Gerhard Hofer · Carbon Consulting
Energy & Material Flow Modeling for Industrial Decarbonization
Industrial Process Modeling & Scenario Analysis
Turning complex energy and material systems into clear, actionable engineering insight.
Industrial decarbonization is rarely a single technology decision. It is a system problem shaped by energy flows, equipment constraints, operational realities, and financial trade-offs.
We support organizations facing high-stakes engineering and investment decisions with high-fidelity process modeling and structured scenario analysis, enabling confident choices around retrofit pathways, technology options, and operational optimization.
Our work helps you decide:
- Where energy efficiency improvements have the largest impact.
- Which equipment retrofits are technically and economically viable.
- How to operate with lower emissions without compromising reliability.
- Which decarbonization pathways are economically sound under uncertainty.
>> Progress doesn’t always require new equipment; often it just takes a clearer view of what’s already there. <<
Solid Waste Combustor (Generated with DWSIM↗︎)
High Temperature Heat Pump (Generated with DWSIM↗︎)
Moving Bed Heat Exchanger (Generated with DWSIM↗︎)
Services
Operational & Retrofit Modeling
We build detailed models of industrial energy and material flows to identify efficiency gains, retrofit opportunities, and practical operational improvements.
- Energy and mass flow modeling of industrial systems.
- Heat integration and efficiency optimization.
- Retrofit and technology integration studies.
- Fuel-switching and electrification pathway assessment.
- Operational strategy development.
Decarbonization Scenario Analysis
We compare CO₂ reduction pathways using engineering models and techno-economic analysis, helping teams evaluate tradeoffs before committing capital.
- Strategic modeling for decarbonization planning.
- Comparison of retrofit and low-emission technology pathways.
- Techno-economic analysis.
- Uncertainty analysis for investment decisions.
- Executive-level technical memos and briefing reports.
Independent Technical Review
We provide objective review of vendor models, engineering studies, and simulation chains to help de-risk decisions and clarify complex technical claims.
- Validation of models and assumptions.
- Independent review of vendor proposals.
- Reconstruction or simplification of complex process models.
- Focused technical audits.
Working Approach
We deliver high-quality engineering insight with minimal overhead, so you can make decisions faster without drawing internal resources away from core work.
Efficient onboarding
You provide available documentation and operating data; we establish scope quickly and begin work without long lead times.
Independent technical work
Model development and analysis are conducted independently, so you get focused, unbiased engineering insight without internal coordination overhead.
Structured communication
We keep meetings minimal: short alignment calls at the start and conclusion, with concise progress updates during analysis.
Flexible engagement scope
Engagements range from rapid technical reviews to multi-week modeling and scenario studies, depending on the decision you need to make.
The objective is always the same: clear, technically grounded guidance for complex engineering and investment decisions.
Typical Partners
We support organizations facing important technical and capital allocation decisions, providing specialized modeling expertise where internal capacity is limited or independent analysis is needed.
- Infrastructure investors requiring independent technical diligence and risk assessment.
- Developers and project sponsors evaluating retrofit, electrification, and low-emission investment pathways.
- Engineering, procurement, and construction (EPC) firms needing advanced modeling support for complex industrial projects.
- Industrial and municipal operators considering operational optimization and decarbonization.
- Waste-to-energy and thermal system developers advancing process design and implementation.
- Researchers and consultants seeking rigorous 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:
- Thermal processes
- Fluidization technologies
- Boiler and combustion systems
- Waste-to-energy technologies
- 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, high-quality technical work.
If you are evaluating technology upgrades, reviewing engineering proposals or vendor models, or exploring decarbonization pathways before committing capital, feel free to reach out.
Submit a brief description of your project and the decision you need to make, and we will follow up.
