Executive Summary

John Zink helped a major North American refinery resolve a long-standing operational issue in one of its key process heaters. Through a detailed pre-turnaround survey and onsite inventory assessment, it was noted the wrong burner tips were being used, causing chronic flame impingement and suboptimal heat transfer.

Following targeted tip replacements, the site achieved:

  • Increased process throughput
  • Improved energy efficiency
  • Notable reductions in CO₂ and NOx emissions
  • $4 Million annual economic impact

This project exemplifies how expert combustion support can deliver transformative results with minimal capital expenditure.

The Challenge

One of the site’s process heaters had been operating under firing restrictions for over a year due to flame impingement, confirmed by elevated tube skin temperature readings. To maintain safe operations, operators were forced to reduce firing and adjust pass flows, compromising overall heat transfer and limiting product recovery. Despite routine maintenance, the constraint persisted, prompting the site to engage John Zink ahead of a planned turnaround.

Our Approach

Thorough Pre-Turnaround Assessment

Our team conducted a deep-dive survey, including extensive time in the warehouse to validate stored burner parts against engineering drawings. While parts were well organized, many were outdated or incompatible (i.e. built for oil-firing) with the current burner configuration.

Tip Validation & Planning Support

We identified discrepancies between existing hardware and current design standards, enabling the site to order correct components before the turnaround and avoid costly downtime.

On-Site Inspection & Tip Replacement

During the outage, several burner tips were confirmed to be incorrect. Once the correct tips were installed, the heater saw immediate performance improvements, removing firing constraints and allowing operators to optimize heat input across all passes.

Measurable Outcomes

Following the correction:

  • Heater throughput improved with higher stable firing rates
  • Product yield increased by shifting more feed to higher-value streams
  • Excess oxygen levels dropped, improving combustion efficiency and NOx emissions
  • Overall fuel usage decreased, supporting sustainability targets (ie. GHG reductions)

The combined impact resulted in a substantial boost in operational and economic performance, including multimillion-dollar annualized value and a meaningful reduction in carbon intensity. The refinery was able to realize nearly $4 million in annual value from these improvements. With an ROI exceeding 10,000%, the project delivered exceptional returns on a minimal investment.

The Takeaway

This case reinforces the power of preparation and precision. By verifying components ahead of the turnaround and applying deep combustion expertise, John Zink helped unlock significant hidden value, without a major capital project.

Why John Zink?

John Zink, a Koch Engineered Solutions company, delivers industry-leading combustion and emissions control solutions. Backed by proven expertise and a century of innovation, we help our partners optimize performance, reduce emissions, and create lasting value.

Explore how John Zink’s proven expertise can support your goals.

.