Vapor Control

Flare Gas Recovery, Vapor Recovery, Vapor Combustors, and more

flare gas recovery

Flare Gas Recovery (FGR) is the process of recovering the waste gases that would normally be flared, so they can be used as fuel gas elsewhere in the facility. This results in reduced emissions and cost savings.

Flare Gas Recovery Systems (FGRS) perform the following processes:

  • Isolating the flare header with a proprietary-design liquid seal or staging valve
  • Recovering normally flared gases and delivering them back into the facility so they can be processed and re-used as fuel gas
  • Removing liquids
  • Compressing gases up to a defined pressure level

A facility’s safety depends on properly integrating the Flare Gas Recovery System into the relief header and the flare system. The compressor skid is only one piece of the package – all components must be properly designed and built to ensure safe and reliable operation of the entire package. This is why it is so important to utilize the expertise of a company like Zeeco with Flare Gas Recovery and Flare System experience.

Typical FGR Sizing:

  • Flowrate Ranges: 0.1 to 10MM SCFD (11,100 Nm3/hr)
  • Pressure Ranges: 35 to 300 psig (20.7 barg)

Services Offered:

  • Engineering Studies – let us help you determine if a FGR system is right for your facility. Our engineers will recommend system sizing, compressor technology, and ancillary equipment. They will develop the cost estimate and evaluate the payback period to help you decide the economic feasibility.
  • Engineering, design, fabrication, supply, installation, and startup of FGR packages.
  • Field support after equipment startup.

Put Zeeco’s Experience to Work for You

Zeeco’s staff members have extensive experience in design, fabrication, and installation of Flare Gas Recovery Systems, along with a full range of vapor control, vapor combustors, and vapor recovery (VRU) systems. We can evaluate the existing flare system including the normal flow to the flare, size the Flare Gas Recovery system, design the liquid seal drum, and recommend proper integration of all the equipment and controls for your specific application.

vapor recovery

Wherever liquids are loaded into trucks, ships, or rail cars, VOCs can escape into the atmosphere and create both harmful and unacceptable emissions levels.

Zeeco offers the industry's most advanced vapor recovery systems (VRUs) to match your precise application to ensure maximum capture of hydrocarbon vapors. We custom-engineer vapor recovery or control systems for all fuel compositions and concentrations, flow rates, and ambient conditions. What's more, our carbon bed and mechanical VRU systems are designed to recover the maximum amount of liquids that can be monetized as valuable energy, while eliminating fugitive emissions that can lead to unsafe operating conditions.


Standard systems for the oil and gas industry, including:

    • Marine loading terminals
    • Truck loading terminals
    • Railcar loading
    • Storage terminals
    • Oil tanks
    • Well sites
    • Gas treatment facilities
    • Maximum recovery rate of liquids
    • Simple operation
    • Low operating costs
    • Liquid ring or dry vacuum pump systems

VAPOR Combustors

Zeeco's fully automated Vapor Combustor Units (VCU) are put to work primarily in liquid loading and tank storage operations where they effectively destroy the harmful emissions that would otherwise be released to the atmosphere. Zeeco's vapor combustors are fully enclosed, operating in a similar fashion to a thermal oxidizer, with destruction efficiencies that meet or exceed the most stringent clean-air standards. Designed for automatic starting and stopping, these high-efficiency vapor combustors operate with a wide range of products with no smoke or visible flame.


  • Liquid loading rates up to 50,000 bph per unit
  • Destruction efficiencies greater than 99.9%
  • High turndown capability.
  • Smokeless performance from 0% to 100% operation.
  • Detonation arrestors are attached to the combustor stack to prevent flashbacks into terminal piping.
  • Operation can be tied into pump operations to turn system on and off when needed for loading operations.
  • USCG Certified Anti-Flashback Burners
  • Combustor burner assembly allows auxiliary air from the air assist blower to mix with the vent vapors and establish combustion while tempering air (for temperature control)
  • Air-assist blower designed for staged air flow to adjust for varying vent vapor flow rates
  • Controls system with fully automatic flame ignition and monitoring
  • Combustor stack with temperature recorder for state recording purposes.

biogas & landfill flares

Biogas flare systems are used to dispose of gases that are produced from decomposition of organic matter or biomass. Typical examples are gases produced from landfills, wastewater treatment (anaerobic digesters), or other biomass sources. Gases are typically mixtures of methane, carbon dioxide, small amounts of nitrogen, oxygen, hydrogen sulfide, and others. Biogas must be handled in a specific manner to ensure combustion to a high degree of efficiency. In addition, the possibility of oxygen in the gas mixture coming to the flare means flame arrestors and special flame arresting burners must be employed. Biogas can be burned to a high degree of efficiency in either an elevated flare or an enclosed ground flare system.


If your facility is an environmentally sensitive area where NOx emissions are tightly regulated, such as one of the EPA’s 8-hour ozone Nonattainment areas, then you will also need an ultra-NOx VCU.  Zeeco has developed the TriClean VCU, which is an ultra-low emission VCU that can achieve NOx emission of less than or equal to 15 ppm (0.018 MMBTU/hr.) and CO emissions of less than 10 ppm (0.01 MMBTU/hr.).

Exterior of Biogas and Landfill Flare System


Zeeco can provide combustion and emissions control solutions wherever hydrocarbon processing takes place. Customers can find our equipment and services in upstream, midstream, and downstream oil and energy processes.

We also offer products and support for other industries and applications such as tank/terminal loading and storage, pharmaceutical, carbon black, pulp & paper, steel, food processing, and more.