John Zink_Flare Gas Recovery

8/11/2019 John Zink_Flare Gas Recovery

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© 2006 John Zink International Luxembourg Sarl 1






John Zink BackgroundJohn Zink Background

•• Privately owned by KIPrivately owned by KI•• 75 years in business75 years in business

•• 1000+ employees1000+ employees

•• Global locationsGlobal locations




Quality, Safety, and EnvironmentQuality, Safety, and Environment


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John Zink ProductsJohn Zink ProductsJZ®

• Process Burners•

Flares• Thermal Oxidizers• Vapour Recovery and Combustion• Flare Gas Recovery• Refractory

TODD® Combustion• Industrial and Marine

Boiler Burners

Gordon-PiattTM

• CommercialBoiler Burners

Kaldair ®

• Flares

KEU GmbH• Thermal Oxidizers• Heat Recovery



John Zink has been for many years theJohn Zink has been for many years theleader in the design and manufacturingleader in the design and manufacturing

of industrial flares and relatedof industrial flares and relatedequipment.equipment.

In addition John Zink has been theIn addition John Zink has been theindustry leader in design and supply ofindustry leader in design and supply ofvapour vapour recovery units.recovery units.

This experience is combined in FGRThis experience is combined in FGRsystems which recover valuable flaresystems which recover valuable flare

gasses to reuse as fuel or feedstock.gasses to reuse as fuel or feedstock.



Why Flare Gas Recovery (FGR) ?Why Flare Gas Recovery (FGR) ?

FGR provides the benefit ofFGR provides the benefit ofconservation of resources andconservation of resources and

reduction of emissions by recoveringreduction of emissions by recovering

process vent gases, with oftenprocess vent gases, with oftenconsiderable HV, instead of flaring.considerable HV, instead of flaring.

““Environmental control with goodEnvironmental control with goodpaybackpayback ””



Benefits:Benefits:

•• Reduce Combustion EmissionsReduce Combustion Emissionsincluding NOincluding NO XX, CO, and SO, CO, and SO XX

•• Reduce Fuel Gas ConsumptionReduce Fuel Gas Consumption

•• Reduce Flaring Light, Noise, and Odor Reduce Flaring Light, Noise, and Odor •• Reduce Steam ConsumptionReduce Steam Consumption•• Extend Flare Tip LifeExtend Flare Tip Life

•• No impact on existing safety reliefNo impact on existing safety reliefsystemsystem•• Improved PR & company imageImproved PR & company image



Flare Gas Recovery UnitFlare Gas Recovery Unit



FG is withdrawn from upstream of liquid seal drum and through LRFG is withdrawn from upstream of liquid seal drum and through LR C dischargedC dischargedinto separator and available as plant gas. Positive P is maintaiinto separator and available as plant gas. Positive P is maintai ned to prevent airned to prevent air

ingress. If FG gas stream exceeds FGR full capacity gas will flingress. If FG gas stream exceeds FGR full capacity gas will fl ow to flare, if FGow to flare, if FGstream is less then system will turndown by staging compressorsstream is less then system will turndown by staging compressors and/or bypass.and/or bypass.





Liquid SealLiquid SealTo maintain a positive pressure in the flare header andTo maintain a positive pressure in the flare header andprevent undesirable vacuum to pull in air from flare tip.prevent undesirable vacuum to pull in air from flare tip.

•• Existing liquid sealsExisting liquid sealsmay be too shallow tomay be too shallow to

provide hydrostaticprovide hydrostatichead and causehead and causeoperating problems.operating problems.

•• JZ liquid seals warrantJZ liquid seals warrantsteady gas flow to flaresteady gas flow to flaretip which providestip which providesincreased smokelessincreased smokelesscapacity.capacity.






Liquid SealsLiquid Seals

•• Typically new liquidTypically new liquidseals are required.seals are required.•• In some applications,In some applications,

new internals can benew internals can beprovided to be installedprovided to be installedin an existing liquidin an existing liquidseal.seal.



Compressor TechnologiesCompressor TechnologiesCompressors

Dynamic Positive Displacement

Reciprocating Rotary

Piston

Diaphragm

Screw

Lobe

Liquid Ring

Sliding Vane

Centrifugal

Axial

Thermal / Jet



Liquid Ring Compressor To compress the flare gas for discharge into seperator.




Separator To separate compressor seal liquid from flare gasses.To separate condensed hydrocarbons from seal liquid.

To discharge compressed gasses into plant fuel gassystem or feedstock.

Service Liquid CoolersTo remove the heat of compression.

System Control LogicFor fully automated unattended operation.




Typical System Project ScopeTypical System Project Scope

Stage 1 - Engineering Study, SiteInvestigation & ProcessEngineering

Stage 2 - Process/Mechanical DesignEquipment SelectionProcurement

Stage 3 - Fabrication & Assembly

Stage 4 - Installation AssistanceStage 5 - Commissioning Support &

Operator TrainingOngoing - Service & Maintenance




FGR Engineering StudyFGR Engineering Study

•• Identify Use for Recovered GasIdentify Use for Recovered Gas•• Review of the Existing Flare SystemReview of the Existing Flare System•• Flare Header Flow and Positive PressureFlare Header Flow and Positive Pressure

•• Characterize Flare Gas AvailabilityCharacterize Flare Gas Availability•• Evaluate Flare Gas CompositionEvaluate Flare Gas Composition•• Select Gas Compressor TechnologySelect Gas Compressor Technology

•• FGRU DesignFGRU Design•• System Cost/Benefits AnalysisSystem Cost/Benefits Analysis•• FGRU ProposalFGRU Proposal




Process Simulation

• Process simulation aids in refining scope• Stream Properties are calculated

• Determines the Material Balance for System




Engineering StudyEngineering Study

•• Determination of flare flow activity is important inDetermination of flare flow activity is important inestablishing recovery system design capacityestablishing recovery system design capacity

•• Determination of the average flare gas flow rate isDetermination of the average flare gas flow rate isimportant step in evaluating the project economicsimportant step in evaluating the project economics

•• Larger projects (higher average flow rates) offer theLarger projects (higher average flow rates) offer thebest returnbest return

•• Uses other than fuel may increase project returnUses other than fuel may increase project return




John Zink Capabilities

•• Determination of flare flow activity to establishDetermination of flare flow activity to establishrecovery system design capacity.recovery system design capacity.

•• Determination of the average flare gas flow rate toDetermination of the average flare gas flow rate toevaluating the project economics.evaluating the project economics.

•• Evaluation of flare process and available recoveryEvaluation of flare process and available recoverytechnologiestechnologies

•• Integration with existing flare systemIntegration with existing flare system•• Design of flares and liquid seal vesselsDesign of flares and liquid seal vessels•• Established field service & maintenance networkEstablished field service & maintenance network•• Approx. 30 years experience in flare gas recovery Approx. 30 years experience in flare gas recovery




Commissioning, Start-Up,Training and Service

• John Zink engineers andtechnicians are involved inevery start-up

• On-site or in-house training

• Service & Maintenancenetwork




#1 Flare Gas Recovery Case Study

Oil Refinery in the Western U.S.Oil Refinery in the Western U.S.•• FGR Design Recovery Flow Rate:FGR Design Recovery Flow Rate: 4,900,000 scfd4,900,000 scfd•• FGR Mean Recovery Flow Rate:FGR Mean Recovery Flow Rate: 2,400,000 scfd2,400,000 scfd

(97% Flare Activity Reduction)(97% Flare Activity Reduction)

•• Year 1 Operating & Maintenance:Year 1 Operating & Maintenance: $182,000$182,000•• Year 1 Value of Recovered Gas:Year 1 Value of Recovered Gas: $3,698,000$3,698,000Flare Emissions ReductionFlare Emissions Reduction•• NONO

XX: 34.6 ton/yr : 34.6 ton/yr CO: 188 ton/yr CO: 188 ton/yr

•• HC: 71.4 ton/yr HC: 71.4 ton/yr SOSO XX: 74.8 ton/yr : 74.8 ton/yr

Payback inPayback in ~~ 14 months14 months




#2 Flare Gas Recovery Case StudyLarge refinery process flareLarge refinery process flareObjective is toObjective is to maximisemaximise economic nuisance flaring reductioneconomic nuisance flaring reduction•• Gas processing design rate: 12,000Gas processing design rate: 12,000 scfmscfm (17.3(17.3 MMscfdMMscfd ))•• Gas processing average rate: 10,400Gas processing average rate: 10,400 scfmscfm (15(15 MMscfdMMscfd ))•• Recovered gas HV: 688 Btu/Recovered gas HV: 688 Btu/ scf scf •• Recovered gas utilized as fuel gasRecovered gas utilized as fuel gas

Results:Results:•• First year recovery: $11.3 MMFirst year recovery: $11.3 MM•• Payback: 20 monthsPayback: 20 months

•• Flaring reduction: 82%Flaring reduction: 82%Basis of EconomicsBasis of Economics•• Fuel value: $3.00/MMBtuFuel value: $3.00/MMBtu

•• Cost of Electrical power: $0.062/kWhCost of Electrical power: $0.062/kWh



Flare Gas Recovery Design




Flare Gas Recovery Unit












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LLiiss

Location Compressor Type Pressure YearOlin Chemicals-Brandenburg, KY 100 psig 1978Dow Chemical-Beaux Bridge, LA 250 psig 1980Flint Hills Refining-Minneapolis, MN ane 80 psig 1981Texaco Refining-Lawrenceville, IL 100 psig 1983Pennzoil Refining-Shreveport, LA 85 psig 1984Sohio-Toledo, OH ing 75 psig 1985Flint Hills Refining-Corpus Christi, TX ing 60 psig 1985Texaco Refining-Port Arthur, TX ing 65 psig 1986Engineers-Madras, India L ing 75 psig 1987Unocal Refining-Nederland, TX ing 80 psig 1988Environmental-Perth, Australia L ing 100 psig 1989Fina O&C Refining-Nederland, TX ing 80 psig 1989Koch Hydrocarbon-Hutchison, TX 300 psig 1994

Fina O&C Refining-Big Spring, TX ing 120 psig 1995HAR-Athens Greece ing 65 psig 1996Shell Products-Buenos Aires, Argentina L ing 100 psig 1999Lion Oil-El Dorado, AR ing 90 psig 2000ConocoPhillips-Ponca City, OK ing 85 psig 2002

ConocoPhillips-Ponca City, OK ing 105 psig 2003

Sliding VaneReciprocatingSliding VReciprocatingReciprocatingLiquid R Liquid R Liquid R

iquid R Liquid R

iquid R Liquid R Rotary Screw

Liquid R Liquid R iquid R

Liquid R Liquid R

Liquid R

John Zink Users List




John Zink Users ListJohn Zink Users ListHunt Refining Tuscaloosa, AL Liquid Ring 120 psig 2004

NCRA Coffeeville, KS Liquid Ring 30 psig 2004Frontier Refining Cheyenne, WY Liquid Ring 85 psig 2005Repsol YPF La Plata, Argentina Liquid Ring 80 psig 2005ConocoPhillips Ponca City, OK Liquid Ring 110 psig 2005Calcasieu Refining Lake Charles, LA Liquid Ring 45 psig 2005Ergon WV Newell, WV Liquid Ring 120 psig 2005Valero St Charles Norco, LA Liquid Ring 120 psig 2006Suncor Sarnia, ON Canada Liquid Ring 112 psig 2006







Thank you !Thank you !




No WarrantyNo Warranty

This technical documentation and the information contained therein is beingdelivered to the user AS-IS and John Zink Company makes no warranty as to itsaccuracy or use. Any use of this technical documentation or the informationcontained therein is at the risk of the user. Documentation may include technical

or other inaccuracies or typographical errors. John Zink Company reserves theright to make changes without prior notice.

COPYRIGHT NOTICE• Copyright © 2006 John Zink Company, LLC, All Rights Reserved.

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