Proven Techniques for Boosting Production Facility Profitability
Today’s oil and gas operators have access to a wide array of tools for enhancing the efficiency and profitability of their production facilities. Yet, many operators still leave untapped opportunities on the table—especially when it comes to maximizing the capture and value of the entire production stream.
For operators looking to drive higher profits and streamline operations, a sharper focus on capturing every molecule of value can deliver powerful results. In this article, we explore three proven strategies that forward-thinking producers are using to unlock hidden profits, slash emissions, and boost facility efficiency — all by leveraging the transformative capabilities of EcoVapor technology.
Example 1 – Full Vapor Capture for Increasing Gas and Liquids Production
A leading operator partnered with EcoVapor to evaluate the efficiency, effectiveness, and economic impact of advanced vapor recovery technologies. A production pad with two horizontal wells was selected as the test site for a head-to-head comparison between EcoVapor’s ZerO2™ solution and a traditional vapor recovery tower (VRT).
In the base case, the pad was operated using only a VRT before the tanks. The produced crude oil was stored in production tanks. Any tank vapor gas not meeting pipeline specification for oxygen content was flared.
In the test case, the VRT was replaced with a vapor recovery unit (VRU) and an EcoVapor ZerO2 E300 oxygen removal unit. In this site configuration, the VRU pulled the tank vapor from the storage tanks where it was routed to the ZerO2 for oxygen removal to meet pipeline specification.
The site was operated continuously for 77 days in both scenarios.
The table below summarizes the results of the test as reported by the customer.
| 2x Horizontal Well Pad | VRT (partial capture) | Tank Capture (full capture) | Improvement (%change) |
| Days operated | 77 | 77 | Same |
| Liquids production (boe/d) | 1,091 | 1,125 | + 3% |
| Recovered gas (mscf/d) | 137 | 188 | + 37% |
| Capture efficiency | 7% | 98% | + 27% |
| Gas value (BTU/scf) | 2,104 | 2,665 | + 27% |
The customer determined the NPV of full vapor capture using ZerO2 was two times higher than that of partial capture using the VRT. By capturing and selling more BTU-rich tank vapor gas, typically the most valuable gas stream on a well site, the operator realized increases in liquids and gas production by 3% and 37%, respectively.
A notable side benefit was a 66% reduction in VOC, NOX, and GHG emissions compared to the VRT, which resulted in pad emissions being consistently below permitted limits.
Benefits of ZerO2 vs. VRT:
- Improved profitability and return on investment through additional liquids production and incremental vapor gas sales.
- Substantial reductions in emissions of VOC.
- Reduction / elimination of flaring and generation of NOX.
- Enhanced wellsite safety profile.
- De-risked the production sites, both environmentally and through flow assurance.
Example 2 – Monetizing Brownfield Gas Capture
An operator in the Permian Basin opted for the EcoVapor ZerO2™ oxygen removal system to treat rich tank vapor gas at multiple well site locations to ensure oxygen levels met pipeline specifications for direct sale, instead of resorting to blending or flaring the off-spec vapor.
Importantly, the operator installed a dedicated custody transfer meter for the recovered gas stream, enabling precise measurement of both volume and gas composition, ensuring full capture of the value from heavy hydrocarbons such as propane, butane, pentane, and hexane+ present in the tank vapor.
The ZerO2 was instrumental in using this dedicated meter, as continuous compliance with pipeline specifications was essential.
The result was improved profits of brownfield sites by capturing BTU-rich tank vapor and selling it at a premium price, elimination of tank flaring, and improved operational efficiency by commingling tank vapor streams into a centralized oxygen treating location.
The operator claimed that they were generating more profits from capturing and selling the valuable tank vapor collected from multiple locations than they were from their conventional gas production.
Example 3 – Reducing Operating Costs of Tankless Production Facilities
Maintaining surge vessel pressure is a critical factor for maximizing efficiency and uptime of tankless production facilities. Traditionally, operators use Vapor Recovery Units (VRUs) to maintain constant surge vessel pressure, however, in many cases a VRU is over-engineered and expensive for this application when compared to alternatives.
The EcoVapor EcoForce™ is a continuously operating, variable-speed blower that helps optimize the efficiency and profitability of your tankless production facilities.
The three major benefits of the EcoForce™ system include:
- Maintain Vessel Pressure. EcoForce™ units automatically adjust their speed to maintain constant surge vessel pressure, minimizing the potential for wasting valuable product gas.
- 100% Vapor Recovery. Effective recovery of flash gas from surge vessels, overflow tanks, and produced water tanks, directing it to the sales line for maximum value. After separation, crude oil and condensate are routed to a surge vessel, ensuring a steady flow to the LACT meter and sales pipeline. Surge vessels or tanks also serve as emergency storage during unexpected process upsets or pipeline shutdowns. While flash gas is not stored for long, it continuously forms and accumulates. The EcoForce™ system efficiently recovers these high-value vapors, turning potential waste into profits.
- Boost Flare Performance. Alternatively, EcoForce™ systems can boost flare line pressure to improve the efficiency and performance of your flares and enclosed combustors.
The EcoForce system delivers all these benefits at a lower operating cost than most VRUs. EcoForce™ can be designed into new facilities as well as easily retrofitted into existing facilities.
READ MORE: EcoVapor Vapor Recovery System Product Page
EcoVapor Solutions for Unlocking Efficiency and Profitability
Whether your operations utilize tanks or tankless production systems, EcoVapor technology can help you capture the full value of your production stream to generate incremental profits and simultaneously reduce emissions.
Additionally, our product lines offer a full range of capacities, delivering a true life-of-well solution. As production naturally declines, we can adjust treating capacity and operating costs to match your evolving needs.
Contact us today to learn how we can help you maximize the value of your operations and minimize emissions by converting waste streams into revenue.
Contact
Joe Hedges
Director of Sales
EcoVapor Recovery Systems, a DNOW Company
7402 N. Elderidge Parkway, Houston, Texas 77041 E: joe.hedges@dnow.com
O: 844-NOFLARE (844-663-5273)
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