Flare Systems

Flame Front Generator (FFG) Pilot Ignition System

The John Zink Flame Front Generator (FFG) Pilot Ignition System provides reliable, robust ignition of flare pilots with more than 40 years of proven performance. Using an electric spark to ignite a controlled air-fuel mixture, the FFG system ensures safe and efficient pilot ignition, even at distances exceeding 1,000 feet. 

Overview

Reliable Ignition. Anytime. Anywhere.

Ensuring safe and efficient pilot ignition in flare systems is critical for both operational reliability and environmental compliance. The John Zink Flame Front Generator (FFG) Pilot Ignition System delivers a proven, remote ignition solution that has been trusted for decades. 

By combining ignition fuel and compressed air at a mixing tee, the FFG system generates a controlled flame front that travels through an ignition line to the pilot tip, ensuring consistent ignition without the need for direct access to the flare. 

Designed for flexibility and safety, the FFG system can be installed over 1,000 feet away from the pilot, providing remote operation and easy maintenance at grade. Available in both manual and automatic configurations, the FFG ignition process can be powered by either a line-powered transformer (standard) or a piezoelectric unit in rare, manual only applications. . 

With local indicator lights and remote alarm contacts, operators can monitor ignition status in real time, reducing unplanned downtime and maintenance risks. The FFG system can be serviced and maintained without shutting down the flare, making it an efficient, cost-effective solution for flare pilot ignition. 

Features

  • Remote Pilot Ignition – Ignites flare pilots from a safe distance, reducing exposure to high-heat environments. 
  • Reliable Flame Front Technology – Uses an electric spark to ignite a controlled air-fuel mixture, ensuring consistent ignition. 
  • Long-Distance Operation – Can be installed over 1,000 feet from the pilot, offering operational flexibility and safety. 
  • Manual or Automatic Operation – Supports both manual piezoelectric ignition and automatic line-powered ignition. 
  • Easy Maintenance at Grade – No need for flare shutdowns during maintenance. 
  • Real-Time Monitoring – Includes local indicator lights and remote alarm contacts for ignition status updates. 
  • Flexible Fuel Compatibility – Works with natural gas, propane, and hydrogen, offering fuel efficiency and adaptability. 
  • Durable Design – Constructed with schedule 80 carbon steel or stainless-steel piping for longevity and reliability. 
  • Supports Multiple Pilots – Can be configured to ignite multiple pilots sequentially, optimizing ignition efficiency.

Benefits

  • Enhanced Safety – Allows remote ignition of flare pilots, reducing personnel exposure to high-risk areas. 
  • Reliable Performance – Proven over 40 years, the FFG system ensures consistent, effective ignition. 
  • Lower Maintenance Costs – At-grade maintenance eliminates the need for costly flare shutdowns. 
  • Operational Flexibility – Can be installed at long distances from the pilot, offering greater site adaptability. 
  • Fuel Efficiency – Optimized air-fuel ratios for natural gas, propane, and hydrogen ensure effective combustion. 
  • Weather & Environment Resistant – Functions reliably in extreme temperatures and harsh conditions. 
  • Seamless Integration – Compatible with existing John Zink flare systems, making retrofitting simple and cost-effective. 
  • Immediate Ignition Feedback – Real-time monitoring and alarm notifications reduce the risk of flare outages.
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Operational Profitability

We help our customers boost their profitability and minimize downtime across their operations by identifying and removing bottlenecks in their processes, creating more efficient and reliable performance. 

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Energy Efficiency

John Zink offers advanced solutions, including cutting-edge burners and heat recovery systems, that help our customers optimize energy efficiency across many different industries while reducing emissions and operational costs.

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Operational Reliability

John Zink specializes in engineered-to-order solutions that significantly enhance operational reliability for industrial facilities worldwide. With decades of expertise in combustion and emission control, we ensure your operations are not just efficient, but consistently reliable. 

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Refining

John Zink is a global leader in combustion and emission control, with a strong presence in the refining market. Our extensive portfolio includes advanced process burners, flares, and vapor control systems designed to enhance operational efficiency, safety, and environmental compliance for refining operations.

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Liquefied Natural Gas (LNG)

John Zink has advanced solutions, including flares and vapor recovery systems, designed to optimize LNG operations and ensure compliance with stringent environmental regulations. John Zink's commitment to innovation and customer-centric approach has positioned the company as a trusted partner for LNG projects worldwide.

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Petrochemical & Chemical

John Zink serves the petrochemical and chemical industries with advanced combustion solutions and emission control systems. With a focus on reducing emissions, improving efficiency, and enhancing safety, our expertise is backed by a strong reputation and a history of innovation in this sector.

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3 Proven Ways to Optimize Your Flare Systems and Reduce Emissions: Advanced Insights for Refinery Operators

Refineries rely on flares to safely burn waste gases, but these systems can also be significant sources of greenhouse gas (GHG) emissions. With tighter regulations and increasing sustainability goals, optimizing flare systems is essential. This article outlines three proven methods to reduce emissions and enhance flare efficiency, sharing advanced insights from John Zink’s decades of experience.

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Techniques to Reduce Greenhouse Gas Emissions from Flares

Increased focus on greenhouse gas emissions is driving operators to explore ways to reduce those emissions. The flare is one area of interest for reduced emissions. This paper will explore various techniques that can be used to reduce greenhouse gas emissions from flares.

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Cold Weather Considerations for Flare Operations

Cold weather can create serious challenges for steam or water-assisted flares, leading to ice buildup that threatens both safety and performance. Ice blockages inside the flare can increase back pressure and risk overpressuring connected equipment, while external ice formations may compromise structural integrity and endanger personnel.

This guide outlines key equipment vulnerable to cold conditions and steps to mitigate risks. Cold weather, defined as any condition that causes water to freeze on or inside the flare system, becomes a concern when ice accumulates enough to impact operation or stability. For specific operational guidance, always refer to the manufacturer’s manual.

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Ensuring Flare Pilot Reliability: Preventing and Mitigating Fuel Supply Failures

Pilots are the heart of a flare. Without healthy pilots, a flare can easily become a vent. When a failure occurs in pilot fuel piping, it can significantly affect pilot performance and consequently flare performance. No one expects when installing a flare for the pilot fuel piping to fail, but it does happen. Insufficient tightening of threaded connections, flanges without double nuts or another mechanism to prevent loosening, flame impingement from adjacent flares, flame impingement from a damaged flare, improper piping support, and corrosion are all potential causes of pilot fuel piping failing. This paper will discuss steps that can be taken to mitigate the issue if it arises and preventative measures to lessen the probability of it occurring. The following assumptions are made:

  1. A flame front generator (FFG) is available and functional.
  2. The vent gas can’t be routed to another flare.
  3. The damaged flare will not be shut down for repair.


(Warning: Operation without pilots can result in the venting of waste gas and its consequences and may violate local regulations.)

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