Custom-Engineered Vapor Recovery Units: When One-Size-Fits-All Doesn’t Fit

38 minutes ago
3 min read

An off-the-shelf VRU is built for average conditions. A custom-engineered VRU is built for your conditions—and that’s where the performance difference shows.

Today’s operating environment demands a laser focus on maximizing operational efficiency, cost containment, and squeezing the most profit out of producing assets. Vapor recovery isn’t just important for regulatory compliance anymore, it is critical for achieving the full economic potential of your well site. Operators rely on Vapor Recovery Units (VRUs) to capture valuable hydrocarbons, reduce emissions, and stay compliant. But as it turns out, not all VRUs are created equal.

While off-the-shelf VRUs may work in limited, predictable applications, many facilities face operating conditions that demand a more tailored approach. This is where custom-engineered VRUs from Platinum Control deliver a clear and measurable advantage.

The Limitations of Off-the-Shelf VRUs

Off-the-shelf VRUs are in the Platinum Control product catalog, so this article is not to say that a custom-engineered unit is always better. Instead, it is a case of when a designed solution is the most advantageous.

Standard VRUs are designed to address a range of “average” conditions. They’re built for speed to market and lower upfront cost, but that simplicity can come at a price.

Common challenges with off-the-shelf VRUs include:

· Poor performance under fluctuating flow rates or pressures

· Limited ability to handle variable gas compositions

· Inefficiencies caused by over- or under-sizing

· Increased maintenance due to units not operating at peak efficiency

· Difficulty meeting site-specific regulatory or safety requirements

In real-world operations, where conditions are rarely static, these limitations can combine to result in lost product, higher emissions, excessive downtime, and frustrated operators.

Why Custom-Engineered VRUs Perform Better

Platinum Control designs custom-engineered VRUs around the actual operating conditions of each site, not theoretical averages. Every system is purpose-built to your specifications for optimizing performance, reliability, and compliance over the long term.

Key benefits include:

Optimized Performance Across Variable Conditions. Custom VRUs are engineered to handle changing flow rates, pressures, and gas compositions without sacrificing efficiency. This ensures consistent vapor capture even as production profiles evolve.
Right Sized from the Start for Maximum ROI. Instead of forcing your operation to adapt to a standard unit, a custom VRU is sized precisely for your throughput and operating envelope, reducing energy consumption and avoiding unnecessary capital spend.
Improved Emissions Control and Compliance. Custom designs incorporate site-specific regulatory and permitting requirements, helping operators meet emissions limits more reliably and with greater confidence, especially in regions with tightening oversight.
Increased Reliability and Reduced Downtime. By selecting components matched to the application, including compressors, controls, valves, and safety systems, custom VRUs experience fewer failures and longer service intervals.
Seamless Integration with Existing Infrastructure. Custom VRUs are designed to integrate smoothly with existing tanks, flares, control systems, and automation platforms, minimizing installation challenges and operational disruption.

The table below summarizes the primary differences between off-the-shelf and custom engineered VRUs.

When a Custom VRU Outperforms Off-the-Shelf Solutions

Custom-engineered VRUs consistently outperform standard units in scenarios having these variables:

Variable production rates common in unconventional fields with ongoing development and mature fields as production naturally declines
High-BTU or mixed gas streams that challenge standard compressor designs
Space-constrained facilities requiring compact or unconventional layouts
Facilities with intermittent operations, such as truck loading or batch processing
Sites with strict emissions limits where performance margins matter
Operations prioritizing long-term operating cost over lowest upfront price

In these scenarios, a custom engineered VRU can prove advantageous by delivering stable performance and measurable returns.

The Platinum Control Difference

Platinum Control brings deep engineering expertise and field experience to every VRU project. From initial evaluation and system design to commissioning and long-term support, their custom-engineered approach ensures each VRU is built to perform where it matters most: in the field, under real operating conditions.

Don’t Settle for Average Vapor Recovery! Contact Contact us today at sales@platinumcontrol.com or 432-695-4992 to discuss a custom-engineered Vapor Recovery Unit designed specifically for your facility – maximizing recovery, minimizing emissions, and delivering performance you can rely on.