Skid-Mounted LNG & LPG Flare Systems for Terminals and Bunkering Facilities

Created on 06.25

Reliable BOG and Vapor Disposal Solutions for LNG/LPG Storage, Transfer and Bunkering Operations

LNG and LPG terminals, bunkering facilities, storage plants, and FSRUs continuously generate hydrocarbon vapors during loading, unloading, storage, maintenance, and emergency operations.
ZeXuan's Skid-Mounted LNG/LPG Flare System provides a safe, efficient, and rapidly deployable solution for the controlled combustion of boil-off gas (BOG) and hydrocarbon vapors while helping operators meet environmental and safety requirements.
ZeXuan Skid-Mounted LNG/LPG Flare System with integrated burner, piping, and control components at an industrial terminal

Why Effective BOG Management Matters

Operating Scenario
Typical Cause
Operational Challenge
LNG Loading & Unloading
Pipeline cooldown and cargo transfer
Short-term high BOG generation
Storage Operations
Ambient heat ingress into storage tanks
Continuous vapor accumulation
Emergency Venting
Equipment malfunction or overpressure conditions
Sudden large-volume gas release
Maintenance & Purging
Nitrogen purging and commissioning activities
Disposal of combustible gas mixtures
LNG/LPG Bunkering
Vessel fueling operations
Rapid fluctuations in vapor generation
Methane-rich LNG vapor can have a significantly higher environmental impact than CO₂ if released untreated. Safe combustion remains one of the most reliable methods for reducing emissions and maintaining facility safety.
LNG/LPG BOG management infographic showing vapor generation from storage tanks and controlled combustion via flare system

System Overview

The ZeXuan Skid-Mounted LNG/LPG Flare System integrates all major process and safety components into a compact modular skid for rapid deployment and simplified installation.

Integrated System Components

Module
Function
Flare Burner System
High-efficiency combustion of LNG/LPG vapors
Pilot Burner System
Continuous ignition source
Air Supply System
Natural draft and forced-air combustion support
Safety Protection System
Multi-layer safety barriers and interlocks
PLC Control System
Automated operation and monitoring
Ignition System
Reliable startup and flame stabilization
Instrumentation Package
Real-time process monitoring

Key Technical Features

Multi-Stage Combustion Control

Feature
Benefit
Automatic burner staging
Matches combustion capacity to gas flow
PLC-based control
Stable operation across varying conditions
Dynamic load adjustment
Prevents over- or under-firing
Wide turndown capability
Efficient operation from low to peak loads

Hybrid Air Supply Technology

Feature
Benefit
Natural draft combustion
Reduced energy consumption
Forced-air assistance
Stable flame under changing conditions
High-temperature combustion
Improved methane destruction efficiency
Wind-resistant design
Reliable outdoor operation
Combustion temperatures are maintained above 800°C, achieving methane destruction efficiencies exceeding 99%.

Continuous Pilot Burner System

Feature
Benefit
Dedicated pilot flame
Reliable ignition source
Continuous monitoring
Reduced flameout risk
Automatic re-ignition capability
Enhanced operational reliability
Suitable for variable gas compositions
Stable combustion performance

Cryogenic Service Design

LNG boil-off gas can reach temperatures as low as -160°C (-256°F), creating significant challenges for conventional flare systems.
Cryogenic-grade piping and components for LNG flare systems showing insulation layers, valves, and materials rated for -160°C operation

Low-Temperature Engineering Features

Component
Material / Design Solution
Process Piping
Cryogenic-grade materials
Valves
Low-temperature-rated assemblies
Flame Arrestors
Cryogenic-compatible construction
Sealing Elements
Specialized low-temperature elastomers
Structural Components
Austenitic stainless steel and alloy steel
Safety Systems
Verified for cryogenic operation

Multi-Layer Safety Protection

Safety Features

Safety Function
Purpose
Flame Arrestor
Prevent flashback
Flame Detection System
Continuous flame monitoring
Pilot Flame Verification
Ensure ignition readiness
High-Pressure Protection
Prevent overpressure conditions
Emergency Shutdown (ESD)
Rapid system isolation
Ignition Failure Protection
Safe startup sequence
Nitrogen Purging System
Minimize combustible mixtures
PLC Safety Interlocks
Automated protective actions

Risks Mitigated

Potential Hazard
Protection Strategy
Flashback Explosion
Flame arrestor system
Uncontrolled Methane Release
Continuous monitoring and shutdown logic
Burner Flameout
Pilot burner and flame detection
Pressure Surges
Pressure protection devices
Combustion Instability
Automated burner staging

Intelligent Automation & Monitoring

Function
Description
Automatic Operation
Fully automated unattended operation
Manual Control Mode
Operator-controlled operation during maintenance or testing
Burner Load Management
Real-time combustion adjustment
Remote Monitoring
SCADA/DCS integration available
Alarm Management
Automatic fault notification
Data Logging
Operational history recording

Skid-Mounted Design Advantages

Conventional Fixed Flare
ZeXuan Skid-Mounted Flare
Months of installation work
Deployment within hours
Requires civil construction
Minimal site preparation
Permanent installation
Relocatable solution
Extensive field commissioning
Factory-tested before shipment
High installation cost
Reduced project cost

Factory Acceptance Testing (FAT)

Every flare system undergoes comprehensive testing before shipment.
Test Item
Verification
Burner Ignition Test
Reliable startup
Flame Detection Test
Response verification
Safety Interlock Test
Protection system functionality
ESD Test
Emergency shutdown performance
PLC Logic Simulation
Control sequence validation
Leak Tightness Test
System integrity verification
Cryogenic Compatibility Check
Low-temperature suitability

Typical Applications

Industry Segment
Application
LNG Receiving Terminals
BOG disposal during unloading and storage
LNG Bunkering Facilities
Vapor management during vessel fueling
LPG Storage Terminals
Pressure relief and vapor disposal
Peak Shaving Plants
Tank pressure control
Satellite LNG Stations
Routine vapor management
FSRU Facilities
Offshore BOG handling
Maintenance Shutdowns
Temporary flare capacity
Terminal Expansions
Interim vapor disposal solution

Key Benefits

Benefit
Value
Skid-Mounted Design
Fast installation and relocation
LNG/LPG Compatible
Broad application flexibility
Cryogenic Ready
Reliable operation down to -160°C
High Destruction Efficiency
>99% methane reduction
Automated Operation
Reduced labor requirements
Multi-Layer Safety Protection
Enhanced operational safety
Remote Monitoring
Improved asset visibility
Factory-Tested System
Faster commissioning

Applications Served

  • LNG Import & Export Terminals
  • LNG Bunkering Stations
  • LPG Storage Facilities
  • Peak Shaving Plants
  • FSRU Projects
  • Satellite LNG Facilities
  • Temporary LNG/LPG Installations
  • Maintenance & Emergency Operations
Looking for a customized solution?
Learn more about our Skid-Mounted LNG/LPG Flare System.
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