Vapor & Biogas Equipment Services

Preventative Maintenance Plans

At John Zink, we understand the importance of maintaining your equipment for long-term reliability. Our Preventative Maintenance (PM) Plans are designed to help you minimize unplanned downtime, maximize equipment availability, and extend equipment life under optimal process conditions.

Troubleshooting

Experiencing issues with your vapor and biogas systems? Our expert technicians are here to diagnose and resolve them swiftly. Leveraging extensive industry experience, expert knowledge, and cutting-edge engineering tools, we provide rapid issue resolution, minimizing downtime and restoring operations quickly.

With tools like InSite™, we can remotely access the PLC and HMI for more effective and efficient troubleshooting when needed.

Carbon Replacement

John Zink offers turnkey services to replace degraded activated carbon with new, virgin activated carbon. Over time, the carbon in VRUs can mechanically degrade, producing dust that contaminates and clogs other processes. A complete carbon replacement removes this dust, providing a clean start for your VRU. 

Our carbon replacement projects typically include:

• Removing the old activated carbon from the VRU
• Inspecting and cleaning the interior of the carbon vessels, including the support screens
• Making minor repairs to carbon support screens if necessary
• Installing new activated carbon into the vessels
• Performing a saturation to establish a hydrocarbon heel on the new carbon
• Placing the VRU into cleanup mode and fine-tuning the system for optimal operation
• Returning the unit to normal service

Benefits:

• Eliminates dust from carbon vessels, addressing various VRU issues 
• Provides a fresh start with virgin activated carbon
• Offers an opportunity to upgrade your carbon type with the highest working capacity available 
• Allows for seal fluid flushes and other maintenance activities that cannot be done during routine quarterly maintenance while the VRU is offline

Refractory Replacement

Proper refractory is essential for maintaining high temperatures, enhancing energy efficiency, ensuring safety, reducing emissions, and optimizing overall system performance while safeguarding the structural integrity of the stack. Replacing refractory in your stack is a specialized task that requires expertise. John Zink’s experienced team is equipped to handle the job, ensuring safety, efficiency, and compliance with industry standards. Our skilled technicians oversee the entire process, from lockout-tagout procedures to restarting the unit once work is completed.

BWC Boost

BWC Boost is an exclusive John Zink process designed to enhance the Butane Working Capacity (BWC) of your carbon. Specifically developed to extend the lifespan of activated carbon in a vapor recovery unit (VRU), the BWC Boost process is a cost-effective alternative to full carbon replacement. For carbon with a low BWC grade and minimal dust content, this process removes hydrocarbon residues trapped in the carbon bed without the need for carbon removal or replacement. Testing shows typical improvement to a BWC B grade on a variety of carbon conditions.

Benefits:

• Restores carbon to a higher BWC
• Extends carbon life
• Enhances performance in both BWC and emissions capture
• Requires less downtime (2 to 3 days compared to 5 for standard VRU carbon replacement)
• Eliminates the need for spent carbon disposal