Biogas Management Through Enclosed Ground Flare: A Sustainable Approach
CRA delivered a customized enclosed ground flare system for Ion Exchange India Ltd. to support safe and environmentally compliant biogas management at the SCG Dayasa project in Indonesia. The system was engineered to handle excess and off-spec biogas under low-pressure conditions, ensuring complete and smokeless combustion while minimizing visible flame, odour, noise, and thermal radiation. The solution emphasized operational safety, regulatory compliance, and stable performance across varying bio-gas compositions.
Safely Disposing Excess Biogas While Controlling Emissions and Site Impact
Ion Exchange required a biogas disposal system capable of safely oxidizing excess or off-spec biogas generated during plant operations. The key challenges included:
- Reliable combustion of low-pressure biogas with variable composition
- Requirement for smokeless operation to avoid visible flame and odor nuisance
- Containment of heat, noise, and radiation in proximity to plant infrastructure
- Stable ignition and flame monitoring under fluctuating flow conditions
- Safe operation in hazardous environments with minimal operator involvement
The system needed to deliver consistent combustion performance while meeting environmental and safety expectations.
Fully Enclosed Ground Flare with Automated Combustion Control
CRA engineered and supplied an enclosed ground flare system designed to ensure stable, complete oxidation of biogas within a sealed combustion chamber. The solution focused on combustion efficiency, automation, and environmental control.
Core Components Delivered
- Fully enclosed combustion chamber with optimized air injection
- Forced air supply system for controlled smokeless combustion
- Automated ignition and flame detection system
- Integrated piping, instrumentation, and safety interlock
- Skid-mounted structural configuration for controlled installation
Engineering and Design
- Combustion design optimized for 800 Nm³/hr biogas flow
- Low-pressure system design suited for 10–20 mbar inlet conditions
- Air injection and chamber geometry tailored for methane and H₂S oxidation
- Noise, heat, and emission containment through enclosed configuration
- Safety-focused interlock logic for hazardous area operation
Fabrication and Commissioning
- In-house fabrication and assembly of the enclosed flare system
- Factory checks of ignition, airflow, and control logic
- On-site installation and commissioning at the SCG Dayasa facility
- Performance validation across varying flow rates and gas compositions
Stable, Smokeless Biogas Disposal with Environmental Complianc
- Complete and smokeless oxidation of biogas within an enclosed chamber
- Effective control of odor, noise, and thermal radiation
- Stable combustion performance under variable operating conditions
- Automated operation with minimal operator intervention
- Reliable and safe performance in a hazardous operating environment
Deliver flaring systems that enable safe and sustainable biogas management
This project demonstrates CRA’s capability to deliver enclosed ground flaring systems that enable safe, sustainable biogas management. By combining advanced combustion engineering with automation and environmental control, CRA provided Ion Exchange India Ltd. with a robust solution for compliant biogas disposal. The installation reinforces CRA’s expertise in designing flaring systems that balance safety, performance, and sustainability across diverse biogas applications.
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