Low-Carbon Fuel & Hydrogen Production Systems Development
Owner’s Process Engineer for Advanced Pyrolysis and Syngas Technologies
Process Engineering International, LLC (PROCESS) served as the Owner’s Process Engineer for a technology startup developing innovative, low-carbon fuel and hydrogen production systems based on post-consumer plastic and tire feedstocks. The client sought support in advancing pilot-to-commercial technologies involving pyrolysis, syngas purification, and hydrogen fuel generation.
PROCESS provided technical leadership and engineering support across multiple development phases. This included reviews of pilot-scale pyrolysis systems, syngas purification concepts, commercial unit designs, and carbon-sequestration technologies. Additional support encompassed air-permit preparation assistance, detailed equipment assessments, and evaluation of potential commercial sites.
To move the client toward commercialization, PROCESS facilitated a series of engineering workshops to define the strategic design path for a next-generation prototype pyrolysis system. PROCESS engineers also performed safety assessments, energy optimization studies, and process/instrumentation reviews for both pyrolysis and gas-processing pilot units. Technical content was additionally developed to support investor marketing materials.
Services Provided
PROCESS delivered a comprehensive set of engineering services and technical work products, including:
- Micro-pilot unit design basis and complete detailed process engineering design package
- Syngas purification
- Process Flow Diagram (PFD)
- Syngas technology assessment
- Pyrolysis technology evaluations, including process safety, risk assessment, and performance reviews
- Pyrolysis heat and energy optimization study
- Pyrolysis process flow diagrams (PFDs)
- Control and instrumentation optimization assessments for pilot and commercial systems
- Technical sections for required air permits
- Heat and material balances (HMB) for continuous and batch pyrolysis systems
- Vendor and unit-operation technology advisement
- Greenfield and brownfield site layout concepts and utility requirement assessments
- Process descriptions and contributions to technical brochures and marketing packages
- Evaluation and impressions of potential chemical engineering new hires
Project Outcome
Following completion of the advisory phase, PROCESS transitioned into a full process design role for both pilot-scale and commercial pyrolysis units, while continuing to provide ongoing engineering consultation to support the client’s technology development and commercialization pathway.