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CLEAN COMBUSTION. CLEAR SOLUTIONS.

John Zink Carbon Adsorption Vapor Recovery System

John Zink Company

A Global Leader in Environmental systems


John Zink Company, LLC is a global leader in developing next-generation products, technologies and solutions that preserve and improve air and water quality. With our worldwide manufacturing and service capabilities, John Zink provides petroleum and chemical terminals around the globe with a safe, effective method to reduce emissions. From state-of-the-art research and development through manufacturing and commissioning services, John Zinks engineers develop customized solutions to help optimize your entire system to meet even the toughest environmental regulations.

Quality Management
 John Zink operations meet the requirements of the internationally recognized ISO 9001:2000 Quality Management System.

Safety and Health Management


 The companys OHSAS 18001 certification underscores our commitment to providing a culture of safety that focuses on identifying and eliminating workplace hazards while maintaining health and safety compliance.  John Zink is a recipient of the Voluntary Protection Program (VPP) Star Certification, OSHAs most prestigious designation, for outstanding safety and health performance.

Environmental Management
 John Zink and its operations meet the requirements of the internationally recognized ISO 14001 Environmental Management System.

Pictured above, a John Zink marine vapor recovery unit located in Europe. John Zinks VRUs are designed to meet worldwide standards such as ASME, ANSI, DIN, ATEX, EN, NEC, IEC, and CENELEC.

The Worlds Most Advanced Vapor Recovery Technology From John Zink Company

John Zinks Carbon Adsorption Vapor Recovery Units (VRUs) safely prevent harmful volatile organic compounds (VOCs) from being released into the atmosphere during operations that involve the transfer of evaporative hydrocarbons. Because John Zinks VRUs are highly adaptable for a variety of applications, our engineers can customize an emission control solution that optimizes your specific system. Our VRU systems are available with Adsorption-Absorption (ADAB) and Adsorption-Condensation (ADCON) configurations, as well as varying vacuum technologies to best suit specific facility needs.

Chemicals Suitable for Vapor Recovery Applications (Partial List):


Benzene Carbon Tetrachloride Chloroethane Crude Oil Dichloroethane Distillate Fuels Ethylbenzene Gasoline Hexene Jet Fuels Methylene Chloride Naphtha Pentene Propane Trichloroethane Xylene Butane Chlorobenzene Chloroform Cyclohexane Diesel Fuels Ethanol Ethyl Tert-Butyl Ether Hexane Isobutane Methanol Methyl Tert-Butyl Ether Pentane Perchloroethylene Toluene Trichloroethylene

Potential applications for use of this system are as follows:


Storage tank vents Railcar loading facilities Process vents Truck loading racks Marine terminals

The U.S. Environmental Protection Agency has recognized John Zinks


VRU technology as being both the Best Demonstrated Technology (BDT) and Maximum Achievable Control Technology (MACT).

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Superior Performance

John Zinks VRUs are designed to meet the most stringent emissions requirements worldwide. In typical installations such as truck, rail, tank and marine loading, our VRUs achieve emission control efficiencies of 99% or better. Most systems are designed to meet 1 10 milligrams of VOC

released per liter of product loaded, or 1 10 grams per cubic meter of vapor vented. John Zink has designed VRUs that meet stricter emissions standards including the TA Luft standard of 150 milligrams of VOC released per normal cubic meter of vapor vented (approximately equal to 0.15 mg/l).

Recovered Product (in liters per 1000 liters loaded)

Recovered Product for Various Loading Operations*


2.5 2 1.5 1 0.5 0

Truck/Rail Vapor Balanced Loading

Truck/Rail Non-Vapor Balanced Loading

Barge Loading

Ship Loading

Loading Operation Type


Gasoline Ethanol Benzene Stabilized Light North Sea Crude

* Typical power consumption for Truck/Rail Vapor Balanced Loading may be found in the plot below.
Power Consumption vs. Daily Loading for a Typical Gasoline Truck Loading Application*
Estimated Power Consumption (kW)
160 140 120 100 80 60 40 20 0 0 4,000,000 8,000,000 12,000,000 16,000,000

Daily Product Loaded (Liters)


for systems designed for 10 g/Nm (10 mg/l). John Zink will optimize each system * Values are typical based on the individual application. Power consumption may vary.
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Liquid Ring Vacuum Pump - ADAB

Dry Vacuum Pump - ADAB

John Zinks Vapor Recovery Difference

John Zink has a proven track record of success with vapor recovery technology; there are more than 2,000 John Zink brand vapor control systems in service in more than 40 countries. Our Research, Development and Test Center, located in Tulsa, Okla., is the launch pad for low-emission systems that address our customers needs while preserving and protecting the environment. Our service organization is the largest in the industry. With our 24-hour service hotline, you can depend on the kind of service that keeps your operations running strong around the clock, around the world. Put our expertise to work on your vapor recovery systems and get to know John Zinks vapor recovery difference.

As Compared to Vapor Combustion Technologies:


Can be installed in a hazardous area No flame to serve as an ignition source  Positive rate of return on investment due to value of recovered product Marine loading requires no vapor conditioning No trade-off pollutants No supplemental fuel requirements

As Compared to Other Vapor Recovery Technologies:


 Worldwide acceptance as standard for evaporative hydrocarbon vapor control Near ambient pressure and temperature operation, no vapor holder, no refrigeration Proven reliability Easy to operate and maintain Highest emission control efficiency Low capital and operating costs Electricity is only required utility

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Carbon Adsorption-Absorption Process with Dry Vacuum Pump

John Zinks ADAB vapor recovery design is suitable for a wide variety of applications. It is most commonly used to control hydrocarbon vapor emissions at terminals handling petroleum fuel products. John Zinks VRUs combine physical adsorption with absorption to recover hydrocarbon vapors and return the recovered product to storage.

The use of dry vacuum pump (DVP) technology


offers significant advantages over other vacuum technologies:
Reduced power consumption  Ethylene glycol and associated equipment are eliminated from system Decreased maintenance costs No product contamination  Greater flexibility with products that can be loaded into the VRU

The VRU is equipped with two identical adsorber vessels filled with activated carbon. One adsorber is on stream receiving vapors in the adsorption mode while the other adsorber is off stream in the regeneration mode. Switching valves are provided to automatically alternate the adsorbers between adsorption and regeneration, which assures uninterrupted vapor processing capability. The VRU will automatically start when a loading operation is ongoing and shutdown in a standby mode when the operation is complete.

PRODUCT LOADING RACK

CONDENSATE COLLECTION

During adsorption, the inlet hydrocarbon vapor-air mixture to be processed flows up through the on stream adsorber vessel. In the adsorber, the activated carbon adsorbs the hydrocarbon vapor and allows clean air to vent from the bed with only minimal hydrocarbon content.

PRODUCT LOADING PUMP

STORAGE TANK

LEAN ABSORB

(REGENERATION MODE)

ADSORBER

AIR VENT TO ATMOSPHERE

(ADSORPTION MODE)

ADSORBER

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3
PURGE AIR

During regeneration, previously adsorbed hydrocarbon vapor is removed from the carbon and the carbons ability to adsorb vapor is restored. Carbon bed regeneration is accomplished with a combination of high levels of vacuum and purge air stripping. At the end of the regeneration cycle, the adsorber vessel is re-pressurized and then is placed back on stream.

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A dry vacuum pump (DVP) is the source of vacuum for carbon regeneration. The DVP extracts concentrated hydrocarbon vapor from the carbon bed, and discharges directly into the recovery device, a vertically packed absorption column. To limit the vapor temperature inside the DVP, absorbent is circulated through the outside jacket and is injected directly into the vacuum pump.

4
ABSORBER VACUUM BOOSTER BLOWER AS REQUIRED

5 4
DRY VACUUM PUMP

In the absorber vessel, the hydrocarbon vapor from the DVP flows up through packing, while a hydrocarbon liquid flows down through packing. Inside the absorber, the vapor is liquefied, and the recovered hydrocarbon is returned back to the absorbent storage tank. A small stream of air and residual vapor exits the top of the absorber and is recycled to the on stream carbon bed for re-adsorption.

ABSORBENT & RECOVERED PRODUCT HYDROCARBON VAPOR AIR

A lean absorbent supply pump and a rich absorbent return pump are provided to circulate the required absorbent.

6 6
RICH ABSORBENT RETURN PUMP

VALVE OPEN VALVE CLOSED

BENT SUPPLY PUMP

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Carbon Adsorption Absorption Process with Liquid Ring Vacuum Pump

Liquid ring VRU systems operate along the same principles as the dry system previously described. However, this system includes a liquid ring vacuum pump (LRVP) to regenerate the carbon beds. LRVPs are robust and relatively inexpensive, with a proven history of successful operation.

They are available in a variety of configurations so the system can be tailored to fit your specific needs. John Zink has made available its own specially formulated vacuum pump seal fluid Z-SEAL for use in this serivce.

The LRVP strips the rich hydrocarbon vapor stream from the adsorber and discharges it into a three-phase separator. Each LRVP requires a specially blended ethylene glycol-based sealing fluid to operate.

ABSORBENT & RECOVERED PRODUCT HYDROCARBON VAPOR AIR SEAL FLUID VALVE OPEN VALVE CLOSED

The seal fluid is pumped from the separator through a seal fluid cooler to remove the heat of compression.

(REGENERATION MODE)

ADSORBER

AIR VENT TO ATMOSPHERE

(ADSORPTION MODE)

ADSORBER

The separator is provided to allow efficient separation between the vacuum pumps seal fluid, hydrocarbon condensate, and the non-condensed hydrocarbon vapor. The non-condensed hydrocarbon vapor is discharged from the separator vessel and recovered by means of a packed-bed absorber column in the same manner as previously described.

PRODUCT LOADING RACK

PURGE AIR

ABSORBER CONDENSATE COLLECTION

VACUUM BOOSTER BLOWER

AS REQUIRED

SEPARATOR LIQUID RING VACUUM PUMP

2
SEAL FLUID PUMP

3
SEAL FLUID COOLER PRODUCT LOADING PUMP STORAGE TANK

LEAN ABSORBENT SUPPLY PUMP RICH ABSORBENT RETURN PUMP

The ADAB VRU based upon either dry vacuum pump or liquid ring vacuum pump technology may be provided with a high efficiency (HE-ADAB) vacuum system. The enhanced vacuum system consists of a rotary-lobed vacuum booster blower operating in series with the vacuum pump. The addition of the booster blower allows the carbon beds to be regenerated under a higher vacuum (lower absolute pressure) and provides significantly higher pumping capacity at high vacuums than is possible through the use of only the vacuum pump. An enhanced vacuum system more thoroughly regenerates the activated carbon and can, as a result, provide several potential benefits including use of less carbon, the achievement of lower emission levels, reduced system power requirement, and less overall capital cost.

Modular System

John Zinks VRU design is configured in modular packages to help meet customer needs.
Convenient, flexible equipment installation Fits in varied plot spaces  Ample space for equipment maintenance  Greater ease of retrofitting the system
Vacuum Pump Skid Booster Blower Platform

Pictured above is a VRU inlet header skid, ready for shipment. All motor operated switching valves are located near grade for easier maintenance.

Regeneration Skid

Continuous Emission Monitoring System


As an optional feature, John Zink offers a Continuous Emission Monitoring System (CEMS) that includes an analyzer to measure hydrocarbon content in the VRU vent stream. The CEMS performs emission data averaging and can achieve VRU energy savings when utilizing the CEM Start mode of operation. The carbon beds are left on stream until their effective adsorption capacities have been expended before regeneration occurs. Typical energy savings using this mode of operation have ranged between 30 to 50%.

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John Zink introduces VaporWatch, a new vapor control remote monitoring system. With VaporWatch, operators can securely access real-time online operating data directly from their desktops or from a personal computer anywhere around the world. This remote access capability ultimately results in more efficient equipment operation, reduced downtime for loading terminal operations, and lower operating and maintenance costs.

An enhanced maintenance package is also available that includes a proactive service plan that generates customized equipment performance reports and a dedicated monitoring system for customer equipment. The enhanced version also maintains data on the pressures, temperatures, emissions, and other vapor control performance. Technicians can reference these reports to help diagnose and eliminate operational difficulties, predict equipment failures, and service equipment.

View real-time data with excellent ability to observe trends Ability to monitor key system parameters simultaneously

View historical data and trends; keep stored data for up to 10 years Hands-on maintenance tool to recognize problems before they occur

Exceptional Service

Equipment Rentals

John Zinks worldwide service organization is the largest, most technically savvy team of its kind. Our service technicians are trained in the latest technologies to evaluate existing systems for upgrades and retrofits, to troubleshoot operations, and to help plan your next turnaround.
Scheduled preventative maintenance Emergency call-out available 24 hours a day, 7 days a week Equipment retrofit packages Carbon screening, testing, and replacement services Start-up assistance Installation assistance Operator training Equipment relocation  Annual vapor control course available at the John Zink InstituteSM

Avoid loading rack downtime with John Zinks Portable Emission Control System (PECS). The PECS is a self-contained, trailer-mounted vapor combustor that ensures stable, smokeless combustion and maintains temperature control over a wide range of vapor combustion. This cost-effective, temporary solution helps regulate operational issues at transport loading terminals. The PECS is equipped with a vapor blower for low-pressure applications, anti-flashback burners, and flame and detonation arrestors. Bundle a PECS rental with other John Zink services such as installation, start-up, on-site operator assistance and training, or dismantling to save both time and money.

worldwide service and support

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CLEAN COMBUSTION. CLEAR SOLUTIONS.

www.johnzink.com
u.s.A. canada
John Zink World Headquarters
John Zink Company, LLC 11920 East Apache Tulsa, Oklahoma 74116 UNITED STATES OF AMERICA

vaporcontrol@johnzink.com
EUROPE MIDDLE EAST AFRICA
John Zink Europe Headquarters
John Zink Int. Luxembourg S. r.l. Zone Industrielle 'Riedgen' L-3401 Dudelange LUXEMBOURG

ASIA-PACIFIC
John Zink Asia-Pacific Headquarters
John Zink Asia-Pacific, a division of Koch Asia-Pacific, Inc. 4th Floor, Takanawa Muse Building 3-14-13, Higashi-Gotanda, Shinagawa-ku, Tokyo 141-0022 JAPAN Tel: +81-3-4332-5550 Fax: +81-3-5423-1627 Other: SINGAPORE AUSTRALIA PEOPLE'S REPUBLIC OF CHINA

LATIN AMERICA
John Zink Latin America Headquarters
Koch Tecnologia Qumica LTDA. Rua Tanabi nr. 276 gua Branca CEP 05002-010 - So Paulo-SP BRAZIL

Tel: +1-918-234-1800 +1-800-421-9242 Fax +1-918-234-2700

Tel: +352-518991 Fax: +352-518611 Other: UNITED KINGDOM FRANCE ITALY SPAIN THE NETHERLANDS GERMANY INDIA

Tel: +55-11-3865-3571 Fax: +55-11-3871-0405 Other: ARGENTINA MEXICO

2009 John Zink Company, LLC

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