Epcon Industrial Systems engineered a centralized Direct-Fired Thermal Oxidizer (DFTO) system for a large-scale LNG terminal requiring safe, flexible treatment of vent gases from multiple process sources. Designed to replace conventional flaring, the system delivers high destruction efficiency, improved operational safety, and centralized emissions management across liquefaction, storage, loading, and relief systems. This project demonstrates Epcon’s ability to engineer DFTO solutions for complex, multi-source LNG terminal operations.
LNG Terminal Direct-Fired Thermal Oxidizer for Multi-Source Vent Gas Management
Executive Summary
Project Overview
A large-scale LNG terminal operator required a robust air pollution control solution to manage vented hydrocarbon gases from numerous operations, including liquefaction units, storage tanks, loading systems, and safety relief devices. The facility sought a centralized DFTO capable of handling widely varying flow rates and compositions as a high-efficiency alternative to conventional open flaring.
Epcon Industrial Systems was selected to design and deliver a DFTO system engineered for continuous operation, rapid response, and compliance with international LNG safety and emissions standards.
Epcon Industrial Systems was selected to design and deliver a DFTO system engineered for continuous operation, rapid response, and compliance with international LNG safety and emissions standards.
The Challenge
The LNG terminal faced critical challenges related to process variability, safety, and compliance:
- Managing widely varying flow rates and hydrocarbon compositions from multiple vent sources (liquefaction, storage, loading).
- Rapidly responding to sudden gas surges and high load swings (up to 10:1 turndown ratio) during startup, shutdown, and upset conditions.
- Traditional flaring solutions lacked the efficiency, control, and performance required to meet modern regulatory and sustainability goals.
- Ensuring continuous, safety-critical operation with integration to existing terminal DCS and emergency shutdown systems.
The Solution
Epcon engineered a custom Direct-Fired Thermal Oxidizer specifically for centralized LNG vent gas management. The system is designed for high-capacity, high-turndown operation with robust safety interlocks.
High-Capacity, Wide-Turndown Combustion Chamber
High-Capacity, Wide-Turndown Combustion Chamber
- Features a high-capacity refractory-lined combustion chamber built for durability.
- Advanced burner technology is capable of extreme turndown ratios (up to 10:1), enabling stable operation from low idle to maximum surge capacity.
- Automated fuel and air control maintains optimal destruction efficiency and stable combustion temperature (~1,400°F – 1,600°F) under all load conditions.
- Engineered for rapid response to sudden gas surges without compromising the required residence time (≥0.75 seconds).
- Includes integrated safety instrumentation such as flame monitoring, gas detection, and pressure relief.
- Control system is fully integrated with the terminal’s DCS and Emergency Shutdown (ESD) systems for safety-critical operations.
- Consolidates multiple vent sources into a single, controlled oxidation point, enhancing safety.
Technical Specifications
| Feature / Component | Specification / Benefit |
| Oxidizer Type | Direct-Fired Thermal Oxidizer (DFTO) |
| Maximum Flow Capacity | 20,000 – 40,000 SCFM (Site-specific high-volume capacity) |
| Operating Temperature | 1,400°F – 1,600°F |
| Turndown Ratio | Up to 10:1 (Handles rapid load swings) |
| Destruction Efficiency | 99.9% Methane and VOC Removal (Exceeds regulatory requirement) |
| Residence Time | ≥0.75 Seconds |
| Construction | Refractory-Lined Carbon Steel with Alloy Components |
| Compliance | International LNG, EPA, and Local Environmental Standards |
The Results
“The DFTO provided the safe, compliant solution we needed. We eliminated the liability of open flaring while securing 99% destruction across all our production variability.”
Since commissioning, the DFTO system has delivered measurable safety and environmental benefits:
Since commissioning, the DFTO system has delivered measurable safety and environmental benefits:
- Reliable 99% destruction of methane and VOC emissions under all operating conditions.
- Improved terminal safety by replacing open flaring with controlled thermal oxidation.
- Reduced the overall emissions footprint and enhanced environmental performance.
- Simplified vent gas handling through centralized treatment.
- High availability and positive operator feedback confirmed Epcon as a preferred partner.
Industry
Applications
This robust DFTO system is ideal for high-risk, multi-source infrastructure where safety, compliance, and high availability are critical, including:
- LNG Export and Import Terminals
- Natural Gas Processing and Petrochemical Facilities
- High-Risk Energy Infrastructure
- Any Operation Requiring Replacement of Flaring with Controlled Oxidation
Next Steps
Eliminate Flaring Risk and Guarantee 99% Compliance
Open flaring is a liability that risks both safety and regulatory approval. Epcon’s centralized DFTO is the high-availability, controlled solution engineered to manage your most complex, variable vent streams while guaranteeing international compliance.
If your facility is seeking to eliminate flaring or requires a reliable emissions system for highly variable gas streams, your next step is simple. Contact our LNG engineering team directly for a process safety review, or initiate a chat now to discuss your specific vent stream composition and required turndown ratio.
Open flaring is a liability that risks both safety and regulatory approval. Epcon’s centralized DFTO is the high-availability, controlled solution engineered to manage your most complex, variable vent streams while guaranteeing international compliance.
If your facility is seeking to eliminate flaring or requires a reliable emissions system for highly variable gas streams, your next step is simple. Contact our LNG engineering team directly for a process safety review, or initiate a chat now to discuss your specific vent stream composition and required turndown ratio.
Contact Epcon for Custom Solutions
Epcon offers full engineering, fabrication, and installation of afterburner-based thermal oxidizers, quench systems, wet scrubbers, and full emissions-control lines — customized for chemical, petrochemical, and industrial gas-stream applications.If your facility handles acid gases, H₂S, solvent exhaust, or other challenging emissions, contact our engineering team to discuss a tailored solution.
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