Flare Gas Recovery (FGR) isn’t a new idea. However, most solutions catch it after the flare system has already done its job, after pressure builds, valves open and hydrocarbons are released into the atmosphere.
We think there’s a better way.
At Apollo, we’ve been working on a new approach – one that intercepts the gas before it ever reaches the flare system. It’s simpler. Smarter. And in the right setting, far more effective.
What the regulations say
Not all flaring is treated equally. It’s typically categorised as:
- Routine – when everything’s running as it should
- Non-routine – from things like separator spill-off, temporary route closures, or off-spec product
- Emergency – safety-critical actions like blowdowns or H₂S disposal
Only the last one is exempt from intervention. That leaves a real opportunity, particularly around routine flaring.
Our proposal
We were asked to explore FGR options on a mature North Sea platform. Instead of starting downstream, we proposed capturing only the most material routine sources upstream of the flare system.
We identified three key contributors, accounting for nearly 400 kg/hr of flare gas. By focusing here, we avoid complex retrofits around the flare KO drum. We also steer clear of impacting critical systems, such as ignition or purging.
Our proposed system is conservatively sized at 650 kg/hr. That includes margin for production changes and future flexibility.
Why this matters
- Efficiency – Targeting only the worthwhile sources keeps the system lean and avoids overengineering
- Simplicity – Fewer valves, fewer pressure risks, fewer operational headaches
- Impact – Emissions reduction right at the source, before combustion even happens
This isn’t about catching everything. It’s about catching the right things, in the right place, at the right time.
What’s next
We recommend flow measurement as the next step to validate predictions and fine-tune the system design. However, the strategy is clear: use upstream intervention to render downstream emissions irrelevant.
If net zero is the destination, we’ll need more than ambition – we’ll need better engineering decisions. Ones that challenge convention, reduce complexity and unlock impact without compromise.
Want to know if this approach could work on your asset? Our emissions specialists can walk you through it oilandgas@apollo.engineer