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©2019 John Zink Company LLC **Proprietary & Confidential** 2
Important Notice
The information contained in these materials is for informational purposes only and is provided “AS IS”, without warranties of any kind. Your use of the information contained herein is at your sole risk. We expressly disclaim any express or implied representations, warranties or guaranties, including without limitation, the implied warranties of merchantability and fitness for a particular purpose. We will have absolutely no liability (whether direct, indirect or consequential) in connection with these materials (and/or the information contained therein) including without limitation, any liability for damage to person or property. We also reserve the right to make subsequent changes to the materials without prior notice. For purposes of this notification, “We” includes John Zink Company LLC and its affiliates and their respective employees, partners, principles, agents and representatives, and any third-party providers or sources of information or data.
This presentation is subject to copyright and the information presented is confidential and/or proprietary to John Zink Company, LLC. Accessing, using, copying, and/or changing the presentation or any part hereof is strictly prohibited
For information on patents and trademarks, see johnzinkhamworthy.com/legal-notices
©2019 John Zink Company LLC **Proprietary & Confidential** 4
Ethylene market
► Ethylene is a key building block for plastics, polyester
and synthetic rubber. China is the world’s largest
petrochemical consumers and importers
©2019 John Zink Company LLC **Proprietary & Confidential** 5
Spent Caustic Incinerator
► SPENT CAUSTIC : blow down from caustic scrubber towers used
to remove acid gases and traces of other impurities from raw
cracked gas streams in ethylene plants.
► Typical compositions:
► small amounts of hydrocarbon
► approx. 5-7 wt. % sodium carbonate
► approx. 3 to 4 wt. % sodium hydroxide
► less than 1 to 3 wt. % sodium chloride
► Balance: water.
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Spent Caustic Incinerator
► DESIGN PHILOSOPHY AND GENERAL DESIGN
CONSIDERATIONS
► Usually 2 trains – 100% back-up
► Typical size: 6000 Kg/hr of spent caustic
► Systems are operations and maintenance intensive
► Refractory is typically a critical part of the package due to
salt attack
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Basic Process
❖ NOX
❖ CO
❖ TOC
❖ Dioxins
❖ Optimal fuel consumption
❖ HCl / Cl2
❖ Particles
❖ (Dioxins)
❖ NOX removal
❖ others ?
Combustion System
Flue Gas Treatment
Waste Streams
To stack
Target Variable
©2019 John Zink Company LLC **Proprietary & Confidential** 8
Typical Emission Limit
NOX
Carbon Monoxide
[DRE]
EMISSION LIMIT
Particulate
100 mg/Nm3
CHINA
80 mg/Nm3
Up to 99.9999
20 mg/Nm3
Dioxine 0.1 ng TEQ/Nm3
©2019 John Zink Company LLC **Proprietary & Confidential** 9
Basic Process
▪ BASIC PROCESS SECTIONS
Burner
ThermalOxidizer
ConditioningTower
SaturationQuench
Particulate /Acid Gas Removal
CombustionSection
CoolingSection
Dry Removal
Wet Removal
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Spent Caustic Incinerator
► DESIGN PHILOSOPHY: DOWN FIRED CONFIGURATION
- Prevent build up of material that
would occur in horizontal or
vertical up-flow units
- In horizontal or vertical up-flow
chamber — Material would collect
at bottom of T.O. & could not be
removed unless system was
shutdown
- As solid or melted material “falls”
downward (gravity) during
operation, it will pass through the
oxidizer into next section for
further treatment
©2019 John Zink Company LLC **Proprietary & Confidential** 12
Dioxin
► Group of chlorinated dioxins and furans of similar chemical
structure.
► The most Toxic form of dioxins is 2,3,7,8 Tetrachlorodibenzodioxin ( 2,3,7,8
TCDD) which is sometimes referred to Seveso poison.
©2019 John Zink Company LLC **Proprietary & Confidential** 14
JZ KEU Combustor burner
- Multi purpose liquid
combustion system
- BAT for Dioxin Free
combustion of Chlorinated
hydrocarbons
©2019 John Zink Company LLC **Proprietary & Confidential** 15
JZ KEU Combustor burner
WORKING PRINCIPLE
©2019 John Zink Company LLC **Proprietary & Confidential** 16
JZ KEU Combustor burner
OPTIMIZED COMBUSTION PROCESS OF THE 3T OF COMBUSTION,
TEMPERATURE, TIME AND TURBOLENCE
ADVANTAGES:
► Equal temperature level across the section of flame
► Zero Dioxine formation
► Low formation of Nox
► High destruction efficiency
©2019 John Zink Company LLC **Proprietary & Confidential** 17
JZ KEU Combustor burner
- BAT for Dioxin Free combustion of
Chlorinated hydrocarbons
- Clean shape
- Good Mixing
- No Hot Spot
©2019 John Zink Company LLC **Proprietary & Confidential** 19
Combustion section
- Regulations require 850 ⁰C
operating temperature for 2
seconds for hydrocarbon
wastes and 1100 ºC for 2
seconds for > 1% halogenated
substances
- JZ demonstrated good
performance @ 950-980 ⁰ C
Burner /Combustion
Zone
ThermalOxidizer
©2019 John Zink Company LLC **Proprietary & Confidential** 20
Refractory
Alkali attack (sodium attack)
- Castable is not suitable.
- Brick should be considered
- Alkali reacts with free Al2O3
- Minimize free Al2O3 and porosity in
the refractory system
©2019 John Zink Company LLC **Proprietary & Confidential** 21
Cooling Section
▪ Dry - Conditioning Tower Hot Flue Gas Inlet
Cooled Flue Gas
ConditioningWater, Air, or
Recycled Flue Gas
Clean OutConnection
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Cooling Section
▪Wet Conditioning Tower
QuenchWater
QuenchedFlue GasInternal
Downcomer
Manway
Clean Out / Blow Down at Bottom of
Cone
Contactor Tube
Weir
Hot Flue Gas
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Particulate Removal— Wet
▪ Venturi-Type Scrubber
ScrubbingWater
QuenchedFlue Gas
ToSeparator
ConvergingInlet Diverging
OutletThroat
EncapsulatedParticulate
Particulate
©2019 John Zink Company LLC **Proprietary & Confidential** 24
Particulate Removal— Dry
▪ Baghouse
Flue Gas w/Particulate
CleanedFlue GasCleaned Gas Plenum
Hanging Bag Section
ParticulateCollectionHoppers
©2019 John Zink Company LLC **Proprietary & Confidential** 25
Equipment Configurations
▪ Downfired Salt System – Quench to Saturation
CombustionAir Blower
ThermalOxidizer
VentStack
Fuel
QuenchPot
WasteInjection
High Velocity Scrubber
Mist Eliminator
Make-Up Water
Make-Up WaterRecycle Quench Water
ContactorSection
©2019 John Zink Company LLC **Proprietary & Confidential** 26
Equipment Configurations
▪ Downfired Salt System— Condition to Low Temperature
ConditioningTower
ThermalOxidizer
ESP OPTION
BAGHOUSE OPTION
Stack
Air
Fuel
WasteInjection
Flue Gas
600 oF
350 oF
Dry Salt
Dry Salt
Air and/orH2O
Dry Salt
©2019 John Zink Company LLC **Proprietary & Confidential** 27
Waste Heat Boiler
BurnerCombustion
ProcessWaste Heat
BoilerParticulate
RemovalStack
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Waste Heat Boiler: water tube type
- Cooling below melting points of
the solids formed in the
combustion process
- Soot blowers will be required .
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Waste Heat Boiler: membrane type
- The external surface of the
boiler are completely covered
by tubes full of water;
- The heat transfer between the
hot flue gas and the water will
occurs thanks to the radiation
phenomena.
- A layer of salt may freeze on
the wall acting as “refractory”
©2019 John Zink Company LLC **Proprietary & Confidential** 31
References
Saudi Kayan (Al-Jubail, Saudi Arabia)
SCOPE OF SUPPLY
- Thermal oxidizer burner
- Combustion chamber
- Conditioning chamber
- Combustion air blower
- Quench air blower
- Bag-house filters
- Flue gas stack
©2019 John Zink Company LLC **Proprietary & Confidential** 32
References
Sharq (Al-Jubail, KSA) SCOPE OF SUPPLY
- Burner
- Combustion chamber
- Quencher
- Flexiventuri
- Scrubber
- Reheater
- SCR Catalyst
- Stack
©2019 John Zink Company LLC **Proprietary & Confidential** 34
References
Repsol (Puertollano, Spain)