Nothing goes to waste in the oil and gas industry—even when they are vapors. A ‘Vapor Recovery Unit’ (VRU) emerges as a solution in this situation. Think of it like the business version: “Why throw it away when you can reuse it?” This amazing equipment catches the vapors from hydrocarbons like methane and propane, turning them into something useful and keeping the revenue flow predictable. But what is VRU, and why is it crucial in the oil and gas industry? Let’s simplify it. 

In this article, we will explore all the aspects of these modern systems and discover how they contribute to hydrocarbon recovery while operating sustainably. Let’s explore VRUs’ science and their role in recycling waste!

What is Vapor Recovery?

It is the sustainable process of removing hazardous vapor and toxic fluid contaminants from crude oil, natural gas, and other petroleum products. The primary purpose of vapor recovery is to enhance the purity of crude oil products and prevent the intense spread of toxic and hazardous pollutants in the air. At the same time, it saves money by reusing hydrocarbons for industry that would have gone to waste.

This process is also executed in chemical processing industries to recover undesirable vapors from storage units, maintaining their purity while making them safer for use and transport. Due to its positive perspective towards sustainability, several nations adhere to the compulsion to remove the vapors.  

Is Vapor Removal Mandatory?

Yes, contemplating the recent sustainable initiatives in the oil and gas industry, vapor recovery is mandatory. In several nations, Environmental Protection Agencies (EPA) have implemented vapor removal specifications. These are legally mandatory for all operators and producers involved in the processing and storage of petroleum, natural gas, and other petrochemical products.

The EPA mandates vapor removal to minimize harmful air emissions at natural gas processing plants, hydrocarbon storage facilities, and natural gas wells in the United States. It comes under the New Source Performance Standard 40 CFR, Part 60, Sub-part OOOO, commonly referred to as the ‘Quad O.’

These updated regulations demand operators eliminate at least 95% of vapors produced in hydrocarbon storage facilities. They also require oil and gas management to develop sustainable ways of reducing vapor pressure in tanks and minimizing excessive emissions. One of the most efficient and highly preferred systems for vapor removal is the Vapor Removal Unit (VRU).

What is a VRU (Vapor Recovery Unit)?

Vapor Recovery Units (VRUs) are highly preferred systems in the oil and gas industries that help eliminate and recover undesirable or surplus vapors in crude oil or distillate tanks. These systems enable operators to adhere to current emissions inhibitions while recovering lucrative hydrocarbon gas. 

The recovered vapors, which would have been flared or vented without the VRU, can now be used for fuel or revenue generation. The VRU systems are capable of recovering the following hydrocarbons & additives: 

When it comes to natural gas-producing wells and installations, VRUs accumulate the low-pressure vapors from multiple low-pressure systems. Once the vapors are gathered, VRU enhances their pressure to the required inlet for primary compressors or fuel usage. Additionally, VRUs are also utilized to recover the vent gas from distillate tanks or crude oil at storage facilities. VRU systems work as a transforming tool in achieving sustainable recovery practices. 

How Does a Vapor Recovery Unit Work?

Based on the power supply or energy source, VRUs are mechanically driven and powered by either an electric motor or a gas engine. The system functions in an approach similar to previous ‘Ideal Gas Law’-based compression systems. With numerous distinct configurations, VRU systems can be used across various types of oil and gas facilities and plants. 

A VRU functions by integrating the processes of adsorption and desorption. Below is the detailed working of VRU systems.

•  Adsorption: 

One of the vessels in the carbon adsorption system receives vapors from the vapor collection system. The activated carbon in the vessel captures the hydrocarbons from the vapors as they move through in order to purify the air. After cleaning, the air passes out through a vent stack.

• Desorption/Regeneration: 

The desorption process begins when one vessel reaches near capacity, indicating that the carbon is saturated along with hydrocarbons. To dry the carbon for reuse, the hydrocarbons are removed with the help of vacuum systems. This approach ensures the VRU’s extended, perpetual operation.

• Hydrocarbon Recovery: 

Following desorption, the carbon’s hydrocarbons are extracted and delivered to an absorber, usually a packed tower. To encourage absorption back into the liquid stream, the recovered hydrocarbons are added to the active liquid in this tower, which is often the product being loaded.

• Return to the Tank: 

To assure that the recovered hydrocarbons rejoin the product stream, they are subsequently put back into the tank from where they were extracted earlier.

This is how VRU functions sustainably. It efficiently recovers the vapors while offering a number of advantages. 

Benefits of a VRU System

Here are the benefits of the VRU system.

• Environmental Compliance

By implementing VRUs, oil and gas companies will demonstrate a commitment towards sustainability and avoid expensive fines and legal concerns. This ensures adherence to significant environmental regulations.

• Emission Reduction 

With the objective of maintaining a cleaner and healthier environment, vapor recovery units are paramount in reducing emissions of Volatile Organic Compounds (VOCs) as well as hazardous air pollutants.

• Enhanced Reputation 

By utilizing VRU, a company may demonstrate sustainability and environmental responsibility, which will captivate investors and environmentally aware consumers.

• Improved Security

VRUs capture and contain the harmful VOCs, making industrial practices safe for workers as well as the nearby community. 

• Cutdown in Expenses 

The enhanced recovery of valuable VOCs through VRUs can result in a cutdown in expenses. Such stored compounds can highly be reused or sold, converting waste into useful resources. 

• Operational Efficiency 

By installing VRUs correctly, industrial processes can be streamlined, leading to enhanced vapor management and related operational benefits.

• Optimization of Resources 

VRUs boost resource efficiency and reduce waste by recovering and reusing VOCs, which is part of sustainable practices and resource optimization.

• Reduced Carbon Footprint 

VRUs aid in combating climate change by lowering greenhouse gas emissions through the prevention of volatile organic compounds (VOCs).

• Efficiency of Energy

By recovering and utilizing the energy from vapors they have caught, VRUs can be designed to function more energy efficiently in industrial practices by all means. 

• Improvement in Air Quality 

VRUs lower the release of pollutants that are hazardous to human health and contribute to meeting air quality standards.

These are the major benefits of VRUs that underline VRU as a key component in promoting sustainability, operational efficiency, and reducing carbon footprints.

Wrapping Up

Vapor Recovery Units (VRUs) are one of the most important systems within the oil and gas industry. They capture and reuse vapors that would otherwise be wasted or released as toxic emissions. These effective alternatives not only help companies meet major environmental standards, but also minimize expenses, improve operational efficiency, and enhance safety. 

VRUs reduce pollutants and improve air quality while optimizing resources by transforming what was once waste into useful resources. Implementing VRUs highlights the positive approach of the oil and gas industry toward a more sustainable and responsible future.