  • Extremely stable pilots
  • Superior manifold connection
  • High stability flame retention ring
  • Mechanically superior design

Callidus Inner Steam Assist Flares – Proprietary advanced technology for optimal combustion and smokeless performance. The advanced design improves steam efficiency and smokeless performance. Features:

  • High steam efficiency
  • Plug welded brackets
  • Stainless steel injection nozzles
  • Energy efficient pilots
  • Extremely stable pilots
  • Venturi inlet at steam injectors
  • Computer-aided design

Callidus nViro-XSR™ – Safe, efficient combustion that complies with the latest EPA regulations, designed to provide:

  • Lowest operating cost compliance by using less steam and supplement gas.
  • Increased hydraulic capacity
  • Increased maximum smokeless rates
  • Low noise with operation proven by industrial-scale testing

Callidus® vertical stack structures help safely and efficiently dispose of waste gases. Elevating the flare tips reduces noise and safety hazards to protect your plant, personnel and the environment.

Features:

  • Multiple support options to meet budget and project requirements
  • Proven Callidus designs
  • High-quality parts

Benefits:

  • Reduced radiation at ground level
  • Minimal footprint requirements
  • Longer life
  • Smokeless operation with additional Callidus technologies

Elevated Demountable Flares – can easily support future expansion efforts by providing extra space for additional risers. Placing multiple risers on a single derrick structure maximizes land usage by greatly reducing the total amount of plot space needed for flaring.

Callidus Totally Enclosed Ground Flare (TEGF) systems eliminate light and noise from flaring waste gases. Totally Enclosed Ground Flare units can be designed for unlimited air control or for specific air and temperature control to combust very clean gases at minimum required temperatures.

Features:

  • Smokeless combustion
  • Turnkey systems including installation
  • Skids 100% pre-wired, pre-piped, assembled and tested
  • Flame finder technology

Benefits:

  • Easy, on-line maintenance
  • Very low noise levels
  • No radiation outside the combustor
  • Reduced emissions

Callidus Multipoint Ground Flares give you the benefit of unlimited smokeless capacity and reduced radiation. Reduction in thermal radiation levels of 60% or greater are often achieved.

Features:

  • High surface to area relationship
  • Cast stainless steel brackets
  • Infinite turndown staging system
  • Low radiation and no radiation designs available
  • Smokeless capacities up to 3,500,000 lbs/hr

Benefits:

  • Unlimited smokeless capacity
  • Reduced radiation
  • Extremely stable pilots
  • Easy maintenance – all equipment at grade
  • Extremely long life
  • Better waste gas flow patterns
  • Lower internal pressure drops