JOHN ZINK CARBON ADSORPTION VAPOR RECOVERY SYSTEM

CLEAN COMBUSTION. CLEAR SOLUTIONS.
John Zink Carbon adsorption
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.
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.
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.

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
www.johnzink.com

superior performAnCe
John Zink’s VRUs are designed to meet the most stringent emissions
requirements worldwide. In typical installations such as truck, rail, tank
and marine loading, our VRUs achieve emission control efficiencies of 99%
or better. Most systems are designed to meet 1 – 10 milligrams of VOC
Recovered Product (in liters per 1000 liters loaded)
Estimated Power consumption (kW)
2.5
2
1.5
1
0.5
0
160
140
120
100
80
60
40
20
Recovered Product for Various Loading Operations*
Truck/Rail Vapor
Balanced Loading
Truck/Rail Non-Vapor
Balanced Loading
Barge
Loading
Loading Operation Type
Power consumption vs. daily Loading
for a Typical Gasoline Truck Loading Application*
0
0 4,000,000 8,000,000 12,000,000 16,000,000
daily Product Loaded (Liters)
Ship
Loading
Gasoline Ethanol Benzene Stabilized Light North Sea Crude
* Typical power consumption for Truck/Rail Vapor Balanced Loading may be found in the plot below.
* Values are typical for systems designed for 10 g/nm3 Liquid Ring Vacuum Pump - ADAB Dry Vacuum Pump - ADAB
(10 mg/l). John Zink will optimize each system
based on the individual application. Power consumption may vary.
released per liter of product loaded, or 1 – 10 grams per cubic meter of vapor
vented. John Zink has designed VRUs that meet stricter emissions standards
including the TA Luft standard of 150 milligrams of VOC released per normal
cubic meter of vapor vented (approximately equal to 0.15 mg/l).

JoHn Zink’s vApor reCovery differenCe
John Zink has a proven track record of success with vapor recovery
technology; there are more than 2,000 John Zink ® brand vapor control
systems in service in more than 40 countries.
Our Research, Development and
Test Center, located in Tulsa, Okla.,
is the launch pad for low-emission
systems that address our customers’
needs while preserving and protecting
the environment.
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
running strong – around the clock, around the world.
Put our expertise to work on your vapor recovery systems and get to
know John Zink’s vapor recovery difference.
As CompAred to
vApor Combustion teCHnoloGies:
• can be installed in a hazardous area
• no flame to serve as an ignition source
• Positive rate of return on investment due to value of
recovered product
• Marine loading requires no vapor conditioning
• no trade-off pollutants
• no supplemental fuel requirements
As CompAred to
otHer vApor reCovery teCHnoloGies:
• Worldwide acceptance as standard for
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.
tHe use of dry vACuum pump (dvp) teCHnoloGy
offers siGnifiCAnt AdvAntAGes over otHer vACuum
teCHnoloGies:
• Reduced power consumption
• Ethylene glycol and associated equipment are eliminated
from system
• decreased maintenance costs
• no product contamination
• Greater flexibility with products that can be loaded
into the VRu
1
2
The VRU is equipped with
two identical adsorber
vessels filled with activated
carbon. One adsorber is on
stream receiving vapors in
the adsorption mode while
the other adsorber is off
stream in the regeneration
mode. Switching valves are
provided to automatically
alternate the adsorbers
between adsorption and
regeneration, which
assures uninterrupted
vapor processing capability.
The VRU will automatically
start when a loading
operation is ongoing and
shutdown in a standby
mode when the operation is
complete.
During adsorption, the
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
content.
PRODUCT
LOADING RACK
PRODUCT
LOADING
PUMP
CONDENSATE
COLLECTION
STORAGE TANK
LEAN ABSORB

6
ADSORBER
(REGENERATION MODE)
1
3
ENT SUPPLY PUMP
ABSORBER
5
6
RICH
ABSORBENT
RETURN PUMP
AIR VENT TO
ATMOSPHERE
PURGE AIR
VACUUM
BOOSTER
BLOWER
ABSORBENT &
RECOVERED PRODUCT
HYDROCARBON VAPOR
AIR
VALVE OPEN
VALVE CLOSED
4
ADSORBER
(ADSORPTION MODE)
1
2
AS
REQUIRED
DRY VACUUM
PUMP
3
4
5
6
During regeneration, previously adsorbed hydrocarbon vapor is
removed from the carbon and the carbon’s ability to adsorb
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.
A dry vacuum pump (DVP) is the source of vacuum for carbon
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
through the outside jacket and is injected
directly into the vacuum pump.
In the absorber vessel, the hydrocarbon vapor from the DVP
flows up through packing, while a hydrocarbon liquid flows
down through packing. Inside the absorber, the vapor is
liquefied, and the recovered hydrocarbon is returned back to
the absorbent storage tank. A small stream of air and residual
vapor exits the top of the absorber and is recycled to the
on stream carbon bed for re-adsorption.
A lean absorbent supply pump and a rich absorbent return
pump are provided to circulate the required absorbent.
www.johnzink.com

CArbon Adsorption – Absorption proCess witH liQuid rinG vACuum pump
Liquid ring VRU systems operate along the same principles as the dry
system previously described. However, this system includes a liquid ring
vacuum pump (LRVP) to regenerate the carbon beds. LRVPs are robust
and relatively inexpensive, with a proven history of successful operation.
1
2
The LRVP strips the
rich hydrocarbon
vapor stream from
the adsorber and
discharges it into a
three-phase separator.
Each LRVP requires
a specially blended
ethylene glycol-based
sealing fluid to operate.
The separator is
provided to allow
efficient separation
between the vacuum
pump’s seal fluid,
hydrocarbon
condensate, and
the non-condensed
hydrocarbon vapor.
The non-condensed
hydrocarbon vapor is
discharged from the
separator vessel and
recovered by means
of a packed-bed
absorber column in
the same manner as
previously described.
ABSORBENT &
RECOVERED PRODUCT
HYDROCARBON VAPOR
AIR
PRODUCT
LOADING RACK
PRODUCT
LOADING
PUMP
SEAL FLUID
VALVE OPEN
VALVE CLOSED
CONDENSATE
COLLECTION
STORAGE TANK
ADSORBER
(REGENERATION MODE)
LEAN ABSORBENT SUPPLY PUMP
ABSORBER
SEAL
FLUID
PUMP
They are available in a variety of configurations so the system can be
tailored to fit your specific needs. John Zink has made available its
own specially formulated vacuum pump seal fluid – Z-SEAL – for use
in this serivce.
3
RICH
ABSORBENT
RETURN PUMP
AIR VENT TO
ATMOSPHERE
PURGE AIR
VACUUM
BOOSTER
BLOWER
SEPARATOR
2
The seal fluid is
pumped from the
separator through a
seal fluid cooler to
remove the heat of
compression.
SEAL
FLUID
COOLER
4
1
3
ADSORBER
(ADSORPTION MODE)
AS
REQUIRED
LIQUID RING
VACUUM PUMP
4
The ADAB VRU based
upon either dry
vacuum pump or liquid
ring vacuum pump
technology may be
provided with a high
efficiency (HE-ADAB)
vacuum system. The
enhanced vacuum
system consists of a
rotary-lobed vacuum
booster blower
operating in series with
the vacuum pump.
The addition of the
booster blower allows
the carbon beds to
be regenerated under
a higher vacuum
(lower absolute
pressure) and provides
significantly higher
pumping capacity at
high vacuums than is
possible through the
use of only the vacuum
pump. An enhanced
vacuum system more
thoroughly regenerates
the activated carbon
and can, as a result,
provide several potential
benefits including
use of less carbon,
the achievement of
lower emission levels,
reduced system power
requirement, and less
overall capital cost.

modulAr system
John Zink’s VRU design is
configured in modular packages to
help meet customer needs.
• convenient, flexible
equipment installation
• Fits in varied plot spaces
• Ample space for
equipment maintenance
• Greater ease of
retrofitting the system
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%.
Pictured above is a VRU inlet header skid, ready for shipment.
All motor operated switching valves are located near grade for
easier maintenance.
Booster Blower Platform
Vacuum Pump Skid
Regeneration Skid
www.johnzink.com

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.
Ability to monitor key system
parameters simultaneously
View real-time data with excellent
ability to observe trends
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 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 InsTITuTE sM
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.com

CLEAN COMBUSTION. CLEAR SOLUTIONS.
www.johnzink.com vaporcontrol@johnzink.com
u.s.A.
cAnAdA
John Zink
World Headquarters
John Zink Company, LLC
11920 East Apache
Tulsa, Oklahoma 74116
UNITED STATES OF AMERICA
Tel: +1-918-234-1800
+1-800-421-9242
Fax +1-918-234-2700
© 2009 John Zink Company, LLC 09-4415
EuROPE
MIddLE EAsT
AFRIcA
John Zink Europe
Headquarters
John Zink Int. Luxembourg S.à r.l.
Zone Industrielle 'Riedgen'
L-3401 Dudelange
LUXEMBOURG
Tel: +352-518991
Fax: +352-518611
Other:
UNITED KINGDOM
FRANCE
ITALY
SPAIN
THE NETHERLANDS
GERMANY
INDIA
AsIA-PAcIFIc
John Zink Asia-Pacific
Headquarters
John Zink Asia-Pacific,
a division of Koch Asia-Pacific, Inc.
4th Floor, Takanawa Muse Building
3-14-13, Higashi-Gotanda,
Shinagawa-ku, Tokyo 141-0022
JAPAN
Tel: +81-3-4332-5550
Fax: +81-3-5423-1627
Other:
SINGAPORE
AUSTRALIA
PEOPLE'S REPUBLIC OF CHINA
LATIn
AMERIcA
John Zink Latin America
Headquarters
Koch Tecnologia Química LTDA.
Rua Tanabi nr. 276
Água Branca
CEP 05002-010 - São Paulo-SP
BRAZIL
Tel: +55-11-3865-3571
Fax: +55-11-3871-0405
Other:
ARGENTINA
MEXICO