Gerhard Hofer · Carbon Consulting
Energy & Material Flow Modeling for Industrial Decarbonization
Industrial Process Modeling & Scenario Analysis
Turning complex energy and material systems into actionable engineering insight.
Industrial decarbonization is rarely a single technology decision. It is a system problem involving energy flows, equipment constraints, operational realities, and financial trade-offs.
We support engineering teams and asset owners with high-fidelity process modeling and structured scenario analysis, enabling confident decisions around retrofit pathways and operational optimization.
Our work helps identify:
- Energy efficiency improvements
- Equipment retrofit opportunities
- Low-emission operating strategies
- Economically viable decarbonization pathways
Progress doesn’t always require new equipment; often it just takes a clearer view of what’s already there.
Services
Process & System Modeling
Detailed simulation of industrial energy and material flows to identify operational improvements and evaluate retrofit strategies. Capabilities include:
- Energy and mass flow modeling of industrial systems
- Heat integration and efficiency optimization
- Retrofit and technology integration studies
- Evaluation of fuel-switching and electrification pathways
- Operational strategy development
Decarbonization Scenario Analysis
Structured comparison of CO₂ reduction pathways combining engineering modeling with techno-economic evaluation. Typical engagements include:
- Strategic modeling for decarbonization planning
- Comparison of retrofit and low-emission technology pathways
- Techno-economic scenario analysis (TEA)
- Monte-Carlo uncertainty analysis for investment decisions
- Executive-level technical memos and briefing reports
Independent Model & Technical Review
Objective evaluation of vendor models, engineering studies, and simulation chains helps organizations de-risk engineering decisions and clarify complex analyses. Typical work includes:
- Validation of simulation models and assumptions
- Independent review of vendor proposals
- Reconstruction or simplification of complex process models
- Focused technical audits of decarbonization concepts
Working Approach
Projects are designed to deliver high-quality engineering insight with minimal overhead.
- Efficient onboarding
Clients provide available documentation and operating data; we establish scope quickly. - Independent technical work
Model development and analysis are conducted independently to maximize efficiency and focus. - Structured communication
Short alignment calls at project start and conclusion, with concise progress updates during analysis. - Flexible engagement scope
Assignments range from rapid technical reviews to multi-week modeling and scenario studies.
The objective is always the same: clear, technically grounded guidance for complex engineering decisions.
Typical Partners
We collaborate with organizations that require specialized modeling expertise without expanding internal engineering teams.
- Engineering, procurement, and construction (EPC) firms requiring specialized modeling support
- Industrial and municipal operators evaluating retrofit, electrification, or low-emission pathways
- Waste-to-energy and thermal system developers
- Infrastructure investors requiring independent technical analysis
- Researchers and consultants requiring high-quality simulation support
See selected Project Highlights.
Leadership
Gerhard Hofer, PhD
Founder & Lead Process Engineer specializing in industrial thermal systems, process simulation, and decarbonization pathway analysis
Dr. Hofer’s work focuses on the modeling and evaluation of complex energy systems including:
- High-temperature thermal processes
- Boiler and combustion systems
- Waste-to-energy technologies (#WECCUM)
- Carbon capture and negative emissions systems
He has more than a decade of experience in supporting industrial and research clients with process modeling, system optimization, and techno-economic analysis.
Technical tools include DWSIM, IPSEpro, and custom modeling workflows.
Contact
Discuss your project
We currently take on a limited number of engagements to ensure focused technical work.
If you are evaluating technology upgrade strategies, reviewing engineering proposals, or exploring decarbonization pathways, feel free to reach out.
Submit a brief description of your project and we will follow up to explore potential collaboration.