Captured gas
500k
m³/year
Approximate natural gas capture during the 12-month period instead of combusting the gas.
Replace vapor combustion with revenue-generating vapor recovery.
Fluidstream VaporCommander™ captured tank vapors instead of burning them, delivering more than C$46,000/year in estimated natural gas value and reliable 12-month field operation.
A producer with operations in Southern Alberta, Canada needed a cost-effective alternative to vapor combustor units that could handle variable gas flow, higher discharge pressure, sudden flow interruptions, and harsh seasonal operation. VaporCommander™ provided active vapor recovery, reduced emissions, and operated through Alberta winter conditions without cold-weather stoppages, failures, or maintenance issues.
Performance snapshot
Combustion avoided. Gas captured. Reliability maintained.
During the 12-month operating period, VaporCommander™ captured approximately 500,000 m³ of natural gas that would otherwise have been burned through a vapor combustor unit. Based on the project assumptions, captured gas created more than C$46,000/year in economic benefit, with additional potential carbon-related value subject to current regulatory eligibility and project-specific review.
Economic value
C$46k+
per year
Estimated annual gas value based on the assumptions used in the project case study.
Reliability
0
cold-weather issues
No stoppages, failures, or maintenance issues related to cold weather during the operating period.
Flow range
1,800
m³/day gas
Gas flow ranged from almost no flow to approximately 1,800 m³/day.
Background and challenge
Vapor combustors control venting, but they also burn value.
The operator had a growing number of oil storage tanks producing natural gas from stored oil. To comply with gas venting limits, the gas could not simply be vented. Historically, vapor combustor units provided a relatively simple way to destroy the gas stream, but combustion converts usable natural gas into emissions and removes the opportunity to capture revenue from the produced gas.
The operator needed more than a combustion device. The application required a system that could handle widely varying gas flow, high discharge pressure, sudden stops in gas flow, and both cold and hot weather conditions. The system also needed to capture gas for additional revenue instead of converting the stream into CO₂ through combustion.
Although conventional VRUs were considered, standard systems did not fully address the operating envelope. Conventional VRUs can be expensive, may require additional conditioning equipment, and can be limited where discharge pressures exceed typical compressor-suction assumptions.
01
Venting limits
Tank vapors had to be controlled to meet regulatory gas venting requirements.
02
Combustion tradeoff
VCUs can reduce venting, but they burn natural gas and create greenhouse gas emissions.
03
Variable gas flow
The gas stream ranged from almost no flow to approximately 1,800 m³/day.
04
Winter reliability
The solution had to operate in Southern Alberta, Canada winters that can drop below -40°C.
Why VCUs are limited
Combustors solve disposal, not recovery.
Vapor combustor units can be cost-effective and simple, but their basic function is destruction rather than recovery. They do not actively draw down tank pressure, they do not create a gas revenue stream, and they do not eliminate the emissions profile associated with burning natural gas.
01
Gas value is lost.
A VCU burns gas that could otherwise be captured and monetized. In this case, replacing combustion with recovery created more than C$46,000/year in estimated gas value.
02
Emissions continue.
Combustion reduces venting but releases CO₂. The project analysis estimated 1,196 tonnes CO₂e/year of avoided emissions by capturing gas instead of burning it.
03
Passive operation limits control.
The VCU was a passive system. VaporCommander™ actively draws down and maintains a user-defined inlet pressure, giving operators more control over tank vapor management.
Fluidstream solution
VaporCommander™ as a VCU replacement.
Fluidstream’s patented VaporCommander™ was installed at an oil battery in Southern Alberta, Canada in March 2020. It was selected because it could handle the producer’s variable operating parameters while capturing gas for reuse or sale instead of burning it through a combustor.
The unit’s multiphase capability allowed it to handle gas streams that may contain liquids without relying on a conventional dry-gas assumption. The system also offered autonomous operation, including manual, remote, and automatic restart based on user-defined time lag and motor-load ramp-up.
What changed
Gas capture replaced gas destruction.
During the 12-month operating period, VaporCommander™ captured approximately 500,000 m³ of natural gas. Based on the pricing assumptions used in the project case study, that captured gas created an estimated economic benefit of more than C$46,000/year.
The case study also described potential carbon-tax savings if a carbon tax were applied to combustion emissions. Carbon pricing, carbon-credit eligibility, and regulatory treatment should be reviewed under current rules for each project.
Autonomous operation
Self-regulating pressure control across variable gas flow.
The gas flow ranged from almost no flow to approximately 1,800 m³/day. VaporCommander™ used patented software controls and operating methodology to monitor sensors and operating parameters, adjust speed, and maintain target inlet pressure. The unit could slow to less than 0.01 strokes per minute, which eliminated the need for mechanical recirculatory devices in this application.
01
Wide flow turndown.
The system managed gas flow from near-zero conditions to high vapor rates, supporting stable tank vapor control across changing production conditions.
02
Target inlet pressure.
The unit adjusted speed to maintain the operator’s desired inlet and discharge pressure setpoints.
03
Low intervention.
Manual, remote, and automatic restart logic helped maintain uptime even during upset or low-flow conditions.
According to the operator’s facilities engineer, the ability to adjust operating parameters and allow the unit to self-regulate was valuable because it reduced the need for ongoing intervention once the desired setpoints and controls were established. This is a key operational distinction from passive combustion equipment and many conventional vapor recovery configurations.
Field results
12 months with no failures or maintenance issues, except one minor external fix.
During the 12-month operating period, VaporCommander™ operated without failures, maintenance issues, service issues, stoppages, or cold-weather-related problems, except for a minor fix related to an incorrectly sized hose and cylinder. The system also operated through winter conditions without stoppages, failures, or issues related to cold weather.
Approximately 500,000 m³ of natural gas captured over 12 months.
More than C$46,000/year in estimated natural gas value based on 2021 project
assumptions.
No stoppages, failures, or issues related to cold weather during the
operating period.
Potential carbon-tax or carbon-credit value should be reviewed under current
regulations
and project-specific eligibility.
“The ability to adjust various parameters and allow the unit to self-regulate to maintain our desired inlet and discharge pressures is wonderful. Once you have it dialed in for various target setpoints and PID control, there is little to no intervention required.”
Torxen Facilities Engineer • Original field quote
Winter reliability
Cold-weather failure risk is often built into separator-based systems.
Conventional compressors and VRU systems can experience winter problems when they depend on upstream separators or scrubbers to remove liquids before compression. In cold Alberta conditions, water and condensate can freeze inside separators, scrubbers, drains, and level-control equipment.
Frozen liquids block drainage.
When liquids freeze in separator drains or scrubber bottoms, the equipment may no longer remove liquids effectively, increasing liquid carryover risk.
Level control becomes unstable.
Freezing can impair level instrumentation, control response, and dump operation, creating unstable upstream conditioning.
Carryover can damage compressors.
If liquid reaches a conventional gas-only compressor, the result can include hydraulic loading, lubrication problems, shutdowns, or increased maintenance.
More equipment needs winterization.
Scrubbers, drain systems, piping, controls, and filters all become additional cold-weather maintenance points.
Fluidstream reduces separator dependency.
VaporCommander™ is designed to handle wet gas within compression, reducing reliance on upstream separation as the primary reliability strategy.
Field result supports the logic.
The operating period reported no stoppages, failures, or maintenance issues related to cold weather.
Economic and emissions value
Recovered gas can create value that combustion cannot.
Replacing a vapor combustor with VaporCommander™ changed the economics of the vapor stream. Instead of burning gas with no payout, the operator captured gas that could generate value. The project analysis estimated approximately C$46,400/year of value from captured gas based on forward AECO 5A pricing of C$2.50/GJ and 947.82 ft³/GJ.
Vapor combustor
Controls venting by burning the gas, but releases CO₂ and eliminates the revenue potential of
the
captured natural gas.
VaporCommander™
Captures gas instead of burning it, creating an estimated C$46,400/year in gas value under the
project
assumptions.
Carbon-tax context
The project analysis identified potential C$35,880/year carbon-tax savings if a C$30/tonne CO₂e
tax
applied. Current carbon-tax, credit, and offset treatment must be reviewed under today’s rules.
Operating advantage
Compared with combustion, VaporCommander™ provided active pressure control, autonomous
operation, and gas
recovery rather than gas destruction.
Patent-supported technology
Patented multiphase vapor recovery.
Fluidstream’s patent portfolio supports the operating logic behind VaporCommander™: handling wet, variable vapor streams directly rather than forcing the site into a conventional dry-gas compression model. These patents support Fluidstream’s technical position around wet-gas handling, variable-flow operation, and liquid-aware compression response.
US11098709B2.
A primary anchor for liquid-aware compression response and chamber behavior when liquids influence the compression process.
US10221664B2.
Supports Fluidstream’s broader compression architecture and oil and gas compression relevance.
CA2843321C and CA2883283C.
Canadian patent coverage supporting Fluidstream’s foundational technology and operating methodology.
For operators evaluating alternatives to vapor combustors, conventional VRUs, or scrubber-dependent vapor recovery systems, VaporCommander™ directly addresses the operating window where wet gas, variable gas flow, winter reliability, and low-maintenance operation matter most.
Technical fit summary
Why VaporCommander™ replaced the combustor.
The case demonstrates that vapor recovery can do more than eliminate venting. When the system can handle real oilfield conditions, vapor recovery can capture gas value, support emissions objectives, reduce dependence on combustion, and provide active pressure control.
VCU limitation
Burns gas instead of recovering it, creates CO₂ emissions, and does not generate gas revenue.
Conventional VRU limitation
Can be costly, may require separation-first infrastructure, and may struggle with high
discharge
pressure, variable gas flow, and winter wet-gas operation.
Fluidstream fit
VaporCommander™ handled variable gas flow, operated without cold-weather issues during the
12-month
operating period, and captured gas for economic value.
Result
Approximately 500,000 m³ of gas captured, more than C$46,000/year in estimated gas value, and
reduced GHG
emissions relative to combustion.
Next step
Evaluate VaporCommander™ as a vapor combustor replacement.
Fluidstream can review tank vapor rate, discharge pressure, variable gas flow, wet gas composition, condensate and water exposure, winter operating requirements, power availability, emissions obligations, gas value, and site economics to determine whether VaporCommander™ is a fit.