Routine flaring remains one of the offshore industry’s biggest hurdles on the path to Net Zero. Apollo carried out a feasibility study for a major North Sea operator, showing how flare gas could be recovered and repurposed.
The problem
Our client aimed to align its corporate carbon emissions strategy with the UK Government’s Net Zero commitment and Stewardship Expectation 11, which targets zero routine flaring by 2030. The challenge was to assess the feasibility of installing a flare gas recovery (FGR) system on the FPSO to meet this goal.
Although the FPSO was initially designed to handle high amounts of production gas during early field life, current rates were significantly lower. Excess production gas was continually routed to the flare system, with significant contributions from the separation train. This persistent flaring not only increased greenhouse gas emissions but also resulted in operational inefficiencies.
The background
The North Sea Transition Authority has made clear its expectations for the upstream oil and gas industry to reduce greenhouse gas emissions. For our client, this meant exploring options to retrofit the FPSO to enable zero routine flaring in line with Net Zero goals.
The existing flare system consisted of several main headers routed to a knock-out drum, which was purged using nitrogen, and equipped with high-integrity ignition systems and constantly lit pilots. While reliable, the system resulted in continuous flaring, and our client sought a study to identify potential solutions that could turn this liability into an opportunity.
The process
Apollo was commissioned to conduct a detailed study, evaluating various options for flare gas recovery. These included:
- Flare gas recompression, with recovery back into the process.
- Switching from a closed to an open flare system.
- Automatic ignition solutions.
- Recovery of gas specifically from the LP separator.
The study also quantified the greenhouse gas emissions reduction potential of each option and reviewed timelines for accelerated deployment. Service requirements, including power, cooling, hydraulics, and controls, were considered to ensure each solution was practical and could be implemented with minimal disruption.
The solution
Apollo proposed a Vapour Recovery Unit (VRU) to capture and recycle hydrocarbon gas from the flare system. Designed using updates to the Clients master process model, the VRU was engineered to integrate with existing oil, gas, and water processing trains.
The study also emphasised the importance of incorporating potential gas tie-in options, which would provide a steady supply of fuel gas for heat and power generation. At the same time, the recovered flare gas could act as a buffer during periods of low production, smoothing out supply and further minimising continuous flaring.
The outcome
Apollo’s feasibility study gave the Client a clear, practical pathway towards zero routine flaring. The combination of a VRU, LP separator recovery, and the gas tie-in offered significant reductions in greenhouse gas emissions and operational costs.
By identifying viable retrofit solutions and mapping out their implementation, Apollo helped the Client align with Net Zero commitments and strengthen the FPSO’s performance for the remainder of its field life.
This case study showcases Apollo’s expertise in FGR and emissions reduction – delivering innovative, practical solutions that meet both industry standards and environmental goals.
Following this feasibility study, the project has now progressed to the concept select phase.
Talk to our Oil & Gas team about reducing emissions and improving performance – oilandgas@apollo.engineer
