Winning repeat business with modular oil and gas solutions

UAE

Walter Moraes, founder and chairman of Ferrofab, talks to The Energy Year about the advantages of utilising modular early production facilities for crude extraction and the company’s involvement in innovative solutions for offshore wind farms. Ferrofab is a manufacturer of modular and static oil and gas process equipment for offshore and onshore production and a provider of renewable energy solutions.

Who are Ferrofab’s principal clients in the upstream and downstream?
The energy sector, particularly oil and gas, is a tight-knit ecosystem of key players. Over the years, Ferrofab has established strong partnerships with leading global companies across both upstream and downstream segments. Our client base includes major national and international energy firms, as well as renowned service providers within the industry. Notably, 90% of our clients are repeat customers, reflecting their trust in our capabilities.
For 25 years, we have maintained a core focus on manufacturing modular and static oil and gas process equipment for both onshore and offshore production. While actively expanding into renewables, we believe that oil and gas will remain critical for decades, given the untapped reserves and with the economic viability of renewable solutions still maturing.

Can you comment on the advantages that early production facilities (EPFs) can offer?
EPFs are a valuable solution for operators looking to maximise production efficiency and return on investment, especially in smaller or marginal oil fields. Raw crude often contains impurities such as water – sometimes as high as 60% – sand and gases. Without proper separation and treatment, this oil cannot be directly sold as SAE-grade crude, which is the world standard.
The costs associated with traditional production setups can be substantial depending on the complexity and size of the operations. This can be challenging for operators, particularly in the early stages. Here is where EPFs drive value. Our EPF separation modules are designed for affordability and rapid deployment, with installation typically possible within a few months.
Once the EPF is operational, many clients can expect to recover their initial investment in a relatively short period, depending on production rates and operational efficiencies. This swift return enables operators to reinvest in additional wells or further production modules, allowing them to scale production incrementally with a comparatively low initial capital investment.

What role does R&D play in your expansion strategy?
Ferrofab continuously invests in resources, capabilities and infrastructure to meet the growing demands of the energy industry. With a total manufacturing area of 80,000 square metres in Dubai – our headquarters is situated inside the port’s free zone, and another facility is strategically located near the port quayside for transporting oversized equipment – we are well-positioned to handle large-scale, complex projects.
Our focus on engineering innovation drives our growth. We have a dedicated engineering office in India that supports design solutions, process optimisation and technical research. This enables us to enhance our manufacturing efficiency and explore solutions which address emerging energy trends.
Recently, we completed a significant milestone by delivering two Alloy-825-clad vessels in the Middle East, each weighing 323 tonnes. This project required us to adapt and refine our manufacturing processes, showcasing our ability to deliver bespoke, high-quality solutions for demanding projects.
We are actively exploring opportunities in the renewable energy space, including offshore wind. Having supported pioneering work on floating offshore platforms for wind turbines, we have collaborated with several key players, such as Gazelle Wind Power. Floating platforms represent an important advancement in wind power as they reduce material requirements compared to fixed foundations, lower maintenance costs and enable the optimisation of energy capture in offshore locations.
In line with global decarbonisation goals, we are also researching solutions for hydrogen production, storage and transportation. Transporting hydrogen continues to be a challenge due to the high costs associated with liquefying and storing it under extreme pressure and temperature. One promising avenue is to convert hydrogen into ammonia for safer and more economical transport.
We are keenly exploring opportunities for collaboration with companies in areas such as ammonia infrastructure, hydrogen technologies and CCUS to actively contribute to the energy transition. Over the next two years, we aim to expand our focus on carbon capture and ammonia-based solutions.

What percentage of your revenues comes from international markets?
Around 30% of our revenue is generated in the Middle East, with the remainder coming from international markets. Africa has been a focus for us, given its unique business environment and emerging energy opportunities.
We have successfully established a presence in Ghana, where we own 25 acres of land within a strategic free zone. This location places us near major oilfield service providers, enabling us to support the region’s growing energy needs. Ghana has proven to be a stable and promising market due to its strong governance, safety and transparent business environment.
The Middle East remains central to our operations, with Saudi Arabia being a market of significant interest. Currently, we supply critical components to the Saudi market, with Saudi inspectors being dispatched to our UAE facilities to approve equipment prior to delivery. We are actively working on a plan to establish a geographical presence in the country as well.
We recognise that setting up a large-scale facility in Saudi Arabia, similar to our operations in Dubai, will involve extended approval timelines. However, we remain committed to exploring this opportunity as part of our long-term strategy.
In the UAE, we have made notable investments to expand our infrastructure and ease our client’s logistics and handling costs. Our facility in the Jebel Ali Free Zone is conveniently located close to the quayside, offering a distinct advantage for capably handling oversized equipment. It has proven to be one of the most valuable additions to our capabilities in recent years.

How would you summarise your business outlook for the next five years?
We take pride in our ability to adapt and innovate in a rapidly evolving energy industry. While oil and gas remain the cornerstone of our operations, we embrace the opportunities presented by renewable energy, hydrogen and carbon capture technologies to contribute meaningfully to the global energy transition. Our focus continues to be on building strong partnerships, driving innovation and providing bespoke solutions. We remain committed to delivering value to our clients and being a trusted partner in shaping a sustainable energy future.

Read our latest insights on:

• Ghana
• India
• Saudi Arabia
• UAE