China's First Coal Chemical VOC Flare Gas Recovery Unit Enters Stable Operation

The first volatile organic compounds (VOCs) flare gas recovery unit within China's coal chemical industry has commenced stable operation at Xinye Energy Chemical Co., Ltd. in Xinjiang. The facility is designed to resourcefully utilise combustible gases that were previously emitted through direct incineration.

This new installation is projected to reduce pollutant emissions by over 140 tonnes annually while simultaneously producing 120,000 tonnes of steam as a by-product.

In typical coal chemical production, unutilised recycled hydrogen and process-generated waste gases-containing components such as methane, hydrogen, and carbon monoxide-are routed to the flare system for combustion. These flare gases are characterised by significant compositional fluctuations and unstable flow rates, which have historically presented considerable challenges for recovery efforts. Their long-term direct combustion has represented both an energy waste and an environmental concern.

To tackle this industry-wide issue, Xinye Energy invested 40 million yuan in 2025 to initiate a flare gas recovery and treatment facility upgrade. The project employed innovative technology to construct a new 5,000-cubic-metre gas holder for collecting and storing the flare gas. This is integrated with a direct-fired furnace (TO furnace) possessing a processing capacity of 2,000 cubic metres per hour, along with associated flue gas treatment facilities.

The collected combustible gases are now incinerated, with their energy efficiently recovered for steam production, while ensuring the remaining gas emissions comply with environmental regulations.

Jia Guangsheng, Head of Production Operations at Xinye Energy Chemical, provided a timeline for the project, noting that design studies began in November 2024. The project subsequently moved through technical validation, process selection, and engineering construction phases before entering trial operation on 17 September this year.

Mr. Jia confirmed the facility is now operating stably, with monitoring data indicating that non-methane hydrocarbon emissions are consistently maintained below 20 milligrams per cubic metre-a level that exceeds national emission standards.

The project's benefits are reported to be threefold. According to Dang Yanqing, the company's Safety Director, it yields significant ecological advantages, including the annual reduction of pollutants by over 140 tonnes.

Economically, by using waste heat to produce steam, the facility generates approximately 6 million yuan in annual revenue. This is equivalent to saving 11,500 tonnes of standard coal and reducing carbon dioxide emissions by 30,000 tonnes each year.

Socially, the unit effectively reduces regional VOC emissions. It is seen as playing a positive role in improving air quality across the Urumqi-Changji-Shanshan area and provides a replicable model for volatile organic compound management within the broader coal chemical industry.