Ultra-Low Emission Flare Maintenance: Best Practices for Reliable Performance

Why Ultra-Low Emission Flare Maintenance Matters

Landfill flare systems play an important role in landfill gas (LFG) management by controlling gas migration, reducing greenhouse gas emissions, and supporting compliance with air quality regulations. As air emission requirements become more stringent, many landfill operators are transitioning from traditional enclosed flares to ultra-low emission flares designed to reduce carbon monoxide (CO), nitrogen oxides (NOx) and volatile organic compounds (VOCs).

While these newer flare systems provide important environmental benefits, they also introduce operational considerations. Unlike traditional enclosed flares that utilize natural draft for combustion air, ultra-low emission flares use a premix burner that combines landfill gas with combustion air before ignition. The burner assembly typically incorporates a fine mesh that improves air and fuel mixing, flame stability, and combustion efficiency.

These design improvements also introduce additional equipment, instrumentation, and maintenance requirements. Without a proactive maintenance program, system performance can decline over time, increasing the likelihood of unplanned outages, operational inefficiencies, and compliance concerns.

Preventive Maintenance Priorities for Ultra-Low Emission Flares

A structured preventive maintenance program identifies potential issues before they affect system performance. The following components require regular inspection and maintenance.

Burner Inspection

The burner assembly is often the most maintenance-intensive component for an ultra-low emission flare. Operators should routinely inspect the burner for:

Landfills are dusty operating environments, and burner mesh assemblies can become clogged with particulate matter. Burner backpressure is a useful indicator of when cleaning or maintenance is required.

Proper burner airflow is critical to stable combustion and ultra-low emissions performance.

Ignition & Pilot Systems

Ignition and pilot systems must perform consistently to maintain flare operation.

Routine inspection should confirm:

Unaddressed igniter, thermocouple, or fuel-supply issues can interrupt flare operation.

Instrumentation & Control Systems

Ultra-low emission flares depend on accurate instrumentation to maintain safe and efficient operations.

Preventive maintenance should include inspection and testing of:

Routine calibration and functional testing confirm that operators receive accurate performance data and that alarms and shutdown systems function as intended.

Gas & Air Flow Components

Inspect both landfill gas and combustion air systems routinely.

Gas-side inspections should include:

Air-side inspections should evaluate:

Restricted airflow or gas flow can affect combustion performance and emissions.

Structural Components

Routine inspections should include structural elements supporting safe operation and maintenance access.

Operators should evaluate:

Maintaining safe access supports both equipment reliability and worker safety.

Common Maintenance Challenges

Technicians familiar with traditional flare systems will recognize much of the instrumentation used in ultra-low emission flares. Sensors, controls, valves, and related equipment generally follow established maintenance practices.

The burner assembly often represents the most significant operational difference. Because burner maintenance may require removal, cleaning, inspection, or replacement, maintainability should be considered long before equipment arrives on-site.

Preventive maintenance begins during equipment selection and system design. When evaluating flare equipment, operators should understand how maintenance activities will be performed throughout the equipment’s operating life.

Important questions include:

Systems designed with maintainability in mind often experience shorter outages, lower maintenance costs, and improved reliability.

Best Practices for Maintaining Ultra-Low Emission Flares

A proactive maintenance program should combine routine inspection, preventative maintenance, performance monitoring, and replacement-parts planning. Identifying deterioration early reduces the likelihood of unplanned downtime and reactive repairs.

The following practices improve flare performance and maintenance planning:

Maintenance records also support troubleshooting, planning, and documentation of compliance with operating and permitting requirements.

How APTIM Supports Landfill Gas & Flare System Operations

Through its solid waste services, APTIM provides new flare system installation and maintenance, leachate evaporators, flare system services, and technical support to landfill operators across the US. Our regionally based service technicians help clients evaluate flare performance, optimize landfill gas flare operations, improve system reliability, and address issues that could affect environmental compliance.

Our capabilities include:

By combining engineering, field services, and operational expertise, APTIM helps landfill operators improve system performance, reduce operational risk, and maintain environmental compliance.

Connect with APTIM’s solid waste team to evaluate ultra-low emission flare maintenance needs, plan inspections and repairs, and improve flare performance. APTIM’s engineering and field teams help landfill operators align maintenance activities with operating requirements and system reliability goals.

CONNECT WITH APTIM’S SOLID WASTE TEAM

Published August 2026