Flare Gase Recovery Systems

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    R e c o v e r

    R e u s e

    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 usin

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