Knowledge Hub

Pilots are the heart of a flare. Without healthy pilots, a flare can easily become a vent. When a failure occurs in pilot fuel piping, it can significantly affect pilot performance and consequently flare performance. No one expects when installing a flare for the pilot fuel piping to fail, but it does happen. Insufficient tightening of threaded connections, flanges without double nuts or another mechanism to prevent loosening, flame impingement from adjacent flares, flame impingement from a damaged flare, improper piping support, and corrosion are all potential causes of pilot fuel piping failing. This paper will discuss steps that can be taken to mitigate the issue if it arises and preventative measures to lessen the probability of it occurring. The following assumptions are made:

1. A flame front generator (FFG) is available and functional.
2. The vent gas can’t be routed to another flare.
3. The damaged flare will not be shut down for repair.

(Warning: Operation without pilots can result in the venting of waste gas and its consequences and may violate local regulations.)

Meet Anne Schonacher, a valued member of the John Zink team since 2014. Drawn by John Zink’s culture, she now plays a key role in managing innovation projects, fostering collaboration, and driving solutions from idea to commercialization. She thrives on helping teams bring innovative ideas to life and fostering an environment where experimentation and problem-solving lead to success. 

Increased focus on greenhouse gas emissions is driving operators to explore ways to reduce those emissions. The flare is one area of interest for reduced emissions. This paper will explore various techniques that can be used to reduce greenhouse gas emissions from flares.

Cold weather can create serious challenges for steam or water-assisted flares, leading to ice buildup that threatens both safety and performance. Ice blockages inside the flare can increase back pressure and risk overpressuring connected equipment, while external ice formations may compromise structural integrity and endanger personnel.

This guide outlines key equipment vulnerable to cold conditions and steps to mitigate risks. Cold weather, defined as any condition that causes water to freeze on or inside the flare system, becomes a concern when ice accumulates enough to impact operation or stability. For specific operational guidance, always refer to the manufacturer’s manual.

Meet Bridget Taylor, aftermarket execution manager at John Zink. Bridget joined John Zink in 2015 after earning her mechanical engineering degree, but her connection to the company runs much deeper. With a family legacy tied to John Zink—her grandfather worked at the company, and her father was a frequent customer—Bridget grew up familiar with the innovative work happening here. Now, she brings that personal connection full circle, leading a global team and helping shape the aftermarket portfolio with passion, collaboration, and a commitment to growth. 

Meet Emily Rohr - As the application engineering manager for the vapor control team, Emily combines her passion for customers and engineering with a collaborative spirit, designing innovative solutions to meet emission control needs worldwide. With more than a decade of experience, Emily has grown her expertise and built lasting partnerships, driven by a love for teaching and a commitment to advancing the industry. 

Ethylene oxide (EO) is an important chemical with a variety of uses as a chemical intermediate and as a sterilant. Derivatives of ethylene oxide include ethylene glycol, amines, solvents, and surfactants. As a sterilant, it is used to sterilize medical devices, spices, and other food products.  While its properties make it indispensable, they also demand stringent safety measures. We leverage our deep expertise in combustion and emission control to ensure EO flaring is both effective and safe.

Meet Jonathan Buskirk, who started as a draftsman at John Zink and is now a flares retrofit applications engineer, solving unique customer challenges. Drawn to the company’s supportive culture and focus on self-actualization, Jonathan quickly realized John Zink was the perfect place to grow and explore a variety of skills. Today, he’s helping customers tackle flaring challenges, combining technical expertise with commercial strategy. Jonathan’s journey highlights not only his passion for engineering but also the innovative and empowering environment that makes John Zink stand out. 

Meet Ronnie Springer, who joined John Zink in 2008, starting as a skilled machinist and developing into his current role as manufacturing manager. Passionate about empowering his team, Ronnie focuses on removing obstacles and fostering individual growth. Aligned with John Zink’s values, he thrives in the business’ culture of innovation and collaboration, leveraging the KES network to drive success. 

Meet Christian Tello, who joined John Zink in 2011 as a material coordinator and now leads LATAM business development for aftermarket. Throughout his career, Christian has embraced opportunities to grow, deepen his expertise, and strengthen customer relationships. Proud to contribute to John Zink’s legacy, he values the team’s supportive culture and encourages others to embrace challenges as opportunities for growth.

Meet Bryan Stacy, regional account specialist and a valued member of the John Zink team since 2021. Bryan's journey here began with a recommendation from a friend, and he quickly connected with our guiding principles. In his role with the boiler burner aftermarket team, he thrives on the variety and challenge each day brings, collaborating closely with customers and colleagues alike. Bryan’s experience reflects the supportive, growth-focused culture he’s found at John Zink. 

Refineries rely on flares to safely burn waste gases, but these systems can also be significant sources of greenhouse gas (GHG) emissions. With tighter regulations and increasing sustainability goals, optimizing flare systems is essential. This article outlines three proven methods to reduce emissions and enhance flare efficiency, sharing advanced insights from John Zink’s decades of experience.

Meet Matthew Vuong, a technical service advisor at John Zink who began his journey as an intern in 2015. Over the years, he has taken on various roles, continually expanding his expertise and passion for customer service. Known for his hands-on approach, Matthew ensures our vapor control and biogas equipment operates smoothly in the field. Let’s explore his career journey, favorite traditions, and what drives him to excel at John Zink. 

Meet Bill Lee, a strategic account representative at John Zink. Since joining in 2013, Bill has embraced a variety of roles, from the machine shop to sales, driven by his passion for learning and growth. In this spotlight, Bill shares his career journey, advice for new employees, and what excites him about the future at John Zink.

As industries worldwide look for sustainable energy solutions, Hydrogen (H2) is emerging as a promising alternative to traditional fossil fuels. At John Zink, we’re leading the charge in innovating combustion technologies that meet the evolving needs of our clients. One area of focus is converting tangentially fired boilers from natural gas to hydrogen. This process offers exciting possibilities but comes with its own set of challenges.

As a long-standing customer of John Zink, Qatar Petrochemical Company (QAPCO) reached out to our team during an unexpected emergency. John Zink promptly assembled a team to address the issue and deliver an effective solution. QAPCO required a partner capable of meeting an extremely tight deadline. Within three days of the initial call, John Zink had traveled to QAPCO, met with their leadership team, and committed to providing a 90-meter tall, combined HC and acid flare system within just 32 days—a project that typically takes several months to complete.

Samsung Total Petrochemicals Co., Ltd. replaced a steam-assisted flare tip at their main olefin plant in Daesan, Korea, with the STEAMIZER® XP™ technology from John Zink to increase smokeless capacity, enhance steam efficiency, improve flame stability, and reduce noise pollution. The results were impressive: smokeless capacity increased by approximately 195%, from 40,000 kg/hr to 117,800 kg/hr, using the same steam supply rate, and the flare became quieter and more stable. This success led Samsung Total to order another STEAMIZER XP-60 for the same facility.

Vapor recovery Units (VRUs) play a crucial role in the oil and gas industry by helping to capture and reclaim vapors that would otherwise be released into the atmosphere.

Vapor combustion systems, or Vapor Combustion Units (VCUs), are essential tools in gasoline, crude oil, ethanol, diesel, and other hydrocarbon and petrochemical applications, designed to safely and efficiently manage volatile gases and vapors.

When it comes to ensuring efficient and compliant vapor combustion, John Zink’s Vapor Combustion Units (VCUs) are widely recognized for their reliability and effectiveness. A crucial part of implementing a VCU is the startup process, which involves a series of steps and checks to ensure the system operates as designed and meets regulatory requirements. Below is a detailed overview of our VCU startup process.

When it comes to managing emissions of volatile hydrocarbon vapors, the choice between Vapor Combustion Units (VCUs) and Vapor Recovery Units (VRUs) is a critical decision. We will explore key considerations to help you determine which system is the right fit for your specific operation.

We assisted a major oil refinery in reducing NOx emissions on three 550,000 lb/hr tangentially fired boilers while considering retrofit cost, timeline, and equipment compatibility. The retrofit successfully achieved target emissions, received an award for exceptional performance, and showcased our expertise in optimizing industrial combustion systems.

Meet Stephen McCollam, who joined John Zink in 2013 after earning his master’s degree. Inspired by passionate instructors in a college class, he knew he wanted to be part of John Zink’s team. As a senior process engineer in the process heating group, Stephen focuses on equipment design, technical reviews, and training global teams. He finds the most rewarding part of his job is solving customer problems and seeing those solutions come to life.

Meet Rebecca Hiatt, who joined John Zink in 2022 after graduating from OSU Tulsa. Drawn by John Zink’s culture and the role’s responsibilities, Rebecca found a great fit as a project engineer focused on process flares.

Meet Kayla Chally, an engineering solutions advisor at John Zink. Kayla’s journey with John Zink began as an intern in 2016, and her passion for the company’s culture led her to a full-time position in 2017. In this spotlight, Kayla shares insights into her role, her professional development, and her contributions to John Zink’s innovative environment. Get to know more about Kayla, her achievements, and her beloved pups, Goose and Rooster.

In the highly regulated maritime industry, meeting stringent safety and environmental standards is crucial for operations. Recently, a customer in the Gulf Coast area faced a significant challenge: they needed portable marine vapor control equipment that met U.S. Coast Guard (USCG) requirements. With no existing infrastructure in place for vapor control, they turned to John Zink for a reliable and efficient rental solution.

Meet Ben Bolin, who started as a process engineering intern with John Zink in 2020 and joined full time in 2021 after earning his bachelor’s in mechanical engineering. Drawn by Koch and John Zink’s culture and growth opportunities, Ben is a new equipment applications engineer for the vapor control equipment product line. He handles design work, technical customer interactions, and project support. Ben enjoys seeing projects grow from ideas to operational systems and values the business’ encouragement of creative problem-solving and professional development.

Thermal oxidizers are critical components in controlling emissions and maintaining environmental compliance in various industries. However, beyond their primary role in abating volatile organic compounds (VOCs), hazardous air pollutants (HAPs), and other waste gases, there’s a growing interest in enhancing their efficiency through heat recovery.

As industries continue to evolve, regulatory landscapes shift to ensure safety and environmental sustainability. The recent updates to the EPA’s NESHAP Subpart R, BBBBBB, and NSPS Subpart XXa represent significant changes for facilities handling bulk gasoline terminals and vapor control equipment. Understanding and navigating these updates can be challenging, but with John Zink’s expertise and innovative solutions, compliance becomes not just achievable but an opportunity for operational improvement.

Meet Raegan Peters, an applications engineer specializing in thermal oxidizers. Starting as an intern in 2018, Raegan has grown into a full-time engineer who embodies our business’ values. Her collaborative spirit and commitment to excellence help customers navigate complex projects and find tailored solutions. Raegan’s journey highlights the growth opportunities and supportive culture at John Zink, where she contributes to our legacy by embracing innovation and principled entrepreneurship.

Meet Breann Loeber, whose journey at John Zink began during her sophomore year with the Koch All Access Program. This experience sparked her passion for combustion technology, leading her to join John Zink as an intern in 2021 and transition to a full-time role in 2022. In her role, Breann blends technical design with customer interaction, working closely with customers to design flare systems that meet their needs. She also leads Oklahoma State University (OSU) campus recruiting, coordinates flare school at Koch Engineered Solutions Institute (KESI), and assists with intern programming, all while contributing to John Zink’s legacy of innovation and environmental stewardship.

The future of energy is undergoing a significant transformation, with hydrogen emerging as a promising, eco-friendly fuel source. The growing global demand for hydrogen is driven by its ability to generate water as its only byproduct during combustion, with minimal carbon dioxide emissions, depending on its production method. However, integrating hydrogen into various applications presents unique challenges, particularly when it comes to combustion systems. In this article, we explore how radiant wall burner technology is addressing the issues associated with introducing hydrogen fuels into combustion processes.

The landscape of environmental regulations is constantly evolving, and staying ahead of these changes is crucial for industries dealing with hazardous emissions. A key focus of recent regulatory changes is the Hazardous Organic National Emission Standards for Hazardous Air Pollutants (HON), which impacts more than 200 facilities and targets substances affecting the Synthetic Organic Chemical Manufacturing Industry (SCOMI). One of the critical challenges in these regulations is predicting emission rates of dioxins and furans (CDD/CDF).

Meet Hai Lai, Head of Technology – Vapor at John Zink. Hai started as an intern in 2013, seeking industrial experience before deciding to stay due to the excellent equipment, company culture, and friendships. Over the years, he transitioned from project management to process engineering, eventually becoming Head of Technology for the vapor control team. His journey at John Zink has been marked by continuous learning, mentorship, and contributions to innovative projects like the NOxSTAR™ low NOx combustor technology.

John Zink executed a successful conversion for Puerto Rico Electric Power Authority (PREPA), transforming two 410 MWe tangentially fired boilers at the South Coast Generating Station. The conversion involved equipping unit #5 and #6 boilers with advanced gas burners, safety valves, and pressure-regulating skids. This allowed PREPA to flexibly switch between natural gas and fuel oil firing, achieving fuel cost reduction and adherence to regulations. The conversion preserved existing oil-firing capabilities and optimized boiler performance, resulting in substantial operational benefits for PREPA.

As leaders and organizations strive to reduce carbon emissions, the use of hydrogen as a fuel source continues to surface as a compelling alternative. Process heating through hydrogen combustion isn’t necessarily novel. The refining and petrochemical industries have leveraged the heating content in byproducts (many of those rich in hydrogen) to maximize unit efficiency, reduce the consumption of purchased fuel, and eliminate the release of unburned hydrocarbons to the atmosphere. While the carbon free nature to hydrogen offers a seemingly simple path to carbon free emissions, transitioning to hydrogen presents several challenges that, if unmitigated, will negatively impact the viability of products and services critical to our daily lives.

The control of volatile organic compounds (VOCs) is of utmost importance. VOCs, if released into the atmosphere, can have detrimental effects on the environment, acting as precursors to ozone and smog formation. Consequently, regulations worldwide demand the capture or destruction of VOCs to mitigate their release. To meet these requirements, two primary technologies are employed: vapor recovery units (VRUs) and vapor combustion units (VCUs). In this article, we will assess these vapor control options and introduce a suitable technology where vapor combustion technology is chosen.

Operational interruptions can be a significant challenge, particularly for facilities that require high-efficiency equipment to meet stringent regulatory requirements. This was the situation faced by a railcar cleaning facility that experienced a shutdown due to issues with its existing thermal oxidizer. With a permit demanding a destruction efficiency of 99.99%, finding a quick and effective solution was imperative.

In industrial processes and combustion systems, there’s a hidden hero that often goes unnoticed: the burner tile. It’s a common misconception that this essential component is merely a piece of refractory or firebrick. In reality, the burner tile is the “heart” of the burner, and its proper design, installation, and maintenance are critical for efficient burner performance. This article delves deep into the realm of burner tiles, shedding light on their crucial role in process burners and discussing the six key principles (the 6 Ms) that apply to burner tile design.

John Zink is dedicated to workplace safety, setting standards that prioritize the health and wellbeing of its employees. This commitment has been recognized with the Star of Excellence from the Occupational Safety and Health Administration’s (OSHA) Voluntary Protection Programs (VPP), reflecting not just compliance with safety protocols but a deep-rooted culture of safety involving all employees.

Vapor control systems play a vital role in operations, ensuring the safe and efficient disposal of harmful vapors. To maintain the longevity and reliability of these systems, proper operation and regular maintenance are essential.

Efficiency and safety are paramount in the operation of ethylene-cracking furnaces. These critical processes produce ethylene through thermal cracking of hydrocarbon feedstocks, such as ethane and propane. However, managing heat flux profiles in these furnaces is crucial to prevent issues like coking, tube overheating, and equipment damage. In this blog post, we will explore the significance of heat flux correlations and how they can be applied to various ethylene furnace configurations.

John Zink successfully delivered the SOLEX burner combustion system, achieving less than 5 ppm NOx emissions and nearly zero CO emissions across a broad range of operating conditions. The SOLEX™ combustion system is John Zink's next-generation NOx technology industrial burner for process heaters in general refining service, designed with two combustion zones to achieve single-digit NOx emissions without traditional post-combustion treatment methods, such as selective catalytic reduction (SCR).