Case Study · Hydrocarbon & Chemical
Flare Tip High Emissivity Coating: Flare Life Extended 4 to 10 Times with Saudi Aramco
| Industry | Hydrocarbon & Chemical |
|---|---|
| Asset | Oil-field flares (stainless tips and shells) |
| Customer or location | Saudi Aramco and Middle East operators |
| Products used | Emisshield FLM-2, FLM-6 (sintered) |
| Headline metric | Life 4 to 6× (FLM-2), 7 to 10× (FLM-6) |
| Secondary metric | 50+ flares coated |
| Also measured | Ongoing program |
In an ongoing program with Saudi Aramco and other Middle Eastern oil-field operators, Emisshield FLM-2 and FLM-6 coatings have been applied to more than 50 natural-gas flares to lower shell temperatures and extend flare life. Coated flares run cooler with more uniform combustion, lower visible emissions, and lifespans 4 to 6 times longer with FLM-2 and 7 to 10 times longer with the sintered FLM-6.
01
What was the challenge?
Flare tips and shells were being consumed by radiant heat and corrosive, sour-gas service with high H2S, with short life, visible emissions, and the risk of internal combustion in crosswinds.
02
What was applied?
Emisshield FLM-2 and FLM-6 coatings on stainless-steel flare tips and shells across flare types, applied to improve combustion efficiency and reduce surface temperatures.
03
What were the results?
| Metric | Uncoated | Coated |
|---|---|---|
| Flare lifespan | Baseline | 4 to 6× (FLM-2); 7 to 10+× (FLM-6) |
| Flare metal temperature | Baseline | Lowered |
| Combustion | Non-uniform | Uniform; improved VOC destruction and DRE |
| Air emissions | Baseline | Reduced |
| Service environment | High heat, corrosive, sour gas, high H2S | |
| Crosswind protection | Protects against internal combustion |
04
Why did it work?
A high emissivity surface sheds absorbed radiant energy instead of storing it as metal temperature, so the tip runs cooler and corrosion-erosion slows; uniform surface temperature stabilizes the flame. See Production Increase, component life.
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