ProSep Awarded Multi-Million NOK Contract For Johan Castberg Field Development Project

Mixing TechnologyProSep, an industry-leading technology and service provider for integrated process solutions, announced today it will supply three (3) ProSalt™ units to Statoil Petroleum (Statoil) for the Johan Castberg field development project, located on the Norwegian continental shelf in the Barents Sea.

The ProSalt technology, which utilizes ProSep’s Multiphase Adjustable eXtreme mixer with injection (MAX+), is used for crude oil and wash water mixing upstream of the desalting process. The mixer provides high efficiency (> 90%) mixing of wash water and crude to meet the required outlet specification for crude export. The MAX+ mixer employs a unique mixing cylinder which creates a homogeneous shear force across the cross-sectional area of the crude process flow. This evenly distributed shear force generates a tight water droplet distribution and turbulent mixing conditions within the cylinder. These actions thus maximize the mass transfer area of salt in the crude to the wash water, all done with a relatively low dP (~0.3 bar) throughout the wide range of flow conditions. Chemicals, such as demuslfiers, can be injected in the mixer alongside the wash water, which leads to their more efficient use in the process stream. Additionally, the lower shear stresses applied to the oil and water mixture leads to less emulsion tendencies overall. The ProSalt technology with MAX+ mixers will provide Statoil with efficient usage of wash water and chemicals, while also providing an opportunity to reduce injection volumes of both in comparison to conventional mixing technologies.

“After an extensive evaluation process, it is extremely rewarding to be recognized by Statoil as a leading technology provider and preferred supplier of innovative process optimization equipment at the highest Quality, Health, Safety, and Environment (QHSE) standards,” said Jacek Kacperski, Sales Manager, ProSep Europe. “We are honored to be considered a trusted partner in such a technologically demanding project.”

The Johan Castberg project was notably the biggest offshore oil and gas development in 2017, with an estimated cost of approximately NOK 49 billion. The scope of work consists of a production vessel, 30 wells, 10 subsea templates and two satellite structures with the capacity to recover an estimated 450 – 650 million barrels of oil equivalent. The project is anticipated to begin in 2022.

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 Transform Global Oil and Gas Industry with Major Milestone Achievement for Osorb Media

August 1, 2017 (HOUSTON) – ProSep, the industry-leading technology and service provider for integrated process solutions, today announced a major milestone achievement for one of its proprietary produced water treatments, Osorb Media, a revolutionary, re-generable, modified organo-silica used for the polishing oilfield water and gas streams. ProSep has secured a multi-million dollar order for this water treatment system, which is a momentous breakthrough for this technology that has been in a developmental phase for the past seven years.

“Very few technologies have been commercially accepted in the Oil & Gas industry in such a short time from discovery to first commercial sale, specifically ones that are in the tertiary and/or polishing treatment stage,” said Mahesh Konduru, CEO at ProSep. “We believe that the Osorb technology is truly transformational and the global oil and gas industry will have an opportunity to see this technology in action.”

Prosep’s Osorb Media utilizes a 5000-barrels of water per day (BWPD) system that is designed to reduce Benzene, Toluene, Ethyl Benzene, and Xylene (BTEX) contaminants to less than 15 parts per million (ppm) on an offshore platform. The advantage of using Prosep’s Osorb technology includes a notably low-system footprint, durability of media, and greater flexibility of regeneration.


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 Awarded Contract For Statoil’s Troll B ZMP Project

Technology helps Statoil reduce package size and recognize process efficiencies

ProDryFEBRUARY 14, 2017 (HOUSTON) – ProSep, the industry-leading technology and service provider for integrated process solutions, announced today it will supply one (1) ProDry™ unit to Statoil for the Troll B ZMP Project. ProSep’s project scope of supply – awarded through Aker Solutions – began in January 2017 and is expected to last approximately five months.

“The ProDry™ technology has demonstrated the ability to dehydrate natural gas with nearly 100% approach to equilibrium,” explained Greg Hallahan, ProSep’s Director of Product Development. He continued, “This enhanced performance, as compared to standard injection quills, allows significant cost savings via replacement of standard countercurrent towers, eliminating the large vessels and internals. Additional savings in operating expenses can be realized by minimizing TEG losses and demonstrating resilience to common TEG tower issues, such as TEG foaming and carryover.”

The ProDry™ technology to deployed on the Troll B platform, uses ProSep’s ECLIPSE mixer for triethylene glycol (TEG) injection.  Due to ProDry’s high mixing efficiency, Statoil will replace a standard countercurrent TEG tower with an in-line, co-current mixer and separator/knock-out drum. The required TEG flow compared to a conventional tower will be reduced, allowing the project to utilize spare capacity in the existing TEG regeneration packages.

“The ECLIPSE mixer has been used for various applications, such as H2S scavenging in natural gas production, on a number of platforms in the Norwegian Continental Shelf,” stated Jacek Kacperski, ProSep Sales Manager for Europe. “However, this project represents the first time the ECLIPSE mixer has been installed for gas dehydration with TEG or MEG, the ProDry™ application, and brings to conclusion a years’ long R&D and Business Development effort to reach commercialization. ProSep feels that this application is the first step toward proving the mixers capability as part of an in-line co-current system, which has future applications for subsea developments.

ProSep Inks Distribution Agreement With Puffer-Sweiven


Company aims to expand beyond upstream oil & gas market


puffer-sweiven-logo-3ProSep, the oil, gas, and water treatment specialist has signed a distribution agreement with Puffer-Sweiven, a leading supplier of products and services for process control and flow control.

The partnership aims to leverage ProSep’s mixer and produced water technologies with Puffer-Sweiven’s track record as a successful distributor across multiple industries and ultimately expand ProSep’s offerings beyond the upstream oil and gas market.

“ProSep’s proprietary mixer technologies have helped oil and gas operators achieve significant operating efficiencies during production, reducing expenses by 20 to 60 percent” said Mahesh Konduru, Chief Financial Officer and Head of Operations at ProSep. “Whether it’s Oil & Gas or Utilities, Power, or Paper, we believe that we can help new clients across industries stay competitive as they navigate an increasingly challenging industrial climate.”

The initial terms of the agreement will cover the Gulf Coast region, including Texas and New Mexico. The companies also plan to pursue opportunities in Latin America, where Puffer-Sweiven has offices in Venezuela, Colombia, Chile and Ecuador.

“This partnership could not have come at a better time.  Many industrial producers and utilities are looking for means to optimize their processes and reduce costs.  ProSep’s advanced technology along with the services and complementary products which Puffer-Sweiven can provide will bring real value to our customer base,” said Jeff Deurlein at Puffer-Sweiven.

“For over 70 years, many of the world’s largest companies have trusted Puffer-Sweiven to provide quality and value-added solutions for them on a consistent basis,” said Konduru. “Their sales team, more than 100 strong, is highly informed and in tune with client needs. We are excited about this partnership and look forward to working with them closely to meet our growth goals.”

About ProSep
ProSep is a technology-focused process solutions provider to the upstream oil and gas industry. ProSep designs, develops, manufactures and commercializes technologies to separate oil, water and gas generated by oil and gas production. For more information, please visit

About Puffer-Sweiven
For over 70 years, Puffer-Sweiven has set the standard in equipment and services for process control, automation, safety, and reliability.  Puffer-Sweiven helps process-intensive facilities run more efficiently and safely by delivering quality products, technical support, and knowledgeable staff.  For more information, please visit

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.

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