A new 3D printed methane flare burner, developed through collaboration between Southwest Research Institute (SwRI) and the University of Michigan (U-M), has demonstrated 98% efficiency in eliminating methane emissions during oil production. The device addresses a significant challenge in conventional flaring systems, which can release up to 40% of methane into the atmosphere when affected by crosswinds.
The burner employs a specialized nozzle design that directs methane flow in three directions while incorporating an impeller to guide gas toward the flame. This configuration ensures proper oxygen-methane mixing and allows complete combustion before crosswinds can interfere with the process. The design was created using a combination of machine learning, computational fluid dynamics, and additive manufacturing techniques.
Testing conducted at SwRI’s indoor facility confirmed the burner’s effectiveness under controlled crosswind conditions. “Even the slightest amount of crosswind significantly reduced the effectiveness of most burners. We found that the structure and motions of the fins inside the burner were essential for maintaining efficiency,” said SwRI Principal Engineer Alex Schluneker.
The development comes at a crucial time, as methane poses a significant environmental challenge with 28 times greater global warming potential than carbon dioxide over a 100-year period. The project receives support from the U.S. Department of Energy’s ARPA-E REMEDY program, aligning with the U.S. Methane Emissions Reduction Action Plan announced at COP26.
SwRI and U-M researchers continue their collaboration, with plans to develop an enhanced prototype by 2025. The project aims to further improve efficiency while maintaining cost-effectiveness in real-world applications.
Source: sciencedaily.com