Process Engineering Consulting & Simulation

Process engineering focuses on designing, analyzing, and optimizing industrial systems that convert raw materials into valuable products. In industries such as oil & gas, refining, petrochemicals, and gas treating, process engineering plays a critical role in ensuring that operations run safely, efficiently, and profitably. It involves understanding how fluids, chemicals, heat, and equipment interact in a process unit, for improving  process performance.

At Nexo Solutions, process engineering goes beyond theoretical design. It is applied directly to real-world operations such as amine units, dehydration units, and other gas & liquids processing facilities. The goal is continuously improve  performance and profitability by increasing plant capacity, reducing energy consumption, or eliminating operational challenges like foaming, fouling, or corrosion. By combining field experience with advanced process simulation tools, process engineering becomes a powerful driver of plant optimization and long-term reliability.

Nexo Solutions brings a highly specialized approach to process engineering, built around deep expertise in gas treating, process simulation, and real-world plant optimization. Our team works directly with operators, engineers, and plant managers to evaluate each system individually and develop solutions that are tailored—not generic.

One of the core pillars of our work is process simulation. Using advanced modeling tools, we recreate operating conditions within amine systems, dehydration units, LPG/NGL processing systems, and other gas processing assets. These simulations allow us to evaluate temperature profiles, solvent loading, hydrocarbon behavior, and energy consumption under different scenarios. By doing this, we can identify inefficiencies, predict potential failures, and recommend optimized operating conditions before changes are implemented in the field. 

Another critical area is technology development and selection. Many facilities struggle with underperforming equipment or mismatched technologies—whether it’s filtration systems, coalescers, activated carbon beds, or chemical additives. Nexo Solutions evaluates all available options based on actual process conditions, contamination profiles, and performance requirements. This ensures that the selected technology is not only effective but also cost-efficient and sustainable over time. 

In addition to simulation and design, Nexo Solutions provides onsite troubleshooting, testing, and unit audits. These services include contamination analysis, corrosion and fouling root cause analysis, gas composition testing, and performance evaluations of filters and coalescers. Our approach ensures that both the theoretical and practical aspects of process engineering are fully aligned for optimal results.

A common example of process engineering in action is the optimization of an amine system in a gas treating facility. Many plants experience issues such as solvent foaming, amine losses, reduced throughput, or failure to meet H₂S and CO₂ specifications. These problems are often caused by contamination, poor operating conditions, or improper equipment performance.

In one case, a facility was experiencing high amine losses and unstable operation in their contactor. Nexo Solutions conducted a full process evaluation, including inlet contamination analysis, solvent testing, and process simulation. The results identified hydrocarbon ingress and surfactant contamination as the primary drivers of foaming and solvent carryover. 

Using this data, we implemented a multi-step solution that included:

• Optimization of operating set points 
• Improved filtration and coalescing systems 
• Targeted chemical treatment using antifoams and emulsion breakers 
• Adjustments to separation equipment performance 

The outcome was a significant reduction in solvent losses, improved gas treating efficiency, and increased overall plant reliability.

Similarly, in TEG (triethylene glycol) dehydration systems, issues such as poor water removal, foaming, or contamination can reduce efficiency and increase operating costs. Through process simulation and onsite testing, Nexo Solutions identifies root causes such as glycol contamination, equipment inefficiencies, or improper regeneration conditions. Corrective actions may include equipment modifications, process adjustments, or improved separation technologies.

These types of projects demonstrate how process engineering, when applied correctly, transforms unstable systems into optimized, high-performing assets.

Working with Nexo Solutions provides immediate and long-term benefits for operators and facilities. One of the most important advantages is faster troubleshooting. Instead of relying on trial-and-error approaches, our combination of process simulation, field testing, and engineering expertise allows us to quickly identify root causes and implement targeted solutions.

Clients also benefit from improved plant optimization. By fine-tuning process conditions, selecting the right technologies, and addressing contamination issues, we help facilities increase throughput, improve product quality, and maintain consistent performance. This is especially critical in gas treating and amine systems, where small inefficiencies can lead to significant operational and financial impacts.

Another key benefit is cost savings. Process optimization reduces energy consumption, minimizes chemical usage, and prevents equipment failures. Programs such as operational cost reduction initiatives focus on lowering expenses related to solvent losses, filtration, and maintenance while improving overall efficiency. 

Additionally, our solutions support sustainability and emissions reduction by improving process stability and minimizing waste. From reducing methane and CO₂ emissions to optimizing energy use, process engineering plays a direct role in helping facilities meet environmental and ESG goals.

Nexo Solutions provides one of the most comprehensive offerings in process engineering, combining consulting, onsite testing, laboratory analysis, and advanced process simulation. Every solution is customized to the specific unit, plant, and operating conditions to ensure maximum performance, reliability, and profitability. 

With deep expertise in gas processing, gas treating, and amine systems, we help facilities solve complex challenges such as:

• Solvent foaming and contamination 
• Equipment fouling and corrosion 
• High operational costs 
• Inefficient processes and reduced capacity 
• Failure to meet product specifications  

Our approach is simple: identify the problem, validate it with data, and implement solutions that deliver measurable results.