The Vortex surface (SX) tools shape turbulent flow (made up of solids, liquids and/or gases) into a stable, spiraling flow with laminar-like qualities. In doing so, these SX tools help carry the production flow over long distances, turns and changes in elevation. Although the Vortex flow is established quickly (SX-NGL recovery), the benefits of the flow from one SX tool can go for over six miles.

Here's what a flowline looks like without Vortex:

Here's the flow after passing through the Vortex SX tools:

Although the Vortex surface (SX) series of tools have numerous applications in sweeping out liquids from flowlines/gathering lines (and systems), the following is a list of key applications:

Increased Natural Gas Liquid Recovery: With the Vortex SX-NGL tool, the operator is able to recover up to 10 times more natural gas liquids (NGLs) than recovered with pigging or drip systems alone. Using the energy of the gas itself as the flow medium, the Vortex flow spins the NGLs out of the gas, allowing the operator to recover this revenue stream with minor changes to the value of the gas (7-12 BTU). As with all Vortex tools, with no moving parts, there’s nothing to wear out, nothing to maintain.   

An E. Texas independent conducted a 15-month study on the value of these SX-NGL tools. In one year, over 1.2 million gallons of additional NGLs were recovered from 10 wells on three gathering lines with the Vortex tools, translating to over $2 million in additional revenues. An average well line with Vortex paid for itself in less than 60 days (including the cost of the Vortex tool and associated tanks and installation). There were also additional “non-revenue” benefits like reduced pigging, lower methanol use, reduced hydrate formation and zero line freeze-ups on gathering lines with Vortex.

Green and purple lines also had Vortex SX-NGL tools installed

This SX-NGL tool is popular in rich gas plays such as the Eagle Ford, Bakken, Haynesville and the Niobrara.

More info on this revenue-generating SX-NGL tool can be found here.

Vapor Recovery Unit Replacement: With the Vortex SX-VRU tool, the operator is able to spin volatile organic compounds (VOCs) back into the oil. With the EPA flying infared imaging cameras over oil and gas fields seeking information on emissions violations, the SX-VRU is a cost-effective way to remain in compliance with today’s emissions standards. By spinning vapors back into the oil and condensates, Vortex surface tools allow the operator to cost-effectively replace vapor recovery units with an environmentally responsible, cost-effective, safe tool that reduces friction (and, in turn, the chance of dangerous static fires). The stable flow creates less turbulence, a better separation of fluids and vapors, more volume and more value, and the (flash) gas goes back to the low-pressure compressor and down the production line, The Vortex tool eliminates vapors (making them all liquids) so there is minimal gas going to flare and what little does go is “clean.”

The SX-VRU tool is ideal for higher temperatures where managing gas vapors is more problematic. In one such hot climate install, according to the customer, even with 103-degree ambient daytime temperatures, the vapors off the well were negligible with Vortex.

More info on this SX-VRU tool can be found here.

Reduced Flowback Start-Up Time: With the Vortex SX-FB tool, the operator can dramatically reduce the average flowback startup time to the production tanks by as much as a day. By separating out the mud, the Vortex flow cleans the initial slug of production, translating those initial high-production days to the pay meter and profit rather than waste and pollution  in the flare pit.  

The SX-FB tool is ideal for all flowback startups and is typically set between the high-pressure separator and the heater-treater.

More info on this SX-FB tool can be found here.

Paraffin Mitigation: The SX-P tool is ideal for paraffin prone areas. The SX-P tool creates a stable, spiraling flow that does not allow the paraffin to accumulate on the pipeline wall, thereby reducing the need for hot oil and chemical treatments. Although chemical treatments can be used in conjunction with the Vortex tools, the stable flow also helps keep them suspended for longer, thereby reducing the associated costs and shutdown times. The SX-P is configured with a removable backplate for easy cleaning.

The SX-P tool is used to greatly reduce or even eliminate hot oiling (depending on the severity of the paraffin build-up). Several surface lines in Oklahoma were previously hot oiled every two weeks, but with the Vortex SX-P, hot oiling was eliminated for five-to-six months.

More info on this SX-P tool can be found here.

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Other surface applications include lowering line pressures, reducing compression costs, reducing/eliminating the need for pigging/drip systems, improving the effectiveness of chemical treatments, and preventing liquid load-up, gas pockets (in water lines) and preventing line freezing in winter.

All of the Vortex SX tools are available here.

Key downhole applications are noted here.