For years, flaring—the sight of natural gas burning off a toil sites—has been a familiar part of oil and gas operations. It’s often used for regulation compliance, safety, and/or convenience, especially in places without the infrastructure to handle the gas. But as the world shifts toward sustainability, this practice is facing increasing criticism.
Good thing there’s a better way: vapor recovery.
Not only does it drastically cut down harmful emissions, but it also turns waste into revenue. Understanding the difference between flaring and vapor recovery—and why a vapor recovery system is the smarter option—is key to the future of oil and gas operations.
Flaring is essentially burning off natural gas and other volatile compounds (VOC) that come up during oil production. It used to be seen as an easy solution when there wasn’t a pipeline to handle the gas. But the downsides are becoming impossible to ignore.
For starters, it releases a lot of carbon dioxide (CO₂), a major contributor to climate change. And even when done "efficiently," some methane—a much more potent greenhouse gas—still escapes. The U.S. Environmental Protection Agency (EPA) estimates that methane is around 28 to 36 times more powerful than CO₂ over a 100-year period when it comes to trapping heat in the atmosphere. So even small leaks can have a big environmental impact.
It doesn’t stop there. Flaring also puts out other pollutants like nitrogen oxides (NOx), particulate matter, and VOCs, all of which affect air quality and public health. These emissions run counter to the increasing push for cleaner, more responsible energy production.
The U.S. Department of Energy confirms that flaring not only contributes to unnecessary emissions but also represents a loss of recoverable energy resources.
Vapor recovery flips the script. Instead of burning off gas, these systems capture, compress, and process the vapors—turning what would’ve been waste into something valuable.
It’s the process of collecting hydrocarbon vapors from oil and gas equipment—like storage tanks and separation equipment—that would otherwise be released into the atmosphere. Using vapor recovery units (VRUs)and compressors, those vapors are captured and reused or sold.
The EPA’s technical resource on vapor recovery units details how VRUs can recover up to 95% of emissions from crude oil storage tanks and other equipment.
The environmental case for vapor recovery is strong:
- Lower Emissions: Capturing methane and other gases means fewer greenhouse emissions. Companies like Flogistix report that electric VRUs produce zero emissions, and in 2023 alone, we avoided more than 14 million metric tons of CO₂ equivalent.
- Cleaner Air: Less flaring means fewer pollutants, which translates to healthier air for nearby communities.
- Regulatory Compliance: Environmental regulations are getting tighter. Vapor recovery helps companies stay compliant and avoid fines. Flogistix systems are designed to help meet these standards. The EPA’s methane emissions rule update reinforces the industry shift toward recovery solutions.
- Sustainability: It’s a tangible way for oil and gas producers to show they’re serious about protecting the environment and conserving resources.
Beyond the environmental perks, vapor recovery also makes a lot of business sense:
- Extra Revenue: Captured vapors—like methane, propane, and butane—can be sold at a premium. For example, in the Delaware Basin, vapor captured by VRUs fetched $19.35 per MCF compared to just $1.78 for regular natural gas.
- Waste Reduction: Instead of burning off usable resources, companies can turn those vapors into profit.
- Lower Costs: While there’s an upfront investment, many operators see long-term savings. Flogistix’s Multi-Stream™ solution allows one VRU to handle multiple vapor sources, which in the DJ Basin saved customers more than $1.4 million per year. One operator even cut lease operating expenses in half.
- Better ROI: The boost in revenue and efficiency leads to faster project paybacks. Flogistix even helps customers analyze the economics to make the case for recovery systems.
The EPA’s Lessons Learned document outlines real-world economic and environmental benefits of vapor recovery adoption across U.S. operations.
A typical vapor recovery system setup includes several key components:
- Intake: Where gas enters the system.
- Scrubber: Removes liquids to protect the compressor—Flogistix scrubbers use an internal Blowcase design.
- Compressor: The core of the system that compresses gas for processing or sale. Flogistix offers various models for different site needs.
- Compressor Oil: Keeps everything sealed, cool, and lubricated.
- Driver: Usually electric or gas-powered, this runs the compressor.
- Discharge Scrubber & Cooler: Cleans and cools the compressed gas.
- Recycle: Keeps the unit operating efficiently, even when gas flow is low.
- Discharge: Sends the processed gas out for use or sale.
Flogistix is at the forefront of vapor recovery and production optimization. Our VRUs, including the FX and VRX Series, are built for everything from low-producing wells to full-scale production optimization. We offer both rental and purchase options, with ongoing support and remote monitoring.
What sets us apart? Our Logix PLC control panel allows for advanced monitoring, real-time alerts, and emissions tracking. Plus, our patented Multi-Stream™ technology means one compressor can handle multiple sources—saving space, time, and money.
Flaring may have been a necessary evil in the past, but now there's a clear alternative. Vapor recovery protects the environment, boosts profits, and aligns with where the industry—and the world—is heading.
For oil and gas producers looking to stay competitive and responsible, vapor recovery isn’t just a good idea—it’s the way forward. By investing in the right VRU and working with experienced partners like Flogistix, companies can cut emissions, increase revenue, and build a more sustainable future.
Got questions? Discover why VRUs matter and how they can help your operations in the FAQs.
The Importance of Vapor Recovery
Vapor Recovery Units Effectiveness
Is a Vapor Recovery Unit (VRU) Just a Compressor?
Overcoming Challenges in VRU Implementation
Regulation Benefits of Vapor Recovery
Revenue Benefits of Vapor Recovery
The Emissions Benefits of VRUs
How Does a Vapor Recovery Unit Work?