Vapor Recovery Units: Improving Sustainability in Oil & Gas

The filling of oil and gas storage tanks results in vapors being released into the atmosphere. The reaction of these organic compounds (VOCs) with nitrogen oxides in sunlight leads to the formation of ground-level ozone. This substance is highly toxic to humans and also contributes to global warming. Thankfully, vapor recovery units can help eliminate these explosive and toxic fumes.

In this blog, we cover everything you need to know about vapor recovery units. We cover the basics, working, and key components of the units. We also shed light on the key factors propelling the vapor recovery units market expansion. Let’s dive in!

What Is a Vapor Recovery Unit (VRU)?

A VRU is a designed setup that removes unwanted vapors present in distillate tanks or crude oil. It also helps recover valuable hydrocarbons that can be sold or reused. Using a VRU, operators can reduce emissions and meet the required emission standards. VRUs are mechanically driven. The power source for these units may be a gas engine or an electric motor. VRUs are available in several forms to meet the diverse vapor recovery requirements of gas tanks and oil storage.

What Are the Main VRU Components?

A typical VRU consists of four key components. Below, we’ve explained them in detail:

Gas Compressor: There are various types of vapor recovery compressor packages available for vapor removal. Commonly used gas compressor types include rotary sliding vane, flooded rotary screw, and gas compressors. In addition to these, other air compressor models that are based on the principle of positive displacement can be used.

Scrubber: The scrubber is a device intended for removing fluid impurities from the flow stream of natural gas. They play a key role in VRUs to deal with vapors in distillate tanks or crude oil that have high BTU vent gas.

Variable Frequency Drives (VFDs): VFDs are electromechanical driver systems. They are responsible for adjusting the compressor speed based on the gas flow rate into the VRU.

Switching Device: The switching mechanism has the function of detecting pressure changes in the tanks and activating the compressor. It automatically starts and stops operations based on the pressure conditions inside the tank.

How Does a VRU Work?

Now that you know the key components of a VRU, let’s take a look at how it works. As mentioned earlier, the primary function of a VRU is to remove vapors that accumulate within sealed hydrocarbon tanks. This is achieved through the compression and suction of the gas.

The vapor recovery process involves several steps. First, the rotary screw gas compressor sucks the liquid molecules and transfers them to the scrubber. The scrubber then removes the debris and water vapors. Any unwanted fluids from the tank are also removed. After this, the recovered vapors are pumped into gas lines. Here, the trapped liquids make their way into the pipelines.

Why Are VRUs Being Increasingly Adopted?

Our latest vapor recovery units market assessment reveals the market to witness sustained growth. The market was valued at USD 1,524.11 million in 2024. It is expected to grow at a CAGR of 2.41% between 2025 and 2034.

Governments and regulatory authorities globally are placing increased pressure on industries to reduce VOC emissions. These regulations often require industries to install emission control technologies, including VRUs. Additionally, growing emphasis on improving operational performance and reducing costs is fueling the vapor recovery units market expansion.

What Are the Benefits of Using VRUs?

There are several benefits associated with the use of VRUs. Some of them are:

Cost Savings: VRUs enable vapors to be utilized that would otherwise be vented. These units can also help maximize profits by returning the recovered vapors to the production line for sale.

Reduced Back Pressure: VRUs address the issue of back pressure. They do that by compressing the gas taken from the casing and channeling it back into the production line.

Lower Fire Risks: The collection of combustible vapors from tanks helps reduce fire risks. VRUs also ensure the large majority stays within the system.

Easy Operations and Maintenance: VRU is an advanced technology that’s relatively simple to operate. Additionally, the maintenance requirements of VRUs are low.

What Is the Environmental Impact of Using VRUs?

Below, we’ve explained how the use of VRUs impacts the environment:

Reduced Health and Environmental Risks: Carcinogenic gases present in tanks may pose significant health concerns. VRUs collect these gases and help companies comply with regulations. Research suggests that VRUs can capture higher levels of VOCs as well as methane.

Improved Social and Environmental Responsibility: VRUs eliminate venting and reduce the emissions of dangerous pollutants by a significant amount. Their use demonstrates a commitment to environmental protection and social responsibility.

How Is AI Transforming the Vapor Recovery Units Market?

Artificial intelligence (AI) is improving both the design and operations of VRUs. AI-powered monitoring systems help reduce downtime and extend VRU lifespan. They do so by detecting early signs of equipment failure. The ability of AI algorithms to adjust operations in real time for maximum hydrocarbon capture helps improve vapor recovery efficiency. Emission detection and reporting by AI ensures companies meet stringent environmental regulations. Furthermore, AI-powered industrial automation and control systems help lower operational and maintenance costs by reducing manual intervention.

To Sum It Up

Increased awareness about environmental sustainability and climate change has made capturing toxic vapors a key priority. This is true for both governments globally and oil & gas producers. The ability of VRUs to remove harmful particles and control air quality around processing plants makes them uniquely suited for vapor recovery. The vapor recovery units market demand is only expected to increase in the years to come.