Flaring is a common industrial practice that leads to substantial greenhouse gas (GHG) emissions, health problems, and economic losses. When the causes, magnitudes, and frequency of flaring are properly understood and incorporated into the design and operation of the industrial plants, significant reduction in flaring can be achieved. In this paper, a process integration approach is presented to retrofit the process design to account for flaring and to consider the use of process cogeneration to mitigate flaring while gaining economic and environmental benefits. It is based on simultaneous design and operational optimization where key flaring sources, causes and consequences of process upsets are identified then included in the energy profile of the process to design a combined heat and power system with special emphasis on discontinuous sources due to process upset. Environmental and economic benefits are weighed against the cost of process retrofitting. A base case study for an ethylene process is used to illustrate the applicability of the proposed approach and to evaluate the process performance under varying abnormal situation scenarios. Finally some safety parameters for part of the process are reviewed.
