Modular Flare Gas Recovery System: Integrated LNG Solutions for Distributed Gas
Why Recover Flare Gas?
Around the world, oil and gas fields burn off large volumes of scattered wellhead natural gas (flare gas) every day. This not only leads to severe energy waste but also releases a significant amount of greenhouse gases, causing negative environmental impacts. As global pressure to reduce carbon emissions increases, Flare Gas Recovery Systems (FGRS) convert this otherwise wasted gas into transportable, marketable, and usable energy products such as LNG, CNG, electricity, or NGLs, improving resource utilization efficiency and environmental performance.
With over 20 years of engineering experience in natural gas recovery and liquefaction, Kaitiangas has developed a complete modular flare gas recovery solution for distributed gas sources. This solution enables on-site gas liquefaction, compression, or power generation—helping enterprises reduce costs, increase efficiency, cut emissions, and boost revenue.
Modular Flare Gas Recovery System
Our “Modular LNG Liquefaction Unit” is a highly integrated, skid-mounted natural gas processing system, specially designed for wellheads and remote oil and gas fields. This unit integrates processes such as flare gas purification, liquefaction, and storage into a single container-sized piece of equipment, eliminating the need for the complex infrastructure typical of traditional plants.
Key Advantages of the Flare Gas Recovery System
| Modular Unit Features | Advantages |
| Compact footprint | Standard container structure; easily transportable and adaptable to various terrains |
| Easy installation | Quick flange connections, minimal on-site work, rapid commissioning |
| Energy-efficient | Mixed refrigerant technology; lower energy consumption, stable operation |
| High automation | PLC intelligent control, remote monitoring, reduced labor and O&M costs |
Process Flow: From Flare Gas to LNG
The unit integrates three core processing stages:
- Gas Purification – Using Kaitian’s proprietary TCI technology, acid gases (H₂O, H₂S, CO₂) and heavy hydrocarbons are efficiently removed in a single step. The absorbent liquid is regenerated and recycled via a regeneration column, ensuring efficient and eco-friendly operation.
- Gas Liquefaction – The purified gas enters a cold box, where it is condensed into LNG via heat exchange with a mixed refrigerant. After expansion and pressure reduction, the LNG is stored in cryogenic tanks at temperatures as low as -155°C.
- Mixed Refrigerant Cooling Cycle – The refrigerant is pressurized by a compressor and enters the cold box. It undergoes internal heat exchange and throttling to generate the required cooling, forming a closed-loop system that is stable, reliable, and energy-efficient.
Technical Specifications
| Parameter | Specification |
| Natural Gas Processing Capacity | 20,000 Nm³/day |
| Installed Power | 500 kW (380V) |
| Instrument Air Consumption | 100 Nmi/h |
| Unit Energy Consumption | ≤ 0.6 kWh/Nm³ |
| LNG Storage Temperature | ≤ -155°C |
Application Scenarios
This system is highly adaptable and commercially valuable across a wide range of unconventional and remote gas sources:
| Application Scenario | Use Case |
| Shale Gas / Coalbed Methane | Pilot production and early-stage development |
| Associated Gas from Oilfields | Flare gas zero emissions and carbon credit monetization |
| Biogas / Landfill Gas | Urban organic gas to LNG conversion and reuse |
| Coke Oven Gas / Syngas | Industrial tail gas to clean energy |
| Isolated / Test Wells | Rapid deployment and fast ROI |
KAITIANGAS
KAITIANGAS founded in 2002, specializes in the recovery and treatment of scattered gas resources. The company focuses on the development, engineering, and global promotion of technologies and equipment for natural gas recovery and liquefaction. With proprietary intellectual property, mature system solutions, and a professional team, Kaitian Gas has successfully built and operated flare gas recovery projects at wellheads across China, the Middle East, and Southeast Asia—accumulating extensive field experience and technical advantages.
Our Service System
- Feasibility consulting and on-site survey
- Process package and FEED design
- EPC project execution and system integration
- Commissioning, trial operation, and performance optimization
- Ongoing O&M and upgrade support
We adhere to the philosophy of “Safety, Efficiency, and Sustainability”, providing reliable, full lifecycle support to help clients build a zero-emission, low-carbon energy future.
