Skid‑mounted VRU vapor recovery unit is an integrated pre‑fabricated solution specially developed for petrol station vapor emission control and hydrocarbon resource recovery. Assembled and fully tested within a unified skid frame in factory, this system is well‑suited for both new‑built petrol station construction and old‑site renovation projects where limited on‑site space and tight construction schedules are major constraints.
During fuel unloading, refueling and tank breathing processes, petrol stations generate large volumes of gasoline hydrocarbon vapors. Direct venting of these vapors brings multiple troubles, including valuable fuel loss, elevated VOC emissions, potential fire hazards and non‑compliance with local environmental regulations. Traditional treatment approaches have obvious drawbacks. Incineration burns off recoverable gasoline and raises running expenditure. Activated carbon adsorption generates large amounts of hazardous waste and faces saturation risks under fluctuating vapor loads. Single condensation solution cannot maintain stable recovery efficiency when vapor concentration swings frequently.
Adopting compression‑condensation‑membrane coupling physical process, the skid‑mounted VRU realizes vapor recovery without combustion or chemical reaction. Hydrocarbon vapors are collected through closed piping and sent to buffer module to offset pressure and flow pulse caused by batch‑type unloading operations. Multi‑stage pre‑treatment removes liquid droplets, aerosols and free moisture to protect compressors, heat exchangers and membrane elements from fouling, corrosion and blockage. After compression to raise vapor partial pressure, most hydrocarbon components are liquefied via gradient multi‑stage cooling. Remaining low‑concentration vapors go through membrane separation unit for enrichment. Purified gas meets emission standards, while concentrated vapor stream circulates back for re‑processing to lift overall recovery performance. Recovered liquid gasoline can flow back to underground storage tanks for reuse, cutting fuel loss and operational cost for station operators.
All core components, piping, valves, explosion‑proof instruments and PLC control system are pre‑installed on one compact skid base. Factory‑completed pressure test, explosion‑proof inspection and commissioning greatly reduce field workload. Site workers only need to connect vapor pipelines and power supply, shortening installation and commissioning cycle significantly, and minimizing disruption to daily petrol station business. The whole unit follows ATEX explosion‑proof standards, fitted with over‑temperature, over‑pressure, combustible gas detection interlock and emergency vent bypass to handle abnormal working conditions. Intelligent variable‑frequency control adjusts operating load dynamically according to real‑time vapor flow and concentration, supporting long‑term unattended stable operation.
Customizable on skid dimension, processing capacity and internal layout, skid‑mounted VRU can match various petrol‑station‑specific working conditions. It delivers a practical, low‑footprint solution for global petrol stations to achieve emission compliance, fuel recycling and safe operation simultaneously.