Our Work in the Field
Projects That Define the Industry
From remote oil fields to major refineries, Breakthrough Engenuity has delivered proven solutions across North America and beyond.
Projects
HWSB® Skim Tank Deployment
West Texas, Oklahoma, Colorado, Wyoming, MontanaUSA
Deployed a fleet of HWSB® Skim Tanks across multiple production and SWD sites in the Permian Basin, dramatically increasing oil capture rates while reducing oil carryover rates to below 30 PPM thereby reducing produced water treatment and disposal costs for most major and independent operators.
Results to Date
Recovered 18,000+ barrels of additional oil. Reduced disposal costs by 34%. Zero environmental incidents across all sites.
Eagle Ford Shale Oil Processing Systems
South Texas, USA
Engineered and designed complete central process facilities for high volume produced oil and water processing in multi-well pad operations in the Eagle Ford Shale where older process systems had failed. Developed the first true "plug-n-play" concept for high-volume, efficient three/four-phase separation configured into a 21st century facility design ideal for rapid assembly to meet the high demands of rapidly evolving operations expanded in the shale oil boom.
Results to Date
Processed 45,000 barrels per day at peak. Achieved 99.2% oil-water separation efficiency. Project completed 3 weeks ahead of schedule.
unique Kansas water treating system Retrofit
North Dakota, USA
Retrofitted aging separation infrastructure at a legacy CTB facility. Removed thje top half of a wash tanka nad converted it intot a high efficiency HWSB skim tnak with next-generation patented HWSB® oil-water and DFSD® sand-waterseparation technologies. The project required minimal downtime and was successfully executed during active production.
Results to Date
Increased oil recovery by 22%. Reduced operational downtime by 60%. Extended facility operational life by an estimated 15 years.
Salt Water Disposal Plant Design in Wyoming
Louisiana, USA
Currently engineering a moderate -scale water clarification system upgrade for a group of oil and gas producers in northeast Wyoming. The project involves custom-designs for the clients existing tankage and may incorporate the patented HWSB® ultra-efficient oil-water separation system and the patented DFSD® solids removaL systems integrated with the client's existing infrastructure.
Results to Date
Phase 1 complete. Projected 100% improvement in separation efficiency upon commissioning.
Canadian Oil Sands Water Treatment Initiative
Alberta, Canada
Partnering with a major Canadian operator to deploy HWSB® Skim Tank technology in oil sands produced water treatment. The extreme conditions require specialized materials and engineering adaptations.
Results to Date
Pilot phase showed a remarkable 31% improvement in effluent water qualityover legacy systems. The client commissioned a CFD modelling effort that confirmed the design and its performance. Full deployment took place immediately thereafter and the client decided to duplicate the new system in an adjacent plant.
Appalachian Basin Multi-Site Rollout
Pennsylvania & West Virginia, USA
Coordinated a multi-site rollout of standardized HWSB® Skim Tank configurations across 14 production locations in the Appalachian Basin, streamlining operations for a regional E&P company.
Results to Date
14 sites operational within 90 days. Standardized maintenance reduced service costs by 41%. Operator reported highest quarterly production in company history.
Neuquen Basin Heater Treater Troubleshooting and Re-Design
Neuquén Province, Argentina
Engaged to diagnose and resolvechronic firetube and firetube flange failure issues in an existing heater treater installation in the Neuquén Basin. Breakthrough Engenuity engineers conducted a full root-cause analysis, identified design and operational deficiencies including the internal flow distribution and heat transfer sections, and executed a comprehensive re-design to restore separation efficiency under high-paraffin, variable-flow conditions.
Results to Date
Separation efficiency restored to 98.6%. Emulsion carry-over eliminated. Operator avoided full vessel replacement, saving an estimated $1.2M in capital expenditure.
India's Largest Crude Oil Dehydration System Design
India
Designed India's largest crude oil dehydration system, engineered to process 200,000 barrels of oil per day to refinery inlet quality standards. Breakthrough Engenuity provided full process engineering, vessel sizing, and system integration design to meet stringent BS&W specifications required for direct refinery feed — a landmark project in scale and complexity for the region.
Results to Date
System designed to process 200,000 BPD at refinery inlet quality. Full BS&W compliance achieved in design. Largest crude dehydration installation in India at time of completion.
Completed Projects
HWSB® Skim Tank Deployment
West Texas, Oklahoma, Colorado, Wyoming, MontanaUSA
Deployed a fleet of HWSB® Skim Tanks across multiple production and SWD sites in the Permian Basin, dramatically increasing oil capture rates while reducing oil carryover rates to below 30 PPM thereby reducing produced water treatment and disposal costs for most major and independent operators.
Results
Recovered 18,000+ barrels of additional oil. Reduced disposal costs by 34%. Zero environmental incidents across all sites.
Eagle Ford Shale Oil Processing Systems
South Texas, USA
Engineered and designed complete central process facilities for high volume produced oil and water processing in multi-well pad operations in the Eagle Ford Shale where older process systems had failed. Developed the first true "plug-n-play" concept for high-volume, efficient three/four-phase separation configured into a 21st century facility design ideal for rapid assembly to meet the high demands of rapidly evolving operations expanded in the shale oil boom.
Results
Processed 45,000 barrels per day at peak. Achieved 99.2% oil-water separation efficiency. Project completed 3 weeks ahead of schedule.
unique Kansas water treating system Retrofit
North Dakota, USA
Retrofitted aging separation infrastructure at a legacy CTB facility. Removed thje top half of a wash tanka nad converted it intot a high efficiency HWSB skim tnak with next-generation patented HWSB® oil-water and DFSD® sand-waterseparation technologies. The project required minimal downtime and was successfully executed during active production.
Results
Increased oil recovery by 22%. Reduced operational downtime by 60%. Extended facility operational life by an estimated 15 years.
Salt Water Disposal Plant Design in Wyoming
Louisiana, USA
Currently engineering a moderate -scale water clarification system upgrade for a group of oil and gas producers in northeast Wyoming. The project involves custom-designs for the clients existing tankage and may incorporate the patented HWSB® ultra-efficient oil-water separation system and the patented DFSD® solids removaL systems integrated with the client's existing infrastructure.
Results
Phase 1 complete. Projected 100% improvement in separation efficiency upon commissioning.
Canadian Oil Sands Water Treatment Initiative
Alberta, Canada
Partnering with a major Canadian operator to deploy HWSB® Skim Tank technology in oil sands produced water treatment. The extreme conditions require specialized materials and engineering adaptations.
Results
Pilot phase showed a remarkable 31% improvement in effluent water qualityover legacy systems. The client commissioned a CFD modelling effort that confirmed the design and its performance. Full deployment took place immediately thereafter and the client decided to duplicate the new system in an adjacent plant.
Appalachian Basin Multi-Site Rollout
Pennsylvania & West Virginia, USA
Coordinated a multi-site rollout of standardized HWSB® Skim Tank configurations across 14 production locations in the Appalachian Basin, streamlining operations for a regional E&P company.
Results
14 sites operational within 90 days. Standardized maintenance reduced service costs by 41%. Operator reported highest quarterly production in company history.
Neuquen Basin Heater Treater Troubleshooting and Re-Design
Neuquén Province, Argentina
Engaged to diagnose and resolvechronic firetube and firetube flange failure issues in an existing heater treater installation in the Neuquén Basin. Breakthrough Engenuity engineers conducted a full root-cause analysis, identified design and operational deficiencies including the internal flow distribution and heat transfer sections, and executed a comprehensive re-design to restore separation efficiency under high-paraffin, variable-flow conditions.
Results
Separation efficiency restored to 98.6%. Emulsion carry-over eliminated. Operator avoided full vessel replacement, saving an estimated $1.2M in capital expenditure.
India's Largest Crude Oil Dehydration System Design
India
Designed India's largest crude oil dehydration system, engineered to process 200,000 barrels of oil per day to refinery inlet quality standards. Breakthrough Engenuity provided full process engineering, vessel sizing, and system integration design to meet stringent BS&W specifications required for direct refinery feed — a landmark project in scale and complexity for the region.
Results
System designed to process 200,000 BPD at refinery inlet quality. Full BS&W compliance achieved in design. Largest crude dehydration installation in India at time of completion.
Have a Project in Mind?
Our engineering team is ready to design a solution for your specific production challenges.