John Zink Company, LLC

Flare Gas Recover y Systems

R e d u c e R e c o v e r R e u s e

W h y oF l n r Z i n k s o m c o v e r y ? J ha e Ga C Repany

John Zink Company, LLC

John Zink Company has long been recognized as the world leader in the design and manufacture of industrial flares and related equipment. John Zink also has been an industry leader in the design and supply of packaged vapor recovery systems. This experience led Zinks engineers to develop and offer systems to recover VALUABLE flare gases, compressing them back into the plant for use as feedstock, fuel or product. This technology also reduces plant emissions of combustion by-products such as NOx, CO, and CO2.

Why Flare Gas Recover y?

250

$4,380,000

150

$2,628,000

100

FL

AR

IP

IA

$1,752,000
IN

30

50

24

IN

CH

18

IN

CH

$867,000

NCH 14 I H 10 INC

10

15

20

25

30

35

40

FL AME LENGTH (FEET)

FLARE GAS RECOVERY ECONOMICS

* Based on $2/Million Btu

The chart above shows the estimated heat release associated with elevated flares based on the flame height. The heat release can then be correlated to a potential annual savings resulting from flare gas recovery by using the axis on the right.

A n n u a l Va l u e o f F u e l R e c o v e r e d *

H E AT R E L E A S E ( M I L L I O N B T U / H R )

200

$3,504,000

John Zink Flare Gas Recovery Units (FGRUs) provide many benefits to the end user including:
Getting Star ted

Reduction of plant fuel consumption

Reduction of plant steam consumption

Increase in flare tip life

Rapid return on investment

Reduction of plant emissions

Conservation of otherwise wasted hydrocarbons can dramatically reduce fuel gas costs. In one case a unit costing $1,300,000 paid for itself within the first year of operation. The end user credits the system with recovering over $30,000,000 in gas since installation. This same facility was also able to cut usage of supplemental fuels and smoke suppression steam at the flare for additional savings. In addition to the tremendous economic benefits, the system also significantly reduced plant emissions. Flaring of hydrocarbons produces combustion by-products such as CO2, CO and NOx that are emitted to the atmosphere. When utilizing flare gas recovery, no by-products are produced.

John Zink has been an equipment supplier to the hydrocarbon and chemical processing industries for over 70 years. As a result of this extensive experience the company has gained a thorough view of plant and refinery needs. Our unique knowledge of flare systems and packaged vapor recovery systems enables us to provide the most comprehensive product designs and services available.

Getting Star ted

Engineering Studies
John Zink has the engineering expertise and equipment necessary to help customers determine if Flare Gas Recovery is feasible for their application. Flow measuring equipment easily installed into existing flare lines is available for shipment to the job-site. This equipment automatically stores process information over time that is utilized by our engineering staff to tailor the design of a recovery system to the specific facility requirements. This information is compiled in a report to the client which also includes an economic analysis of the potential payback of an FGRU considering the capital, operating, and maintenance costs.

System Features

Flare Gas Recovery Lease Program

John Zink Company offers a lease program for flare gas recovery systems. We understand that even though Flare Gas Recovery is an excellent economic choice, at times yearly budgets or other financial constraints may mean that the money is simply not available for project approval. With our Flare Gas Recovery Lease Program, John Zink will design, fabricate, and install the equipment in return for a monthly payment after the equipment is installed and recovering valuable gas. The payment will continue until the end of the lease term with provisions for early buyout. The monthly payment made by the customer is less than the monthly value of the recovered gas therefore the customer can still realize a positive cash flow while paying toward the recovery system.

System Features

John Zink Company incorporates state of the art technology into the design of each Flare Gas Recovery System. These features insure that the customer receives the most effective system for the application. In addition, the systems are easy to install, require only minimal maintenance, and are designed with safety in mind.

Compressor Selection
The compressor is the "workhorse" of the FGRU. The compressor selection and design is crucial to the system capacity and turndown capability. During the design phase of the project, John Zink selects the most appropriate type and number of compressors for the application. Liquid Ring Compressor Technology is commonly used because of its rugged construction and resistance to liquid slugs and dirty gas fouling. However, the technical specifications of the application might dictate use of other types of compressors such as rotary screw, reciprocating, sliding vane, or rotary lobed.

Liquid Seal
During operation the FGRU removes gas from the main flare header. Uncontrolled, this could create an undesirable vacuum condition in the header, and allow air to be pulled in from the flare tip. Therefore, a positive pressure must be maintained in the flare header by use of a liquid seal. John Zink Company is the world leader in the design and supply of liquid seal drums. Our liquid seal drums have proprietary internals that insure a steady flow of gases to the flare tip thus increasing the maximum smokeless capacity of the flare with the minimum amount of supplemental energy. Other major advantages of our liquid seal internals include:

Proven performance in numerous flares

Surge resistant internals which minimize entrainment

Minimization of noise caused by uneven combustion

Positive flame arrestor in the event of a flashback

H o w D o e s I t Wo r k ?

Packaged Systems
John Zink FGRUs are skid packaged to the maximum extent possible for ease of installation. Unlike other vendors which supply only certain components, John Zink takes pride in providing a complete system. Our systems incorporate automated controls using a Programmable Logic Controller. An Operator Interface Panel (OIP) can also be provided to enhance the monitoring capability of key process parameters and alarms, and problem diagnosis. The OIP will allow the operator to make system operational adjustments when required. Desk top computer monitoring packages with graphic displays are also available. FGRU controls can also be integrated into an existing DCS.

FL ARE HEADER

Standard Flare Gas Recovery Diagram

PT

CONTROL LOGIC

DRIVER

LIQUID COMPRESSOR

H E AT E X C H A N G E R

How Does It Work?

The FGRU withdraws gas from the flare header upstream of the liquid seal drum and recovers gas that would normally be burned by the flare. The recovery system operates to maintain a slight positive pressure on the flare header upstream of the liquid seal drum. This ensures that air is not drawn into the flare system or the FGRU. If the volume of gas relieved into the flare system exceeds the capacity of the FGRU, pressure in the flare header will build until it exceeds the back-pressure created by the liquid level of the liquid seal drum. At that point, any excess gas volume will begin to flow to the flare. If the volume of gas relieved into the flare system is less than the full capacity of the FGRU, the system is automatically turned down by staging compressors and diverting discharge gas back to the suction header.

DEEP LIQUIDSEAL DRUM

FL ARE S TA C K

RECOVERED GAS

DISCHARGE S E PA R A T O R DRUM

RECOVERED LIQUID

The basic operation of the FGRU using liquid ring compressor technology is as follows: flare gas to be recovered flows directly to the FGRU skid and into the liquid ring compressor(s). The recovered gas and a portion of the sealing liquid combine inside the compressor and are jointly discharged into the separator vessel. Here liquids and gases are separated. Next, the compressor sealing liquid is cooled using a heat exchanger and returned to the compressor. Compressed gas from the separator flows from the system and is piped to a customer designated location. Volumetric control is accomplished by using a suction pressure sensor, which initiates a signal to the programmable logic controller (PLC). The PLC controls the equipment necessary to maintain proper flow to the FGRU. No after-cooling of the gas is required with a liquid ring compressor design because the heat of compression is absorbed by the seal fluid. This effectively allows the system to recover hydrocarbons without the problems associated with polymerization.
Project Execution

John Zink Company understands the importance of communication, cooperation, and the execution of projects in the most professional manner possible. A successful project consists of many steps and we strive to exceed our customers expectations in all of these steps. Much of our time and resources are directed toward optimizing our execution process.

Project Definition
Because of experience, John Zink is uniquely qualified to provide assistance in defining project requirements and evaluating alternatives. Through our engineering studies, we are often involved in projects from their conception.

System Design
We have the all encompassing expertise and resources to customize a system to meet customer specifications.

Project Execution and After market Ser vices

Drafting
Our drawings are computer generated to ensure high quality and flexibility. Both hard copies and electronic copies are provided to our customers.

Manufacturing and Quality Control

John Zink Company owns manufacturing facilities around the world. Utilization of these facilities for the manufacture of our products allows us ultimate control of all quality and scheduling related issues. Our work force is trained and experienced in the manufacture of our systems.

Testing
We test the operation of every FGRU to the maximum extent practical prior to shipment. Customer participation in all phases of inspection and testing is welcomed and encouraged.

Start-up and Training

We provide engineers and technicians to assist in FGRU start-ups and personnel training. This helps to ensure safe operation, prevent equipment damage and extend operating life.

Field Service
We have a comprehensive field service organization. Our technicians are available for both scheduled maintenance and emergency call-outs. They are well trained and are supported by our engineering staff.

Uniquely Qualified

John Zink Company has been providing packaged recovery systems for over 20 years and flare systems and services for over 70 years. In the primary markets served, our experience is unmatched with more installed equipment than any other manufacturer. We have an extensive research and development center dedicated to the industrial-scale testing of our prodJohn Zink International Headquarters

ucts. Our company holds over 270 U.S. patents plus hundreds of corresponding patents around the world. We recognize that the greatest value is achieved through the mutual benefits of long-term relationships between customers and suppliers. We are committed to establishing and cultivating these relationships and to finding better ways to satisfy our customers needs. As a result John Zink Company is a preferred supplier for most of our customers and the sole-source provider for many of them. As part of Koch Industries, the second largest

John Zink Research and Development Center

privately held company in the U.S., John Zink has access to vast technical knowledge and expertise in the products and industries we serve. We embrace a market-based philosophy and are committed to growing our business worldwide. John Zink Company truly represents global leadership with sales, engineering, manufacturing and service capabilities in every region of the world.

John Zink Luxembourg Manufacturing Facility

John Zink U.S. Manufacturing Facility

Uniquely Qualified

R e d u c e R e c o v e r R e u s e

International Headquarters

11920 E. Apache Tulsa, Oklahoma 74116-1300 U.S.A. P.O. Box 21220 Tulsa, Oklahoma 74121-1220 U.S.A. Telephone: 918-234-1800 Fax: 918-234-1968
www.johnzink.com

Other offices are located in major cities around the world.

2000 Koch Creative Services C000303 DL