Flare Gas Recovery
Turning an environmental liability into a $10M revenue line, with 95% of flare gas captured at the source.
Discuss a similar outcome- 95%
- Emissions captured
- $10M
- Clean-energy value generated
- 0
- Days of production downtime
Overview
An offshore flare gas recovery initiative captured 95% of emissions at the source, converting gas that would otherwise have been burned off into a usable power stream. The recovered energy generated $10M in value for the client, turning an environmental liability into a revenue line.
The challenge
What we were asked to solve
Routine flaring is one of the most visible sources of waste in offshore operations, a byproduct gas stream burned off because capturing it was never economical. For this operator, the flared gas represented both a compliance exposure and a stranded asset: energy that could be sold, used, or injected, but was being consumed on site with no return. The challenge was to engineer a capture and conversion pathway that paid for itself rather than adding operating cost.
The approach
How we delivered it
Masarion Energy worked with partner companies to design a flare-to-fuel conversion package sized to the asset's actual gas profile. The team mapped the flare stream, quantified recoverable volumes, and specified low-emission gas turbines capable of running on the captured fuel gas. Conversion infrastructure was engineered for minimal production disruption, with staged commissioning so the asset never lost uptime during the transition.
Results
Measured outcomes
Captured 95% of emissions at the source, virtually eliminating routine flaring on the asset.
Converted recovered gas into a usable power stream rather than burning it off.
Generated $10M in clean-energy value for the client.
Delivered the conversion with staged commissioning and no production downtime.
Impact
Beyond the direct financial return, the project removed a persistent environmental liability from the asset's ledger. The client now operates with a materially lower emissions profile, aligning with the industry's move toward the World Bank's Zero Routine Flaring by 2030 initiative, while monetising an energy stream that previously had no value.