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Reliable sustainable management strategies for flare gas recovery: technical, environmental, modeling, and economic assessment: a comprehensive review

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Abstract

The gas flaring network is an inseparable constituent commonly present in most of the oil and gas refineries and petrochemical facilities conferring reliable operational parameters. The improper disposal of burn-off gases improperly results in environmental problems and loss of economic resources. In this regard, waste to energy transforming nexus, in accord with the “carbon neutrality” term, has potentially emerged as a reasonable pathway to preserve our planet. In a transdisciplinary manner, the present review article deeply outlines the different up-to-date strategies developed to recover the emitted gases (flaring minimization) into different value-added products. To analyze the recovery potential of flare gases, different technologies, and decision-making factors have been critically reviewed to find the best recovery methods. We recommend more straightforward recovery methods despite lower profits. In this regard, electricity generation seems to be an appropriate option for application in small amounts of flaring. However, several flare gas utilization processes such as syngas manufacturing, reinjection of gas into petroleum reservoirs, and production of natural gas liquid (NGL) are also recommended as options because of their economic significance, technological viability (both onshore and offshore), and environmental benefits. Moreover, the adopted computational multi-scale data assimilation for predictive modeling of flare gas recovery scenarios has been systematically reviewed, summarized, and inspected.

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Abbreviations

APG:

Associated petroleum gases

ATR:

Autothermal reforming

CCS:

Carbon capture and storage

CCPP:

Combined cycle power plant

CNG:

Compressed natural gas

CFER:

Cumulative fossil energy requirements

DME:

Dimethyl ether

DOC:

Direct oxy-combustion

EE:

Engineering Equation Solver

EOR:

Enhanced oil recovery

FJGRC:

Fajr-e-Jam gas refinery complex

FGR:

Flare gas recovery

FAWAG:

Foam-assisted water alternating gas

GAG:

Gas-alternating gas

GTL:

Gas to liquid

GTC:

Gas turbine cycle

GTPP:

Gas turbine power plant

GWP:

Global warming potential

GHG:

Greenhouse gas

HRSG:

Heat recovery steam generator

ICE:

Internal combustion engine

KCPF:

Kalabsha Central Processing Facility

LCA:

Life cycle assessment

LNG:

Liquefied natural gas

LPG:

Liquefied petroleum gas

LRC:

Liquid ring compressor

MUG:

Makeup gas

MDEA:

Methyl diethanolamine

MTBE:

Methyl tertiary butyl ether

MCM:

Million cubic meters

MCM:

Million cubic meters

MSCFD:

Million standard cubic feet per day

MGI:

Miscible gas injection

MED:

Multi-effect desalination

MARS:

Multivariate adaptive regression splines

NGH:

Natural gas hydrate

NGL:

Natural gas liquid

OCM:

Oxidative coupling of methane

PO:

Partial oxidation

POM:

partial oxidation of methane

PNG:

Piped natural gas

PRICO:

Poly Refrigerant integrated cycle operations

PID:

Proportional–integral–derivative controller

RICEC:

Reciprocating internal combustion engine cycle

SGAG:

Simultaneous gas alternating gas

SWAG:

Simultaneous water alternating gas

SOFC:

Solid oxide fuel cell

SOFC/GT:

Solid oxide fuel cell/gas turbine cycle

SCM:

Standard cubic meters

SMR:

Steam methane reforming

STC:

Steam power cycle

STPP:

Steam turbine power plant

TEA:

Techno-economic analysis

TVC:

Thermal vapor compression

WAG:

Water alternating gas

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Authors and Affiliations

  1. Environmental Chemistry Division, Environmental Science Department, Faculty of Science, Port Said University, Port Said, Egypt

    Ahmed M. Elgarahy & Khalid Z. Elwakeel

  2. Egyptian Propylene and Polypropylene Company (EPPC), Port Said, Egypt

    Ahmed M. Elgarahy

  3. Chemical Engineering Department, Faculty of Engineering, Port Said University, Port Said, Egypt

    Ahmed Hammad

  4. Mechanical Power Engineering Department, Faculty of Engineering, Port Said University, Port Said, Egypt

    Moustafa Shehata

  5. Egyptian Methanex Methanol Company (EMethanex), Damietta, Egypt

    Amir Ayyad

  6. Chemical and Biochemical Engineering Department, University of Western Ontario, London, ON, N6A 5B9, Canada

    Mohamed El-Qelish

  7. Water Pollution Research Department, National Research Centre, El Buhouth St., Dokki, Cairo, 12622, Egypt

    Mohamed El-Qelish

  8. Department of Chemistry, College of Science, University of Jeddah, Jeddah, Saudi Arabia

    Khalid Z. Elwakeel

  9. Geology Department, Faculty of Science, Suez University, P.O. Box 43221, Suez, Egypt

    Ali Maged

  10. Institute of Process Engineering, Johannes Kepler University Linz, Altenberger Straße 69, 4040, Linz, Austria

    Ali Maged

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Contributions

Ahmed M. Elgarahy: Conceptualization, Visualization Investigation, Data curation, and Writing original draft.

Ahmed Hammad: Investigation, Visualization, Data curation, and Writing original draft.

Moustafa Shehata: Investigation, Data curation, and Writing original draft.

Amir Ayad: Investigation, Data curation, and Writing original draft.

Mohamed El-Qelish: Investigation, Visualization, Data curation, and Writing original draft.

Khalid Z. Elwakeel: Writing-review and editing.

Ali Maged: Data curation, Visualization Investigation, Writing original draft, and Writing-review & editing.

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Correspondence to Khalid Z. Elwakeel.

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Elgarahy, A.M., Hammad, A., Shehata, M. et al. Reliable sustainable management strategies for flare gas recovery: technical, environmental, modeling, and economic assessment: a comprehensive review. Environ Sci Pollut Res 31, 27566–27608 (2024). https://doi.org/10.1007/s11356-024-32864-3

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