John Zink Carbon Adsorption

CLEAN COMBUSTION. CLEAR SOLUTIONS.™ 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 Zink’s engineers develop customized
solutions to help optimize your entire system to meet even the toughest
environmental regulations.
Pictured above, a John Zink marine vapor recovery unit located in Europe. John Zink’s VRUs are designed to meet worldwide standards such as
ASME, ANSI, DIN, ATEX, EN, NEC, IEC, and CENELEC.
Quality Management
• John Zink operations meet the requirements of the internationally
recognized ISO 9001:2000 Quality Management System.
Safety and Health Management
• The company’s 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, OSHA’s 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.
The World’s Most Advanced Vapor Recovery Technology
From John Zink Company
John Zink’s 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 Zink’s 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.
Potential applications for use of this system
are as follows:
• Storage tank vents • Truck loading racks
• Railcar loading facilities • Marine terminals
• Process vents
The U.S. Environmental Protection Agency has recognized John Zink’s
VRU technology as being both the Best Demonstrated Technology (BDT)
and Maximum Achievable Control Technology (MACT).
Chemicals Suitable for Vapor Recovery
Applications (Partial List):
• Benzene • Butane
• Carbon Tetrachloride • Chlorobenzene
• Chloroethane • Chloroform
• Crude Oil • Cyclohexane
• Dichloroethane • Diesel Fuels
• Distillate Fuels • Ethanol
• Ethylbenzene • Ethyl Tert-Butyl Ether
• Gasoline • Hexane
• Hexene • Isobutane
• Jet Fuels • Methanol
• Methylene Chloride • Methyl Tert-Butyl Ether
• Naphtha • Pentane
• Pentene • Perchloroethylene
• Propane • Toluene
• Trichloroethane • Trichloroethylene
• Xylene
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Superior Performance

John Zink’s VRUs are designed to meet the most stringent emissions released per liter of product loaded, or 1 – 10 grams per cubic meter of vapor
requirements worldwide. In typical installations such as truck, rail, tank vented. John Zink has designed VRUs that meet stricter emissions standards
and marine loading, our VRUs achieve emission control efficiencies of 99% including the TA Luft standard of 150 milligrams of VOC released per normal
or better. Most systems are designed to meet 1 – 10 milligrams of VOC cubic meter of vapor vented (approximately equal to 0.15 mg/l).

Recovered Product for Various Loading Operations*

Recovered Product (in liters per 1000 liters loaded)

2.5

1.5

0.5

0
Truck/Rail Vapor Truck/Rail Non-Vapor Barge Ship
Balanced Loading Balanced Loading Loading 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*
160
Estimated Power Consumption (kW)

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)

Liquid Ring Vacuum Pump - ADAB Dry Vacuum Pump - ADAB

* Values are typicalbasedfor onsystems 3

designed for 10 g/Nm (10 mg/l). John Zink will optimize each system
the individual application. Power consumption may vary.
John Zink’s Vapor Recovery Difference

John Zink has a proven track record of success with vapor recovery As Compared to
technology; there are more than 2,000 John Zink® brand vapor control
Vapor Combustion Technologies:
systems in service in more than 40 countries.
• Can be installed in a hazardous area
Our Research, Development and • No flame to serve as an ignition source
Test Center, located in Tulsa, Okla., • Positive rate of return on investment due to value of
is the launch pad for low-emission recovered product
systems that address our customers’ • Marine loading requires no vapor conditioning
needs while preserving and protecting • No trade-off pollutants
the environment. • No supplemental fuel requirements

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
As Compared to
running strong – around the clock, around the world.
Other Vapor Recovery Technologies:
Put our expertise to work on your vapor recovery systems and get to
• Worldwide acceptance as standard for
know John Zink’s vapor recovery difference.
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 Zink’s 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 Zink’s VRUs
combine physical adsorption with absorption to recover hydrocarbon vapors
and return the recovered product to storage.
1
The VRU is equipped with
two identical adsorber
vessels filled with activated
The use of dry vacuum pump (DVP) technology carbon. One adsorber is on
offers significant advantages over other vacuum stream receiving vapors in
the adsorption mode while
technologies: PRODUCT
the other adsorber is off
LOADING RACK
• Reduced power consumption stream in the regeneration
mode. Switching valves are
• Ethylene glycol and associated equipment are eliminated provided to automatically
from system alternate the adsorbers
between adsorption and
• Decreased maintenance costs regeneration, which
assures uninterrupted
• No product contamination
vapor processing capability.
• Greater flexibility with products that can be loaded The VRU will automatically
into the VRU start when a loading
operation is ongoing and CONDENSATE
COLLECTION
shutdown in a standby
mode when the operation is
complete.

During adsorption, the

2 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 PRODUCT
STORAGE TANK
content. LOADING
PUMP

LEAN ABSORB
 AIR VENT TO
ADSORBER ATMOSPHERE ADSORBER
(REGENERATION MODE) (ADSORPTION MODE)

1 1
During regeneration, previously adsorbed hydrocarbon vapor is

3 removed from the carbon and the carbon’s ability to adsorb

3 PURGE AIR
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.
2

A dry vacuum pump (DVP) is the source of vacuum for carbon

4 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
ABSORBER through the outside jacket and is injected
VACUUM
AS
BOOSTER directly into the vacuum pump.
REQUIRED
BLOWER

In the absorber vessel, the hydrocarbon vapor from the DVP

5 flows up through packing, while a hydrocarbon liquid flows

down through packing. Inside the absorber, the vapor is
5 liquefied, and the recovered hydrocarbon is returned back to
the absorbent storage tank. A small stream of air and residual
4 vapor exits the top of the absorber and is recycled to the
on stream carbon bed for re-adsorption.
DRY VACUUM
PUMP

ABSORBENT &
RECOVERED PRODUCT A lean absorbent supply pump and a rich absorbent return
HYDROCARBON VAPOR
AIR
6 pump are provided to circulate the required absorbent.

6 VALVE OPEN
VALVE CLOSED
BENT SUPPLY PUMP

RICH
6 ABSORBENT
RETURN 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 They are available in a variety of configurations so the system can be
system previously described. However, this system includes a liquid ring tailored to fit your specific needs. ­ John Zink has made available its
vacuum pump (LRVP) to regenerate the carbon beds. LRVPs are robust own specially formulated vacuum pump seal fluid – Z-SEAL™ – for use
and relatively inexpensive, with a proven history of successful operation. in this serivce.

The LRVP strips the ABSORBENT & The seal fluid is The ADAB VRU based

1 3 4
RECOVERED PRODUCT pumped from the
rich hydrocarbon upon either dry
vapor stream from HYDROCARBON VAPOR separator through a vacuum pump or liquid
the adsorber and AIR seal fluid cooler to ring vacuum pump
discharges it into a remove the heat of technology may be
SEAL FLUID compression. provided with a high
three-phase separator.
Each LRVP requires VALVE OPEN efficiency (HE-ADAB)
a specially blended vacuum system. The
VALVE CLOSED
ethylene glycol-based enhanced vacuum
sealing fluid to operate. system consists of a
ADSORBER
AIR VENT TO
ATMOSPHERE ADSORBER rotary-lobed vacuum
(REGENERATION MODE) (ADSORPTION MODE)
booster blower
operating in series with
the vacuum pump.
The separator is The addition of the

2 provided to allow
efficient separation
PRODUCT PURGE AIR
booster blower allows
the carbon beds to
be regenerated under
between the vacuum LOADING RACK

pump’s seal fluid, a higher vacuum

hydrocarbon (lower absolute
condensate, and pressure) and provides
the non-condensed significantly higher
hydrocarbon vapor. pumping capacity at
The non-condensed
ABSORBER
VACUUM high vacuums than is
BOOSTER 4 AS
hydrocarbon vapor is
CONDENSATE
COLLECTION BLOWER REQUIRED possible through the
discharged from the use of only the vacuum
separator vessel and pump. An enhanced
recovered by means SEPARATOR vacuum system more
LIQUID RING
of a packed-bed VACUUM PUMP thoroughly regenerates
absorber column in 2 the activated carbon
1 and can, as a result,
the same manner as
previously described.
SEAL
FLUID
provide several potential
PUMP
benefits including
3 use of less carbon,
the achievement of
SEAL
FLUID lower emission levels,
COOLER
PRODUCT reduced system power
STORAGE TANK
LOADING
PUMP requirement, and less
LEAN ABSORBENT SUPPLY PUMP overall capital cost.
RICH
ABSORBENT
RETURN PUMP
Modular System

John Zink’s VRU design is

configured in modular packages to
help meet customer needs.

• Convenient, flexible
Booster Blower Platform
equipment installation

• Fits in varied plot spaces

• Ample space for

equipment maintenance

• Greater ease of
retrofitting the system

Vacuum Pump Skid

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 Zink’s 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 Zink’s 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

www.johnzink.co m
 CLEAN COMBUSTION. CLEAR SOLUTIONS.™

www.johnzink.com vaporcontrol@johnzink.com

EUROPE
u.s.A. MIDDLE EAST LATIN
canada AFRICA ASIA-PACIFIC AMERICA
John Zink John Zink Europe John Zink Asia-Pacific John Zink Latin America
World Headquarters Headquarters Headquarters Headquarters

John Zink Company, LLC
11920 East Apache
Tulsa, Oklahoma 74116
UNITED STATES OF AMERICA
John Zink Int. Luxembourg S.à r.l.
Zone Industrielle 'Riedgen­'
L-3401 Dudelange
LUXEMBOURG
John Zink Asia-Pacific, Koch Tecnologia Química LTDA.
a division of Koch Asia-Pacific, Inc. Rua Tanabi nr. 276
4th Floor, Takanawa Muse Building Água Branca
3-14-13, Higashi-Gotanda, CEP 05002-010 - São Paulo-SP
Shinagawa-ku, Tokyo 141-0022 BRAZIL
JAPAN

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+1-800-421-9242 Fax: +352-518611 Fax: +81-3-5423-1627 Fax: +55-11-3871-0405
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© 2009 John Zink Company, LLC 09-4415