Vapor Recovery System Alternative

Patent Pending

VApOR ReCOVeRy
has not been economical,
effective, efficient and reliable until

NOW.

Consider, for a moment, the benefits of a vapor recovery system that is truly effective
and mechanically reliable. Who wins?

The answer is EVERYBODY WINS!

Oil and gas production revenues increase
Mineral rights owners royalties increase
On-site personnel benefit from a safer working environment
Environmental interests attain their goal of a cleaner environment
The public benefits from additional energy availability and cleaner air
The state and federal governments profit as the severance tax base expands

VRSA

Increase $$$

Zero CO2 emissions from Flaring

By capturing all hydrocarbon vapors, VRSA eliminates flaring and reduces CO2 emissions to
ZERO while adding $$$ to the bottom line. Flaring wastes revenue and increases pollution.

ThE PROblEM
Rich vapors (2000 to 3500 bTU per scf) vented
from atmospheric storage tanks contain VOCs, bTEX
and other compounds that damage the environment.
Economical, reliable and efficient vapor recovery has long
been an elusive goal of oil and gas production companies.
Compressor mechanical failures, oxygen contamination
of recovered vapors and tank pressure regulation problems
have all contributed to the seemingly insurmountable
mechanical and operational problems that have plagued
conventional vapor recovery operations.

Standard vapor recovery practices create a Win-lose

scenario where economic, operational and environmental
interests compete. The usual methods may be cost
effective where large recovery volumes offset the high
maintenance and operation costs; however, on the vast
majority of sites, the equipment is too operational and
maintenance intensive to make economic sense. Even
where conventional vapor recovery systems are in place,
vapors are often vented or flared at the site because of
the cost and annoyance of frequent maintenance and
operation downtime.

A Winning SOlUTiOn
EnginEEREd COnCEPTS

VApOR RECOVERy SySTEM AlTERnATiVE (VRSA)

Engineered Concepts new ideas for processing captured
tank vapors result in an economical, reliable system that
performs even where the operating and maintenance
problems of traditional vapor recovery systems outweigh
the environmental and economic benefits.
VRSA operates in any weather condition and insures a
quick return on investment maximizing recovery and
minimizing downtime - by monitoring and controlling
process, tank and compressor parameters.

The VRSA provides a quick

return on your investment even
in hostile environments

ThE PERfECT SOlUTiOn FOR

liqUid SlUgging APPliCATiOnS

VRSA is particularly effective in recovering and
processing vapors from tanks connected to wells
operating on a plunger lift or at sites that process
liquids from a slug receiver. for plunger lift well
applications, liquid slugs arriving with the plunger

are contained and processed using the most efficient

compressor operating speed to capture all the vapors.
no longer is there any reason to vent the tank because
a large volume of vapor released from a liquid slug
overloads the compressor.

A SElf COnTAinEd

lOW MAinTEnAnCE SOlUTiOn

VRSA allows oil and gas producers to be environmentally
responsible while optimizing their production with no
onsite supervision and minimal maintenance. Completely
self-contained models of the VRSA are available for sites
with and without electricity. Push button start simplicity
and SCAdA capability make the VRSA simple to

operate and monitor. Process operations are automatically

monitored by a PlC that requires no operator interface.
Simple maintenance every 750 hours requires minimal
downtime. On locations equipped with flares, any vapors
produced during downtime are automatically routed
to the flare.

VOCs, BTEX and other environment damaging compounds

can now be captured at a profit to the operator
4

CASe 1
Servicing four wells with common tank battery
Continuous operation
Recovery = 48 Mscfd @ 1704 btu/scf from 72 bbl of oil
Increased Revenues = $209,000 per year
ROI = 181% (6.6 month payback)
Flare CO2 eliminated = 1925 tons per year

CASe 2
Servicing six wells with common tank battery
Plunger lift operations
Recovery = 28 Mscfd @ 1796 btu/scf from 70 bbl of oil
Increased Revenues = $ 128,500 per year
ROI = 109% (10.7 month payback)
Flare CO2 eliminated = 1193 tons per year

CASE 3
Servicing six wells with common tank battery
Continuous operation
Recovery = 43 Mscfd @ 1815 btu/scf from 71 bbl of oil
Increased Revenues = $ 199,400 per year
ROI = 172% (6.9 month payback)
Flare CO2 eliminated = 1855 tons per year

CASE 4
Servicing eight wells with common tank battery
Continuous operation
Recovery = 45 Mscfd @ 1793 btu/scf from 67 bbl of oil
Increased Revenues = $ 206,200 per year
ROI = 177% (6.7 month payback)
Flare CO2 eliminated = 1914 tons per year

CASE 5
Servicing six wells with common tank battery
Continuous operation
Recovery = 95 Mscfd @ 1730 btu/scf from 198 bbl of oil
Increased Revenues = $ 420,000 per year
ROI = 289% (4.1 month payback)
Flare CO2 eliminated = 3877 tons per year

CASE 6
Servicing 30 wells with common tank battery
Continuous operation
Recovery = 65 Mscfd @ 1690 btu/scf from 180 bbl of oil
Increased Revenues = $280,700 per year
ROI = 193% (6.2 month payback)
Flare CO2 eliminated = 2582 tons per year

VRSA SOlVES COnVEnTiOnAl

VAPOR RECOVERy PROblEMS

Problem: Compressed rich hydrocarbon vapors in addition to emitting unburned hydrocarbons, flares
condense and dilute the compressor lube oil resulting in increase the CO2 emissions at the site while wasting the
energy contained in the vapors.
premature connecting rod failure.
VRSA captures all hydrocarbon vapors from the tank,
so that vapors are profitably utilized rather than wasted
at the flare. For most new locations not equipped with a
flare, the VRSAs demonstrated reliability will preclude
the need to install a flare under current regulatory
requirements.

VRSA protects the compressor by using an eductor to

capture and compress the rich vapors to about 25 psig
prior to introducing them to the mechanical compressor.
The non-mechanical eductor eliminates one mechanical
compression stage and the need for a cooler in the process.
Any liquids condensed in the eductor compression stage
do not affect the eductor. The VRSA further prevents
condensation in the compressor by controlling vapor
temperature and/or composition in each mechanical
stage of compression.

Problem: When plunger lift systems restart, high vapor

volumes released from the instantaneous slug of liquids
may exceed the VRU compressors capacity resulting in
venting of the vapor into the atmosphere or to a flare.

Problem: Constant stopping and starting of conventional The VRSA features a slug-containment vessel that controls

vapor recovery units (VRU) increase compressor and

the release of vapors to match the compression capacity.
engine maintenance costs. Cold weather starts are especially
difficult and create wear on mechanical equipment that often Problem: Under some operating conditions, liquids that
are returned to the tank from the compressor aftercoolers
results in lost production.
can cause a runaway recycle effect resulting in higher
The VRSA engine and compressor run continuously
compression loads and / or atmospheric emissions.
and load free during low vapor production cycles. Cold
starting is eliminated and the engine and compressor VRSA eliminates any potential of a runaway recycle by
remain warm as the VRSA circulates gas from the emis- precise control of the process temperatures and pressures.
sions separator through the compressor and back to the
emissions separator. Also, the VRSA controls the tank
pressure thus eliminating the possibility of tank collapse or oxygen ingress due to vacuum.

Problem: Tank unloading, non-sealing thief hatches

and opening of thief hatches are sources for oxygen

contamination on conventional VRUs. Also large volumes
of hydrocarbon vapors are emitted to the atmosphere
Problem: Stock tanks are often located far from the VRU. while the thief hatches are open. These emissions cannot
buried VRU suction lines accumulate condensed liquids be routed to a flare.
that can prevent vapor from reaching the compressor and
The VRSA Process, when used in conjunction with
can damage or destroy the first stage of the mechanical
other Engineered Concepts products and industry
compressor. To remove the liquids, gas is often used to blow
accepted practices, precludes the need to open the thief
the accumulated liquids into a pit. This practice wastes the
hatch when gauging or unloading the tank. The VRSA
gas and liquids and is a source for pollution.
Process thus provides the means to eliminate a source of
A VRSA equipped with a passive pumping system pumps oxygen contamination of the recovered gas stream and
the condensed liquids from the lines to the emissions a source of hydrocarbon emissions to the atmosphere.
separator where they are returned to storage.

Economical and reliable

vapor emissions recovery
regardless of your production
rate or well location.

Problem: flares incinerate valuable hydrocarbon

vapors that are produced from the tank. These vapors
are not completely burned as most flares are not designed
to properly mix air with the vapors prior to ignition.

VApOR ReCOVeRy

SySTEM AlTERnATiVE
1. Slug Containment Vessel - controls release of liquids to
the tank to match the compression capacity.

6. Compressor with Variable Speed Driver - the type of

compressor and the number of stages is dependent on
the specific application.

2. 3 Phase Heated Low Pressure Treating Separator processes paraffinic oils, provides heat for cold weather 7. Positive Displacement Pump - supplies power for the
operations and drives off some light ends before they
eductor and first stage of compression.
enter the tank.
8. PLC, Transducers and Pressure Regulation Equipment 3. Automatic Vapor Temperature Control - optimizes
controls the rate of hydrocarbon liquid processing,
compressor operations by keeping vapor temperatures to
controls engine and compressor speed, controls tank
each compression stage within the operating envelope.
and process pressures and, if the site is so equipped,
automatically controls the flare.
4. Emissions Separator - separates captured vapors.
9. Automatic Switching to Flare - on locations equipped
5. Eductor - eliminates one mechanical compression stage
with flares, any vapors produced during downtime or
and the need for a cooler by capturing and compressing
maintenance are automatically routed to the flare.
tank vapors.
Components described may or may not be necessary for all applications.

VAPOR RECOVERY SYSTEM ALTERNATIVE (VRSA) FLOW DIAGRAM

SET AT 18 PSIG
RECOVERED GAS TO SALES

COMPRESSOR SUCTION PRESSURE MAINTENANCE

PRESSURE
CONTROL
VALVE

LIQUIDS FROM
PRODUCTION UNIT

RECOVERED VAPORS

GAS COMPRESSOR.
OPERATING PRESSURE,
100 TO 350 PSIG

FLASH GAS
PRESSURE TRANSDUCER
LOW SET POINT 2.5 OZ
HIGH SET POINT 12 OZ

ELECTRO-PNEUMATIC
TRANSDUCER

2 PHASE SLUG
CONTAINMENT
SEPARATOR

ELECTRO-PNEUMATIC
TRANSDUCER

SET AT 4.5 OZ

PNEUMATIC LEVEL
CONTROL

SET TO MAINTAIN
6 OZ TANK
PRESSURE

TANK BACK
PRESSURE VALVE

8
FLASH GAS

PLC

3
2

3 PHASE HEATED
LOW PRESSURE
TREATING SEPARATOR

PNEUMATIC
ELECTRICAL

TO ENGINE SPEED CONTROL.

SPEED REGULATED BY
PRESSURE TRANSDUCERS

PRESSURE
CONTROL
VALVE

TANK VAPORS
DRIP
VESSEL

PRESSURE TRANSDUCER.
LOW SET POINT 18 PSIG
HIGH SET POINT 30 PSIG

VRSA VAPOR EDUCTOR

THIEF HATCH
SET AT 12 OZ

CONDENSATE

NATURAL GAS
CONDENSATE

CAPTURED
TANK
VAPORS

SET AT 3.5 OZ

GLYCOL

CIRCULATION PUMP
ATMOSPHERIC
STORAGE TANK

VAPORS
GLYCOL

EMISSIONS
SEPARATOR

www.engineeredconcepts.com

1-877-342-2717

about engineered ConCepts

Engineered Concepts creates environment-friendly, revenue-generating opportunities
for the oil and gas industry by capturing emissions through application of innovative
ideas for efficient, reliable equipment that attains the maximum environmental and
economic impact.

COMBINE the VRSA with these innovative products from Engineered

Concepts to attain a TOTALLY HYDROCARBON EMISSIONS FREE
location at HALF the operating cost.

automatiC seCondary air

Control system - asaC
The Automatic Secondary Air Control System (ASAC) is field proven to reduce fuel costs
and CO2 emissions by as much as 50% by controlling the air-fuel ratio in the firetube
to achieve optimal combustion efficiency. The ASAC system can be supplied for new
natural gas fired processing equipment or easily retrofitted to existing equipment.

Quantum leap natural gas

dehydration teChnology - Qld
The quantum leap natural gas dehydration Technology (qld) is the first TEg
dehydration process verified through the EPA Environmental Technology Verification
Program to capture and convert virtually all hydrocarbon emissions to salable
product while also greatly reducing carbon dioxide emissions. qld substantially
reduces total operating expenses and maintenance while improving operator safety
and eliminating the odors associated with TEg dehydration.