Clean Combustion. Clear Solutions.

Global Thermal Oxidation Solutions

the Proven Leaders in Organic Waste Incineration

As global leaders in developing advanced combustion technologies and environmental solutions with over 50 years
of experience, John Zink and KEU use their vast expertise and technical knowledge to engineer innovative thermal
oxidation systems that effectively incinerate a wide variety of hazardous industrial wastes. From research and
development through manufacturing, advanced testing and skillful field installation, John Zinks and KEUs thermal
oxidation team helps you reduce emissions and comply with the most stringent environmental regulations.

TOTAL PLANT SOLUTIONS

The comprehensive solutions from John Zink and KEU target real economic improvement within customers
processes. With over 3,800 installed systems, our scientists, engineers and designers work together to address
more than just the immediate need. They develop solutions that affect the entire facility from optimizing
equipment to improving the bottom line.
Total solutions are possible because of John Zinks commitment to its human capital, intellectual property,
technical expertise, operational excellence and global focus.
As we look to the future, John Zink is positioned to anticipate global industrys economic and environmental
challenges. We will continue to satisfy customer needs with the expertise and resources to deliver
responsive, innovative thermal oxidation solutions.

Advanced Thermal
Oxidation Solutions
Thermal oxidation has proven to be a safe and effective method
for disposing of hazardous industrial wastes. Virtually all organic
compounds can be thermally oxidized with an assured level
of destruction.
The basic thermal oxidation system, shown in Figure A, consists
of a refractory-lined thermal oxidizer (TO) vessel, burner, stack,
and combustion controls. The oxygen for combustion comes either
from ambient air or is contained in the waste gas stream. Ambient
air may be naturally aspirated draft or forced in by a fan.

Figure A: Basic Thermal Oxidation

Clean Combustion. Clear Solutions.

INNOVATION
Because research, development and testing are vital components of
our mission to advance the art and science of combustion, John Zink
operates the largest, most comprehensive research and development
test center of its kind. Here, the next generation of ultra-low-emission
combustion and environmental systems is engineered and tested
at industrial scale to measure performance under a wide range of
operating conditions.

Thermal Oxidation Test Facility

Our thermal oxidation test facility comprises simulators of up to
seven feet in diameter and 30 feet in height. Here, we measure
the destruction and removal efficiency (DRE), heat-release rates,
chemical species and emissions of many different configurations
of thermal oxidizers.

Joh n Zi n k s T herm al Ox id iz er T est Faci li ty, Headquartered i n T ulsa, Ok la.

15

COMPLETE ENVIRONMENTAL SOLUTION

Configuration 4.4 consists of the following major components:

Two downfired thermal oxidizers for different gaseous and liquid systems containing
inorganic compounds forming solids.
Two watertube boilers equipped with bare tubes and soot blowers to handle solids in
the flue gas.
Two quench-venturi scrubbers to wash out the solids contained in the flue gas.
Two absorption towers to wash out the acid contained in the flue gas (two stage
Configuration 4.4

systems, one acidic and one caustic).

One common ID fan for both systems.
One common gas/gas heat exchanger
for both systems.
One common direct fired heater for
both systems.
One common SCR catalyst chamber for
both systems.
One common stack for both systems.

14

PRODUCTS OF COMBUSTION

* Sub A designates acceptable level.

IDEAL

REAL

CO2 H2O O2 N2 NOX A* SOX A*

CO2 H2O O2 N2 NOX * SOX *

FG

UHC CO

Ideally, the flue gas resulting from high-temperature oxidation of

hydrocarbons (HC) contains CO2, H2O, N2, O2 and some acceptable
levels of oxides of nitrogen (NOx) and oxides of sulfur (SOx). In reality,
the flue gas from a combustion process contains CO2, H2O, N2, O2 and
some concentration of carbon monoxide (CO), unburned hydrocarbons

1.0
.9
.8
.7
.6
.5
.4
.3
T6

.2

T5 t4 t3 t2 t1

i n c reas i n g tem perature

(UHC), NOx and SOx .

99.99

Environmental concerns require that the flue gas exiting a TO meet certain

99.9 99.8

99

98

95

90

80

70

60

50

40

Carb o n M o n o x i de Destru c t i o n E f fici enc y

emission requirements mandated by local and/or federal regulatory

authorities. Thus, it is important not only to destroy the organic portion of

combustion process. For example, SOx and Cl2/HCI produced by thermally

1.0
.9
.8
.7
.6

oxidizing wastes containing sulfontated or chlorinated components must

.5

be removed down-steam. Similarly, inorganic salts or ash contained in

.4

the waste completely, but also to limit the quantities of pollutants that are
produced by the combustion process or that cannot be destroyed by the

i n c reas i n g te mperature

the waste are unaffected by combustion and must be removed to meet

particulate emission requirements.

.3

Meeting CO and UHC regulations is accomplished by the correct

.2
T6

selection of TO residence time, operating temperature and

turbulence - the three Ts of combustion. Figure B is a plot of
residence time versus destruction efficiency for CO and HC at
various temperatures. It shows that CO and HC destruction efficiency
increases as residence time and operating temperature increases.

99.99

99.9 99.8

99

T5 t4 t3 t2
98

95

90

80

70

60

50

40

h ydr o c arb o n D estru c ti o n E f f i c ie ncy

Figure B: Destruction Efficiency

WASTE CATEGORIES

TABLE 1: INDUSTRIAL WASTE AND POLLUTANT CONTROL

Wastes are supplied to a disposal process in the form

Category

Industrial Waste

of either gas, liquid or solid, or a combination thereof.

Gas

Contaminated Air (Hydrocarbon)

Many industrial wastes can be systematically divided

Asphalt fumes

into the categories of gas, liquid, and gas+liquid.

Chloroform

Table 1 lists these categories in the left-hand column.

Hydrocarbon fumes

Pollutant

1.1, 1.2, 1.3, 1.4, 1.5

1.1, 1.2, 1.3, 1.4
Cl2/HCl

2.1, 2.2
1.1, 1.2, 1.3, 1.4

The second column lists a typical waste for each

HCN + H2

NOx

3.0, 3.1, 3.2

category, with the related waste pollutant(s) listed

H2S Vents

SOx

2.1, 2.2

in the third column. For example, a fume stream

Methyl Chloride

Cl2/HCl

2.1, 2.2

NH3

NOx

3.0, 3.1, 3.2

NOx

NOx

3.0, 3.1, 3.2, 3.3

Phosgene

Cl2/HCl

2.1, 2.2

that is predominantly air containing approximately

one percent (10,000 ppmV) HC is listed as a gas
waste, whereas a biosludge is listed as a liquid/
gas waste. Obviously, this second column does not
contain all known industrial wastes. However, it
sufficiently similar to one that is listed, allowing a
similar treatment process to be selected. The fourth
column is a list of process numbers that identify
processes applicable to dispose of waste listed in the
corresponding row.

Tail Gas

1.1, 1.2, 1.3, 1.4

Inert Vents (Hydrocarbon)

1.1, 1.2, 1.3, 1.4

VCM Vents

is likely that a waste that is not listed here will be

Liquid

Cl2/HCl

1.1, 1.2, 1.4

Air/Phthalic Anhydride

1.1, 1.2, 1.4

Air/Polyethylene

1.1, 1.2, 1.4

Propene/Al2O3

Particulate

4.1, 4.2, 4.3

Acrylonitrile

NOx

3.0, 3.1, 3.2

Carbon Tetrachloride

Cl2/HCl

2.1, 2.2

Chlorinated Amine

Cl2/HCl, NOx

4.0

Herbicides

Cl2/HCl

2.1, 2.2

Hexachlorobenzene

Cl2/HCl

2.1, 2.2

Hydrazine

NOx

3.0, 3.1, 3.2

H2O + Creosote

1.1, 1.2, 1.4

H2O + Iso-cynates

1.1, 1.2, 1.4

NOx

Organic Acids

Liquid/Gas

2.1, 2.2

Air/Maleic Anhydride

Nitrosamine

CONFIGURATION
Number

3.0
1.1, 1.2, 1.4

Pesticides

Cl2/HCl

2.1, 2.2

PCB

Cl2/HCl

2.1, 2.2

Pyridine

NOx

3.0, 3.1, 3.2

VCM

Cl2/HCl

2.1, 2.2

Solvent/Catalyst

Particulate

4.1, 4.2, 4.3

Biosludge

Particulate

4.1, 4.2, 4.3

Dye Solution

Particulate

4.1, 4.2, 4.3

Phosphorous Sludge

H3PO4

4.1

Salt Solution

Particulate

4.1, 4.2, 4.3

TPA/Catalyst

Particulate

4.1, 4.2, 4.3

Polypropylene/Catalyst

Particulate

4.1, 4.2, 4.3

Sodium Organic Salts

Particulate

4.1, 4.2, 4.3

Clean Combustion. Clear Solutions.

PARTICULATES

Configuration 4.2

Configuration 4.2 consists of the following:

Configuration 4.3 consists of the following major components:

A downfired thermal oxidizer.

A downfired thermal oxidizer.

A conditioning tower that, by direct contact with water, cools the flue

A conditioning tower fitted with a SaltMasterTM system that lowers

gas to either 600 F or 350 F, depending upon the dry particulate

the flue gas to below salt fusion temperature by direct contact with

removal system selected.

recycle flue gas.

An electrostatic precipitator (ESP) or a baghouse.

A heat-recovery boiler that produces steam by cooling the flue gas

to 350 F.

A vent stack.

Either an ESP or baghouse for particulate removal.

An unlined vent stack.
The SaltMaster system keeps the salt from building up in the bottom of the
conditioning chamber. Salt build-up can cause operating and maintenance
problems. Recycle gas is used for cooling to maximize heat recovery.
Configuration 4.3

13

PARTICULATES

n Particulates
The following three equipment examples
show the process configurations used
to dispose of either a gaseous or liquid
waste that produces flue gas containing
excessive amounts of particulate matter.

Configuration 4.1

Configuration 4.1 consists of the following equipment systems:

A downfired thermal oxidizer.
A quench section that cools the flue gas to
its saturation temperature by direct contact with water.
A wet scrubber that removes the particular matter (not shown).
A vent stack (not shown).
A major advantage of the wet scrubber is its ability to remove both
particulates and any corrosive gases (SO2, HCl) in a single operation.

12

Clean Combustion. Clear Solutions.

Gas or Liquid Waste

DISPOSAL PROCESSES
Four major process technology groups used to dispose of industrial wastes
are described by the following text and diagrams.

n Gas or Liquid Waste

The following five diagrams illustrate each of the process
configurations to dispose of either a gas or liquid waste that produces
a flue gas containing acceptable amounts of SOx and/or NOx.
Configuration 1.1 is simply a TO that is supplied with waste, fuel and
combustion air. Fuel is required when the heat content in the waste
is insufficient (endothermic) to produce an appropriate operating
temperature. An exothermic waste requires a cooling medium such as
excess air, steam, or water for temperature control.
Configuration 1.2 is
Configuration 1.1

the TO fitted with

a heat recovery
boiler. A boiler with
an economizer can
recover as much as
85 % of the heat
energy supplied to
the TO by both the
waste and the fuel.

Configuration 1.2

Gas or Liquid Waste

Configuration 1.3 shows a TO fitted with a gas-to-gas heat

exchanger. In the heat exchanger, the hot flue-gas from the
TO is used to heat the incoming waste gases. This method of
heat recovery can reduce the full consumption of the TO from
16.8 MMBtu/hr to 9 MMBtu/hr (based on 1600 F TO operating
temperature and waste gas preheated from 60 F to 800 F). (Refer
to Figure 1A for savings.)
Configuration 1.4 is a TO fitted with a gas-to-gas exchanger
and a heat recovery boiler. The heat exchanger heats incoming

Configuration 1.3

combustion air or waste gases, and the boiler further extracts the
heat available in the flue gas discharged from the exchanger. This

70

configuration offers flexibility in the amount of steam produced

60

Configuration 1.5 illustrates a catalytic oxidizer fitted with a gas-to-

50

gas exchanger. The heat exchanger preheats contaminated air that

is routed to a chamber containing catalyst material. The catalyst
causes oxidation of the HC to occur at much lower temperatures
than in a TO, thus greatly reducing the fuel usage. The HC content
of the air is generally limited to less than 0.75% because of the
temperature limits of the catalyst.

Fuel sav i n gs ( % )

versus fuel usage.

(Based on 5000 cfm of inert waste gas and 1600F operating temperature)

40
30
20
10
0
0

200

400

600

800

Waste pre h eat te m p ( F)

Figure 1A: Value of Recovered Flue Gas Heat

Configuration 1.4

Configuration 1.5

1000

1200

Clean Combustion. Clear Solutions.

The following comparisons illustrate the potential NOx reduction

Company has developed TANGENT Technology to yield ultra-

that could be achieved by using the TANGENT process compared to

low emissions without raising CO levels. Internal testing has

emission estimates from traditional commercial systems.

shown less than 1ppm NOx and CO emission levels using this

TANGENT Emission values were scaled from data obtained at the

John Zink test facility in Tulsa, Oklahoma during 2009.

new technology. These ultra-low levels can allow greater waste

processing capacities under existing permits. Reducing these NOx
levels to near zero may also result in NOx emissions credits.

Natural Gas Processing Off Gas

Off Gas
Composition

vol %

TANGENT Technology can reduce noise and vibration, may eliminate

CO2

96

the need of SCR or SNCR systems, and can eliminate the handling,

CH4

Figure 3B is the view of a TANGENT System in operation. Using

storage, or disposal of ammoniacal reagents such as aqueous

NH3 or Urea, as well as the associated regulatory burdens. In

Off Gas Flow (lb/hr)

211900
Traditional

TANGENT

addition, heat is more uniformly distributed, resulting in lower

NOx (ton/year)

21.6

1.7

thermal stress on the refractory and burner components, while

CO + UBH (ppmvd)

< 50

< 50

eliminating post-combustion NOx treatment equipment, and

Stack O2 (vol%)

greatly reducing the amount of plot space otherwise required

T.O. Temperature (F)

1550

1550

66

66

for similar NOx performance.

NOx reduction technologies

Configuration 3.3 is a view of the TANGENT system. John Zink

Fuel Firing Rate (MMBtu/hr)

Other potential applications for Tangent technology include:

Figure 3B

Direct Fired Air heaters < 2300 F.

Endothermic liquid waste thermal oxidizers.
Endothermic gaseous waste thermal oxidizers.
Sulfur plant tail gas.
Ethanol plant dryer off gas.

Configuration 3.3

TANGENT Technology U.S. Patent Pending.

11

NOx reduction technologies

Configuration 3.1 is a block diagram of a two-stage combustion process utilizing Selective NonCatalytic Reduction (SNCR) technology to reduce the amount of NOx formed in the thermal oxidizer. It
consists of the following components:
A thermal oxidizer in which a high-temperature oxidizing environment converts
the waste and fuel into H2O, CO2, CO, H2 and NOx.
An ammonia injection section.
A thermal oxidizer in which the ammonia reacts with the NOx to form H2O and N2.
A waste heat recovery boiler that produces steam while cooling the flue gas.
A vent stack.
Configuration 3.1

Model 3C :
TO with SNCR

Configuration 3.2 is a block diagram of a Selective Catalytic

Reduction (SCR) system downstream of a wet scrubber to
reduce the amount of NOx emitted into the atmosphere. It
consists of the following components:
Configuration 3.2

A demister vessel to dry the flue gas and prevent any

soluble salts from entering the catalyst bed.
A direct-fired flue-gas heater.
An ammonia injection section with a static mixer.
A catalyst bed.
A vent stack.
If a scrubber is not required to remove salts or Cl2 /HCL,
the flue gases can enter the ammonia injection section
directly after the quench section.

10

Clean Combustion. Clear Solutions.

Acid Gas Halogenated Systems

n Acid Gas Halogenated Systems

The following two diagrams show configurations of a process to
dispose of either a gas or liquid waste which produces flue gas
containing excessive amounts of SOx or HCl/Cl2.

100

flue gas to its saturation temperature by direct contact with water,

two adiabatic absorbers which remove inorganic acids and chlorine,
and a vent stack. Water is used in the first absorber to remove a
majority of the HCl from the flue gas. The residual HCl and virtually
all the incoming Cl2 leaves the absorber with the flue gas. A second
absorber with caustic is used when either the Cl2 or HCl in the flue gas
exiting the first absorber exceeds allowable levels. This occurs when
excessive Cl2 is formed in the TO (see Figure 2A for HCl/Cl2 equilibrium)
or when the first absorber is used to make reusable acid.

equ i l i bri um con sta n t = K p

Configuration 2.1 consists of a TO, a quench section which cools the

10

1.0
1000

1500

2000

T E M P E R AT U R E C
( P HCI ) 2 ( P O 2 ) 0 . 5
Kp =
( P H 2 O ) ( P OCI 2 )
R earra ng i ng g i v es:
( P CI 2 ) =

( P HCI ) 2 ( P O 2 ) 0 . 5
( P H 2O ) K p

Figure 2A: Equilibrium Constant vs. Temperature

Configuration 2.1

Acid Gas Halogenated Systems

Configuration 2.2 consists of a TO, a

heat recovery boiler which produces
steam by cooling the flue gas to
500 F /260 C, two absorbers,
and a vent stack. The first absorber
is fitted with a lower section
of ceramic packing which cools
the 500 F flue gas to saturation
temperature prior to its entry into
the acid absorption section. The
second absorber removes residual
HCl and CI2.
When the waste stream is highly
exothermic, a cooling medium such as
air, water or steam is added to the TO
to control the operating temperature
of the TO.

Configuration 2.2

Clean Combustion. Clear Solutions.

NOx reduction technologies

n NOx Reduction Technologies

The following 4 diagrams show the process configurations
of John Zinks NOx reduction technologies:
Configuration 3 is a block diagram of a three-stage
combustion process to dispose of either a gas or liquid
that, if oxidized in a single-stage combustion process,
would produce a flue gas containing excessive amounts
of NOx. It consists of the following components:
A reduction furnace in which a high-temperature
reducing (sub-stoichiometric) environment converts

Configuration 3: NOxidizer System

the fuel into H2, H2O, CO, and CO2 , and

the NOx present into N2.
A quench section that cools the flue gas to
approximately 1400 F by direct contact with a cool
recycle gas.
A ReOx furnace that converts the H2 to H2O and
the CO to CO2.
A heat recovery boiler that produces steam by
cooling the flue gas to 350 F.

Figure 3A

A vent stack.

NOx as a function of o 2
and furnace temperature

Recycle flue-gas-cooling in lieu of steam or water is

an integral part of this process and helps maximize
heat recovery.
The purpose of the cooling step between the reducing
stage and re-oxidation stage is to lower the TO
temperature. As shown in Figure 3A, a plot of NOx
concentration versus temperature, the amount of thermal
NOx produced is a function of the operating temperature
and the amount of excess oxygen present. For example,
when 2% excess O2 is present, an operating temperature
of 1600 F produces an equilibrium NOx value of 42 ppmv;
and 2000 F produces a NOx value of over 200 ppmv.
Thus, it is desirable to operate at the lowest practical
temperature. Another consideration is the required level of
destruction of the H2 and CO present, to meet air quality
regulations. The design becomes a trade-off between the
amount of H2 and CO allowed and the amount of NOx
allowed, in the final products of combustion.

w w w . j o h n z i n k . c o m
i n f o @ j o h n z i n k . c o m

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EUROPE
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John Zink
World Headquarters

John Zink Europe

Headquarters

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Headquarters

John Zink America LATINA

Headquarters

John Zink Company, LLC

11920 East Apache
Tulsa, Oklahoma 74116
UNITED STATES OF AMERICA

John Zink Int. Luxembourg S. r.l.

Zone Industrielle Riedgen
L-3401 Dudelange
LUXEMBOURG

n Tel: +1-918-234-1800

+1-800-421-9242
Fax: +1-918-234-2700

n Tel: +352-518991
Fax: +352-518611

John Zink Asia-Pacific,

a division of Koch Asia-Pacific, Inc.
7th Floor, KSS Gotanda Bldg.
21-8 Nishi-Gotanda 1-chome
Shinagawa-ku, Tokyo 141-8538
JAPAN

John Zink do Brasil,

a division of Koch Tecnologia
Qumica Ltda.
Rua Tanabi nr. 276
gua Branca
CEP, 05002 - 010 - So Paulo-SP
BRAZIL

For KEU brand product

information:
John Zink KEU GmbH
Hlser Strae 410
D-47803 Krefeld
GERMANY

n Tel: +81-3-5435-8551
Fax: +81-3-3491-3584
Other:
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n Tel: +55-11-3865-3571
Fax: +55-11-3871-0405
Other:
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