Flare Gas Recovery (FGR): A Sustainable Solution by UnitBirwelco

Flare Gas Recovery (FGR) is one of UnitBirwelco’s most innovative and environmentally sustainable solutions. Delivered through our Birwelco division in Halesowen, which has over 50 years of expertise in flare system design, FGR provides a powerful combination of emissions reduction and cost savings for industrial operations.

Custom-Engineered FGR Systems for Maximum Efficiency

Each FGR system is custom-designed to match the flare gas composition, liquid content, flaring frequency, and flow rate of a client’s facility. To demonstrate the economic viability of our technology, we provide a detailed cost-benefit analysis, considering both equipment and engineering costs alongside the financial advantages of capturing and utilizing recovered gas.

A typical UnitBirwelco refinery installation includes:

• Skid-mounted liquid ring compressor for efficient gas compression

• Seal liquid cooler and separator to ensure optimal gas quality

• Instrumentation, piping, valves, and steelwork for seamless system integration

• Fully integrated control system with local and remote monitoring

Unlike many engineering firms that outsource fabrication, installation, and commissioning, UnitBirwelco manages the entire process in-house—ensuring cost transparency, streamlined execution, and superior quality.

Project Overview:

Offshore Flare Gas Recovery in the Mediterranean:

UnitBirwelco, through its Birwelco division, played a pivotal role in the recovery of associated gas from a crude production field located in the Mediterranean Sea. The project aimed to minimize gas flaring, enhance resource utilization, and ensure compliance with stringent environmental regulations. Birwelco’s scope included the design, engineering, and supply of a comprehensive Low-Pressure Gas Recovery (LPGR) package tailored to the unique challenges of offshore operations.

Project Objectives

• Capture and process associated gas that would otherwise be flared

• Reduce greenhouse gas emissions, improving environmental sustainability

• Deliver a cost-effective, energy-efficient gas recovery system

• Ensure seamless integration with existing offshore infrastructure

Scope of Work

• Liquid Ring Compressor – Handles fluctuating gas volumes and ensures reliable compression

• Separator Drum with Internals – Eliminates liquids and particulates for smooth downstream processing

• Seal Water Heat Exchanger – Regulates temperature for stable system performance

• Seal Water Pump – Ensures optimal circulation and operating conditions

• Instrumentation & Interconnecting Piping – Includes advanced process controls and seamless skid-edge termination

• Package Control System & Local Control Panel – Enables automation, monitoring, and efficiency optimization

Execution Strategy

1. Design & Engineering

UnitBirwelco utilized advanced process simulations and computational modeling to determine optimal system specifications. Material selection was carefully optimized for offshore durability and harsh environmental conditions.

2. Fabrication & Quality Assurance

All equipment was manufactured in-house at Birwelco’s state-of-the-art fabrication facility, ensuring compliance with offshore industry standards. Before deployment, the system underwent rigorous Factory Acceptance Testing (FAT) to verify performance and quality.

3. Installation & Commissioning

A modular skid-based design facilitated rapid, efficient installation. The commissioning process validated process efficiency, safety, and reliability, ensuring the system operated at peak performance.

Project Benefits

• Environmental Impact

• Reduced gas flaring, leading to a significant drop in greenhouse gas emissions

• Lower noise and visible pollution, enhancing environmental and operational conditions

• Regulatory compliance with stringent emissions laws

• Economic & Operational Advantages

• Transformed wasted gas into a valuable resource for power generation and reinjection

• Enhanced operational efficiency and energy utilization

• Increased economic viability of offshore assets through sustainable gas recovery

  
  

Conclusion

Birwelco’s Low-Pressure Gas Recovery package provided an innovative and sustainable solution for offshore associated gas recovery. The project underscored UnitBirwelco’s expertise in delivering tailored energy solutions that meet the evolving demands of the oil & gas industry. Through engineering excellence, high-quality manufacturing, and seamless integration, Birwelco successfully enabled the offshore operator to reduce emissions, enhance efficiency, and achieve long-term operational benefits.