ZEECO® Contour™ System

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Deployed by 9 companies

Steam Assisted Flare Control System

Page last modified

April 2 2025

The ZEECO® Contour™ delivers automated, real-time, direct monitoring, and flare control at a fraction of the cost of indirect measurement systems. Unlike other systems that require direct contact with the flare header, ZEECO Contour uses infrared (IR) technology to assess the flare combustion zone and inject the optimal volume of assist media to ensure proper combustion with high destruction efficiency (DE) – independent of the waste gas composition and flow. Plants around the world operate this system at grade to optimize flare control, prevent non-compliance with environmental regulations, reduce utility consumption, prolong equipment life, and enhance destruction efficiency (DE)

ZEECO Contour System Advantages

- Direct, real-time assessment of the combustion zone and automatic smokeless medium injection

- Ability to differentiate between different waste gas streams

- External to flare header, maintainable without shutting down flare

- External to the heat affected zone, maintainable from grade

- New IR spectrum and methodology overcome shortcomings of previous opacity monitors and similar optical technologies

- Saves utilities, particularly at turn-down and minimum flows

- Affordable versus indirect measurement systems

- Assists with compliance to NHVcz regulations

- Field-proven technology

- Multiple monitors can be integrated for redundancy

Pros & Limitations

Reduces customers operational expenditure by optimizing the applied steam flowrate.

Reduces noise associated with steam injection by optimizing the applied steam flowrate. Less steam means less noise.

Provides a means to automate the smokeless performance of the flare tip.

Helps to ensures high destruction efficiency of the combusted gases, by providing a means to control the assist steam.

Prevents excess steam injection which can lead to decreased flare tip longevity.

Can be located at an accessible location at grade with line of site to subject (365m). There is no need to shut down the flare system to install the unit and maintenance can be performed at any time.

The system can account for flare gas composition swings.

The specific IR wavelength selected are unaffected by atmospheric moisture e.g. humidity, rain, fog.

The system provides real time data as it is measuring the IR radiation emitted from the flare flame.

The system is designed to operate within industrial environment's and complies with ATEX and IECEx requirements.

Care must be taken to position the system such that it is not adversely affected by other sources of IR radiation. For example directly pointed into the path of the sun or where more than one flare tip is within the field of view. Zeeco's engineers can provide assistance to appropriately locate the system.

Specification

Specification Title	Specification Description
Hazardous Area Specifications	ATEX - 95 (94/9/EC) IECEx - 60079-1 NEMA
CE Certification	EMI / RFI for heavy industry, LVD (Low Voltage Directive)
Connectivity	Analog Mode: 4-20mA Digital Mode: Bi - directional RS485