Revolutionizing Oil Production: New Methane Flare Burner Cuts Emissions Dramatically
A groundbreaking study from the Southwest Research Institute (SwRI) and the University of Michigan (U-M) showcases an innovative methane flare burner capable of eliminating a staggering 98% of methane emissions produced during oil extraction processes. Developed utilizing state-of-the-art additive manufacturing techniques and machine learning algorithms, this advanced design marks a significant breakthrough in environmental technology.
The Study Behind the Innovation
The research paper, titled “An Experimental Investigation into Waste-Gas Composition Effects and Wind Influence on Non-assisted Flares Using a Unique Indoor Testing Method,” has been published in Industrial & Chemical Engineering Research.
In conventional oil extraction, methane is often flared off using open flame burners. However, crosswinds can substantially impair their performance, allowing more than 40% of emitted methane to escape into the atmosphere uncombusted. Given that over a century, methane possesses 28 times the global warming potential compared to carbon dioxide—and is even 84 times more potent over just two decades—ineffective flaring undermines climate change mitigation efforts.
Collaborative Efforts for Enhanced Efficiency
This project marries machine learning with computational fluid dynamics to create highly efficient flameless burners capable of functioning effectively under field conditions marked by varying wind patterns. SwRI worked closely with U-M engineers throughout this process to ensure optimal results.
“Inside our controlled facility at SwRI, we measured burner performance against different crosswind scenarios,” stated Alex Schluneker, Principal Engineer at SwRI and co-author of the study. “Even minimal gusts dramatically hindered most burners’ effectiveness.” He noted that optimizing internal fin structures was crucial for sustaining combustion efficiency within this novel design.
Design Innovations That Enable Efficiency
The burner’s sophisticated nozzle base strategically directs gas flow in three distinct pathways while its impeller design facilitates thorough mixing between oxygen and methane before combustion occurs—prolonging contact time before being impacted by external winds. This unique feature is fundamental for enhancing operational efficiency.
“Achieving an ideal oxygen-to-methane ratio is essential,” commented Justin Long, Senior Research Engineer at SwRI. “While incorporating surrounding air enhances combustion ignition quality, excessive dilution can be detrimental.” The U-M team’s extensive computational fluid dynamics analysis led them to devise a model that performs optimally even amid strong winds.
Future Goals: Striving for Greater Eco-Efficiency
Continuing their collaborative efforts into 2025 and beyond, both teams are focused on further refining burner designs aimed at achieving unparalleled efficiency while remaining cost-effective for producers across the industry.
Additional Information:
For further details refer to:
Jenna Stolzman et al., An Experimental Study of Waste-Gas Composition Effects on Non-assisted Flares Using an Innovative Testing Approach,
Industrial & Engineering Chemistry Research (2025). DOI: 10.1021/acs.iecr.4c04067
Citation:
Engineers develop groundbreaking burner technology targeted towards reducing harmful methane emissions (2025).