Scientists from Southwest Research Institute (SwRI) and the University of Michigan (U-M) have designed a new, highly efficient burner that reduces methane emissions during oil production.
This advanced burner, created using 3D printing and artificial intelligence, destroys 98% of methane released during flaring, making oil production cleaner and better for the environment.
Why methane matters
Methane is a powerful greenhouse gas. Over 100 years, it traps 28 times more heat than carbon dioxide, and over 20 years, it’s 84 times stronger.
Oil production often releases methane into the air, and companies try to burn it off using flare stacks.
However, wind can disrupt traditional burners, making them less effective and allowing large amounts of methane to escape.
Some conventional burners fail to destroy up to 40% of the methane, making the problem worse.
To tackle this issue, researchers from SwRI and U-M worked together to design and test a more efficient burner. Their study, published in Industrial & Chemical Engineering Research, shows how the new design can burn methane more effectively, even in windy conditions.
A smarter, more effective burner
The U-M team used machine learning, computational fluid dynamics, and 3D printing to create the new burner. They tested it at SwRI’s indoor facility, where they could control wind conditions and measure its performance.
“We found that even a small amount of wind could greatly reduce the effectiveness of most burners,” said Alex Schluneker, a principal engineer at SwRI. “The new design solves this problem by improving how the gas flows and burns.”
How the new burner works
The key to the burner’s success lies in its innovative design. It has a special nozzle that splits methane gas into three directions. Inside, an impeller (a type of rotating blade) helps mix the gas evenly with oxygen before it burns. This process ensures more complete combustion, reducing the amount of methane that escapes into the atmosphere.
“A good balance of oxygen and methane is crucial for burning efficiently,” said Justin Long, a senior research engineer at SwRI. “If there’s too little air, the methane won’t burn well. If there’s too much, it gets diluted and burns poorly. The U-M team carefully designed the burner to get this balance just right, even in strong winds.”
SwRI and U-M are continuing to work on even better burner designs. Their goal is to develop an even more efficient and cost-effective prototype by 2025.
This breakthrough could be a game-changer for the oil industry, reducing methane pollution and slowing global warming. With better flaring technology, oil production can become less harmful to the environment while keeping operations efficient.
