CalorieSense™ for Flare Stack Control

Real-time BTU analysis for safer, cleaner, and compliant combustion

Flare stacks are vital safety systems in industrial operations, used to combust excess hydrocarbons during both routine and emergency conditions. Yet maintaining stable, efficient combustion is a complex challenge. Flare gas composition can vary dramatically, especially in facilities handling hydrogen-rich or multi-stream waste gases. These fluctuations can lead to incomplete combustion, soot formation, invisible flames, and breaches of environmental regulations.

CalorieSense™ offers a robust solution. As a real-time gas BTU analyser, it continuously measures the calorific value of flare gas using a pressure-based sensing architecture. This approach eliminates the need for optical components, which are prone to fouling and frequent recalibration, making CalorieSense™ ideal for deployment in harsh industrial environments. The system integrates seamlessly with existing control infrastructure, including PLCs, DCS platforms, and edge AI modules, enabling operators to respond dynamically to changing flare conditions.

By delivering continuous BTU data, CalorieSense™ empowers operators to adjust assist gas injection, modulate steam flow, and maintain flame visibility and stability. In hydrogen-rich scenarios, where flames may be nearly invisible and highly diffusive, CalorieSense™ provides critical real-time feedback that allows for proactive control and enhanced safety. Whether installed upstream of the flare header or at individual knockout drums, the system supports smarter flare management across a range of operational contexts—from routine balancing and emergency flaring to predictive diagnostics and emissions reporting.

CalorieSense™ is also designed with compliance in mind. In the United Kingdom, it supports regulatory obligations under the Energy Act 1976 and the Petroleum Act 1998, which require consent for flaring and venting. It aligns with the UK Emissions Trading Scheme and the Industrial Emissions Directive, both of which mandate emissions monitoring and reporting. The system also meets expectations set by the Environment Agency and the North Sea Transition Authority, including the target of zero routine flaring by 2030.

In the United States, CalorieSense™ enables compliance with federal regulations such as 40 CFR Part 60 and Part 63, which govern combustion efficiency and flare gas monitoring. It supports EPA guidelines recommending a minimum of 98 percent combustion efficiency and integrates with state-level requirements from agencies like the Texas Commission on Environmental Quality and the California Air Resources Board.

Across the European Union, CalorieSense™ facilitates alignment with the Industrial Emissions Directive, the EU Emissions Trading System, and the Waste Framework Directive. It supports the implementation of Best Available Techniques as outlined in the BAT Reference Document for Waste Treatment, helping operators meet performance benchmarks and reporting standards.

Built for resilience, CalorieSense™ features industrial-grade enclosuresand compatibility with hazardous area certifications. It is more than a sensor—it is a strategic tool for modern flare control, enabling facilities to reduce fuel gas consumption, improve combustion efficiency, and meet global compliance targets with confidence.

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