Case Study: Natco Group, Inc. achieves up to 45% improved oil separation and a compact, motion‑resistant IGF system with ANSYS Fluent

Computer Simulation Improves Oil Separation in Water Treatment System, Exceeds EPA Standards by as Much as 45 Percent

Natco Group, Inc., a long‑standing provider of well‑head process equipment for the oil and gas industry, needed to optimize its induced gas flotation (IGF) water‑treatment systems for use on space‑ and weight‑constrained offshore platforms. The main challenges were limited deck space, strict weight limits, and uneven gas‑bubble distribution in vertical vessels that reduced oil‑separation efficiency. To address this, Natco worked with ANSYS and used ANSYS Fluent CFD software to evaluate and refine IGF designs before building prototypes.

Using ANSYS Fluent simulations, Natco assessed multiple design concepts, identified deficiencies in the original design, and iterated hardware changes that improved gas distribution and separation performance. The ANSYS‑driven solution produced a small, lightweight package resistant to platform motion, reduced reliance on treating chemicals, and became a core component for offshore produced‑water systems — ultimately exceeding EPA oil‑separation standards by as much as 45% and validating platform resilience under real storm loading (Hurricane Gustav).

Natco Group, Inc.