Author: Nicole Miles

ProSep Awarded Patent for EBS Crude Blending Application

ProSep was recently notified that its proprietary mixing technology has been granted another U.S. patent for the blending of two distinct API crude multiphase process flows to create a consistent homogenous single API blend for easier downstream processing. The Enhanced Blending System (EBS) includes sampling, monitoring, and control of the individual and commingled flows in order to consistently deliver a homogeneous API. The advantages to the customer include upgrading a heavy crude to a more readily process medium grade crude, reduction in diluent light crude required to meet the desire medium crude specification, lower density and viscosity for ease of pumping long distances, and accurate, timely API and BS&W readings for the commingled stream.

ProSep is enhancing Ekofisk’s water stream with a CTour produced water treatment package

ProSep is enhancing Ekofisk’s water stream with a CTour produced water treatment package, which uses existing gas condensate combined with ProSep’s high-efficiency mixers to enhance oil and water separation.

Click here to read the feature article on E&P Magazine online and learn more on how successful pilot tests led to the installation of a full-scale system that is still in operation.




ProSep is ISO 9001:2015 certified!

We are proud to announce that ProSep is ISO 9001:2015 certified! This allows us to keep up with latest industry standards and to ensure we are providing the best in class technology solutions to our customers in the upstream, downstream and midstream sectors. Click on the image to learn more.

Effective Removal of BTEX from Rich Water to Reduce the Concentration of BTEX in Reclaimed Methanol using ProSep’s Osorb System

In the September issue of Hydrocarbon Processing, Gregory Hallahan and Caleb Smathers, ProSep, and Jeff Myers, Williams Company, weigh in on the effective removal of BTEX from rich water to reduce the concentration of BTEX in reclaimed methanol using a new media system. Click on the image to read the article and learn how ProSep demonstrated BTEX reduction with Williams.

Click here to read the article!

ProSep To Offer Live Demonstrations At Offshore Technology Conference 2017

APRIL 25, 2017 (HOUSTON)ProSep, the industry-leading technology and service provider for integrated process solutions, today announced the opportunity to experience four (4) of the company’s innovative technologies at the Offshore Technology Conference in Houston, Texas, May 1-4, booth #7234.

Live demonstrations of the AIM, MAX, TORR, and Osorb® Media technologies will be provided by Caleb Smathers, Sr. Product Development Engineer for ProSep. Gregory Hallahan, Director of Product Development will be on site to answer questions.

“ProSep’s arsenal of proprietary mixer and Osorb technologies have been addressing challenging problems faced globally by oil and gas operators,” said Hallahan. “We are inviting everyone to join us to witness these best-in class technologies in action first hand at OTC.”

Full demonstration schedule:

Tuesday, May 2 Wednesday, May 3








The featured technologies include:

  • AIM, or Annual Injection Mixer: The patented design of the AIM creates intense, balanced turbulence in the mixer for optimized utilization of momentum transfer, measure as pressure drops across the AIM.
  • MAX, or Multiphase Adjustable Extreme Mixer: The design of the MAX is distinct compared to other mixing technologies such as globe valves and static mixers because it provides homogenous, high-efficiency mixing regardless of the process flowrate.
  • Osorb® Media: Osorb Media is both an adsorbent and absorbent, using a unique matrix structure and intermolecular interactions to capture hydrocarbons and organics without the creation of any permanent chemical bonds.
  • TORR™: The TORR coalescing technology, with its small footprint and ability to replace less efficient oil removal equipment, is a scalable technology that addresses future increases in water cut for offshore operators.

 “These technologies are proven and have helped leading global energy producers save critical operating expenses, improve reliability, and meet local regulations by reducing chemical and water consumption by up to 50%, saving millions of gallons of water per year, and removing harmful contaminants – all with favorable payback periods.,” added Smathers. “We encourage everyone to attend and experience our technologies firsthand, and listen to case studies from our global operations.”

ProSep wins order to supply ProMix units to Middle Eastern NOC

HOUSTON — ProSep is to supply four ProMix units to a national oil company based in the Middle East, the company said Tuesday.

“The ProMix technology generates homogeneous and moderate shear force to the dispersed phase across the cross section of the main flow, providing a narrow uniform droplet size distribution, significantly increasing interfacial contact area, enhancing mass transfer between different flows, and meanwhile preventing formation of an emulsion,” said Yi Liu, senior process engineer chief for ProSep.

This technology will enable the client to reduce chemical consumption up to 25% compared to conventional technologies, while maintaining optimal separation performance at its gas oil separation plant. Through ProSep’s technology, the client will benefit from optimized performance, reduced chemical consumption and significant operational savings.

“In the current low oil-price environment we are pleased that our differentiated ProMix technology provides a unique solution to our clients, one that has been proven to reduce chemical consumption between 20-50%,” said Ryan McPherson, ProSep general manager – Middle East. “When combined with a rigorous techno-economic analysis which articulates tangible savings and a high Internal Rate of Return (IRR), greater than 35%, we look forward to working alongside other major clients in the region and elsewhere in the world to reduce their cost and increase operational efficiency.”

Positive NPV and attractive rate of return on investment: (re) Introduction to the ProSep proprietary product line

By Greg Hallahan, Ryan McPherson, Mahesh Konduru

(ProSep) Throughout history, pioneers and inventors, after spending countless hours developing an innovative product, have faced resistance in developing and communicating the benefits of their products to a diverse audience. The result, usually, is a delay in bringing the product to market, slow adoption by clients, or in some unfortunate instances, “death” of the product. Products in all industries have suffered from this resistance and continue to do so today.

As we enter into the second quarter of 2016, oil producers and oilfield service companies are under tremendous pressure to integrate efficient practices and to return to profitability.  Products that are capable of introducing immediate efficiencies, while achieving an attractive rate of return and positive net present value, can assist these companies in returning to profitability now, while providing lasting gains when market forces and volatility subside.

ProSep has, in its 11 year history, provided best in class products to the Oil and Gas Upstream segment with specific focus on process separation solutions. Process separation solutions refers to the upstream business where the fluids, in gas and liquid phase, produced from the well need to be “cleaned up” before transported in pipelines, trucks, stored or re-used.

Technologies for separating liquids (oil and water) and gas (natural gas) have existed for decades with different degrees of innovation added over time. The Oil and Gas industry is notorious for slow adoption of new technology, where risk-aversion with significant amount of capital investment and profits at stake is common, especially concerning technology switches. Additionally, convincing multiple parties within the decision making group, from operators and engineering managers to procurement managers and executives, to switch to a new technology is difficult when each member of the group has a different role and responsibility to the company. This often makes it hard to gain consensus to switch technologies from conventional to the new and innovative.

ProSep has solved this technology switch difficulty with its proven proprietary product line of mixers and produced water treatment. ProSep provides a rigorous techno-economic analysis that articulates concisely the Net Present Value (NPV) and Internal Rate of Return (IRR) for its mixers and produced water products to every client. This analysis will allow clients to vary assumptions specific to their application, allowing NPV and IRR calculations over a range that meets the client’s requirements.

ProSep’s proprietary products include:


This mechanical mixing device replaces injection quills and static mixers, in order to reduce demulsifier chemical usage by 20-50%. In oil separation applications in the upstream segment, ProMix can generate greater than 50% IRR and significantly positive NPV, often with a return on investment in less than a year. Major clients in the North Sea, Middle East, and Latin America has purchased and deployed ProMix products. ProMix can be effectively deployed in the downstream segment as well where clients are currently spending significant amounts of capital on chemical usage.

A ProMix was recently proposed to an operator in the Middle East region with the following specifications and metrics:

Oil Flow Rate (BOPD) 750,000
Reduction in Demulsifier Injected due to ProMix 25%
Water Cut (%) 36%
ProMix Indicative Price ($) 1,000,000
Annual Savings of Demulsifier ($) 960,000
NPV 10 years (12% Discount rate) $4.1 Million
IRR 72%
Increase in Earnings ($) $9.6 Million


The removal and reduction of salt from oil is not only a statutory mandate, but also required for transportation and refining. In most oil and gas separation processes, lowering salt content requires a significant amount of a precious resource: fresh water. Depending on the geography of the site, the value of fresh water can vary from expensive to priceless. Pipeline operators and refiners also place value on crude with low salt content. ProSalt lowers fresh water usage ranging from a 20% to 60% reduction as compared to conventional mixing systems, and often saves customers millions of gallons per year in fresh water injection for desalting vessels. The IRR on a ProSalt ranges from 15-30% on water and energy savings alone with a materially positive NPV depending on the specific application.

ProSalt was awarded the Offshore Technology Conference (OTC) “2009 Spotlight on New Technology Award” recognizing innovative technologies significantly impacting offshore exploration and production. ProSep has successfully deployed numerous ProSalt units with Statoil, Saudi Aramco, and PEMEX.


Processing of natural gas at the production or collection site involves removal of water (dehydration). The presence of vapor phase water in natural gas restricts the amount that can be processed and transported. In addition, capital expenditure is required in the form of tri-ethylene-glycol (TEG) systems to remove water from natural gas. ProDry is ideal for debottlenecking retrofit applications allowing for 15-25% of additional natural gas to be processed and sold, depending on specific conditions; ProDry also reduces the capital expenditure needed to upgrade existing TEG systems to meet additional production capacity. An IRR of 25% with significantly positive NPV can be achieved with the deployment of a ProDry mixer.


ProBlend was developed to combine two crude process streams of differing density/viscosity to meet a required density (API) or viscosity. Based on ProSep’s proprietary mixer technology ProMix, ProBlend provides even pre-distribution of heavy or high viscosity oil into light or low viscosity oil. This blend of crudes is further mixed in ProSep’s modulating mixer design, creating a homogenous blend that is significantly easier to transport than heavy, viscous crude, and simpler to treat in dehydrating and desalting applications. In South America and Canada transportation of heavy crude is expensive. In Venezuela’s Oronoco region and Colombia’s Llanos basin, naptha is sometimes injected to facilitate the transportation of the heavier crude through pipeline. Deploying a ProBlend in these instances would lower transportation cost or naptha (chemical) usage by 10-40% thus driving a positive NPV and high IRR to operators. ProSep has successfully deployed ProBlend units with PEMEX.


ProSep’s proprietary media Osorb has unique capabilities, including the abilities to be regenerated and selectively remove water soluble organics. Because of these capabilities, Osorb has availed itself to a multitude of specialized applications, including removal of BTEX from produced water treatment and oil removal from EOR water streams. Osorb has shown the capability to provide IRR of 35% and positive NPV for a specific application in the Gulf of Mexico. In addition, a 750 BPD unit is currently in operation in the Middle East.

This article was published in the World Oil “Thriving In The Downturn” Newsletter, dated April 19, 2016.

ProSep lands North Sea Statoil contract

Houston-headquartered ProSep, the oil, gas and water treatment specialist, has been awarded a new contract by Statoil. The agreement, which commences in February 2016, will see the company supply its proprietary ProSalt mixer technology to Statoil’s Gudrun platform in the Norwegian North Sea.

The ProSalt mixer enables efficient utilisation of wash water and chemicals as well as improved oil-in-water separation compared to static mixers. The technology will be designed and commissioned for the Gudrun platform to provide a reliable and robust solution within a rapid timeframe. ProSalt’s internal design and material selection will improve its reliability against erosion and corrosion.

Statoil selected ProSalt for the Gudrun platform because of its technical reliability and ability to modulate with changing process conditions. The operator will likely be injecting wash water into the production line towards the end of 2016 based on existing production profiles, and ProSalt’s improved mixing efficiency over static mixers will enable Statoil to meet salt requirement (PTB).

“ProSep’s long-standing relationship with Statoil is a testament to the benefits of our technology,” says Mike Smith, Managing Director – Europe, ProSep. “This is the second deployment of this specific mixer type in the North Sea and we expect to see more operators in the region looking for reliable cost-effective solutions that can save not only OPEX, but scarce offshore resources, such as wash water and power requirements.”

ProSep has recently hired a sales manager in Stavanger, Norway, to cultivate operator relationships and drive its growth in the region. ProSep’s portfolio of proprietary mixing technologies includes ProMix, ProSalt, ProBlend, ProScav, and ProDry. To date over 100 mixers have been deployed worldwide.

ProSep appoints Sales Manager to strengthen Norwegian foothold

Houston-headquartered ProSep, the oil, gas and water process separations technology company, has appointed Jacek Kacperski as Norway Sales Manager. Based in Stavanger, Kacperski joins the company with over a decade’s experience in oilfield services, including sales roles with TDW Offshore and Siemens AS.

ProSep recently renewed its focus on its suite of proprietary technologies – including mixers – which offer operators a cost-effective and reliable solution for reducing chemical consumption, maximising hydrocarbon recovery and process optimisation. Norwegian companies continue to champion best-in-class technology and in this new commodity price environment Kacperski will work hand-in-hand with local operators to drive the development of new and existing opportunities.

Patrick McCarthy, CEO of ProSep, says: “We are excited to welcome Jacek to the team. His knowledge of the local market coupled with his impressive track record make him the ideal person to lead our Norwegian operations. The development and early deployment of ProSep’s mixing technologies trace their roots to Norway and we believe that in the current environment, technologies like ours can play a significant role in enabling operators to optimise their offshore operations.”

Kacperski adds: “ProSep’s portfolio of patented technology is really impressive and I am very proud to become a part of this enthusiastic, innovative and results-driven team. I look forward to strengthening the company’s position as a trusted technology partner in the Norwegian market by offering solutions that can genuinely improve operational efficiencies.”

ProSep enters final stage of ITF JIP for Osorb Media

Osorb Skid ProSep JIP

Houston-headquartered ProSep, the oil, gas and produced water treatment specialist, has entered the final stage of its ITF joint industry project (JIP) with Qatar Petroleum and Petroleum Development Oman (PDO).

ProSep is putting a full scale Osorb® Media unit through a two-phase field trial in PDO’s Marmul oil field, 200 kilometers northeast of Salalah in Oman, to demonstrate the media’s water treatment and regeneration capabilities. Osorb Media is a regenerable organosilica that adsorbs free, dispersed, and water soluble hydrocarbons, as well as many oilfield chemicals from produced water.

Ryan McPherson, General Manager, Middle East for ProSep said: “This project represents a significant step in the evolution and development of Osorb Media. To be part of a JIP with two national oil companies in the Middle East has been a tremendous experience, with all parties truly collaborating towards a shared goal.  The ability to regenerate the media in-situ is fundamental to full-scale technology implementation.  I am looking forward to a successful trial that will enable us to create a regeneration process that is both economically and operationally practical for operators.”

Spent Osorb Media can be regenerated using a variety of techniques and resources and operators often have different options available for this process. The two phases of the project will compare regeneration methods through a rigorous test schedule to ensure that regeneration process options are created that are both economically and operationally practical for all operators.

Wail Saif Salim Al-Harrasi, Corporate Technology Advisor at PDO said: “This JIP is of great importance to PDO as it has the potential to resolve some of the challenges associated with EOR activities, such as de-oiling of polymer contaminated water and enabling the reuse of spent polymer, which in turn reduces the overall cost of EOR.”

Keith Mackie, Director of Strategic Projects and International Development at ITF also noted: “We are delighted to see another ITF project coming to fruition. The development of an offshore capable unit for oil-in-water removal and media regeneration will deliver real benefits to the industry, both in terms of environmental impact and cost.”

The unit will be in country by the end of the year, and the trial is scheduled to begin in January 2016 with completion by end of Q1.

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