flare gase recovery systems

8/3/2019 Flare Gase Recovery Systems

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R e c o v e r

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R e d u c e

John Zink Company, LLC

Flare Gas Recovery Systems


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JohnZinkCompany

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 of fer 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.

WhyFlareGasRecovery?

John Zink Company, LLC


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Why Flare Gas Recovery?

FLAME LENGTH (FEET)

HEAT

RELEASE

(M

ILLION

BTU/HR)

Annua

lVa

lue

o

f

Fue

lRecovere

d*

250 $4,380,000

20 0

15 0

10 0

50

$3,504,000

$2,628,000

$1,752,000

$867,000

5 10 15 20 25 30 35 400

FLAR

ETI

PDIAM

ETE

R

30

INCH

2 4I NCH

1 8I N

CH

1 4I NC

H

1 0 I NCH

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.

* Based on $2/Million BtuFLARE GAS RECOVERY ECONOMICS


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John Zink Flare Gas Recovery Units (FGRUs) provide many

benefits to the end user including:

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 signifi cantly 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.

GettingStartedReduction of plant fuel consumption

Reduction of plant steam consumption

Increase in flare tip life

Rapid return on investment

Reduction of plant emissions


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Getting Started

Engineering Studies

John Zink has the engineering expertise

and equipment necessary to help customers

determine if Flare Gas Recovery is feasible

for their applicat ion. 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 infor-

mation 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.

John Zink has been an equipment supplier to the hydrocarbon and chemical processing

industr ies 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.


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SystemFeatures

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 i s 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.


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Compressor Select ion

The compressor is the "workhorse" of the FGRU. The compressor select ion and

design is crucial to the system capacity and turndown capability. During the design

phase of t he project, John Zink selects the most appropriate t ype and number of

compressors for the applicat ion. 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 com-

pressors such as rotary

screw, reciprocating,

sliding vane, or rotarylobed.

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 effect ive

system for the application. In addition, the systems are easy to install, require only

minimal maintenance, and are designed with safety i n mind.


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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 insurea 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:

How

DoesItWork?

Proven performance i n numerous flares

Surge resistant internals which minimize entrainment

Minimization of noise caused by uneven combustion

Positive flame arrestor in the event of a flashback

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 parametersand 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.


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CONTROL LOGIC

HEAT EXCHANGER

DRIV E R

FLARE HEADER

L IQ UIDCOMPRESSOR

PT

How Does It Work?

St

andardFlareGasRecoveryDiagram

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.


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ProjectExecution

RECOVERED

GA S

RECOVERED LIQUID

DISCHARGE

SEPARATORDRUM

DEEP

L IQ UID-SEAL

DRUM FL A RE

STACK

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 t he

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 necessar y

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.


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Project Execution and Aftermarket Services

John Zink Company understands theimportance of communication, coopera-

tion, 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.

DraftingOur drawings are computer generated to

ensure high quality and flexibility. Both hard

copies and electronic copies are provided

to our customers.

Project Definition

Because of experience, John Zink is

uniquely qualified to provide assistance in

defining project requirements and evaluat-

ing alternatives. Through our engineering

studies, we are often involved in projectsfrom their conception.

System Design

We have the all encompassing expertise

and resources to customize a system to

meet customer specifications.


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U

niquelyQualified

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.

Test ing

We test the operation of every FGRU to the maximum extent

practical prior to shipment. Customer part icipation 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.


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Uniquely Quali fi ed

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 mar-

kets ser ved, 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 prod-

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

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 i n every

region of the world.

John Zink International Headquarters

John Zink Research and Development Center

John Zink U.S. Manufacturing Facility

John Zink Luxembourg Manufacturing Facility


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R e c o v e r

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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 off ices are located in major cit ies around the world.

2000 Koch Creative Services C000303 DL

flare gase recovery systems

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