Gerhard Hofer · Carbon Consulting
Energy & Material Flow Modeling for Industrial Decarbonization
Independent Technical Analysis for Complex Industrial Decisions
Uncover hidden assumptions, understand system boundaries, and make confident technical and investment decisions.
Industrial decarbonization is rarely a single technology choice. It is a systems problem shaped by energy flows, equipment constraints, operational realities, and financial trade-offs.
We support you with high-fidelity process modeling and structured scenario analysis, helping you evaluate retrofit pathways, technology options, and operational improvements under real-world constraints.
Questions we can help you answer:
- Where do energy efficiency improvements have the largest impact in my facility?
- Which retrofit pathways are technically and economically viable under my constraints?
- How can I reduce emissions without compromising operational reliability?
- Which decarbonization pathways remain economically sound under the uncertainties I am facing?
>> 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 ↗︎)
Representative Work
A few examples of recent projects:
District Heating System Strategy & Expansion Assessment
A system-wide expansion assessment identified a pathway to 15–25% lower biomass consumption while eliminating reliance on external peak heat supply.
Expansion Modeling for Paper Plant
The facility analysis showed that expanding production with the existing NGCC would increase operating costs by ~65%, while a CFB retrofit reduced them by ~15%.
Biomass Power Plant Development & Commissioning
Technical support during startup of a 40 MWth biomass power plant, including risk assessment, commissioning, system validation, and multidisciplinary coordination.
Discover more Project Highlights.
Services
Find out how your assets interact before deciding what to change.
Physics-based process models and digital twins uncover bottlenecks, identify efficiency opportunities, and evaluate retrofit concepts before capital is committed.
- Energy and mass flow modeling of industrial systems
- Digital twin development for systems understanding, operational analysis, and optimization
- Heat integration and efficiency boost
- Retrofit and technology integration studies
- Fuel-switching and electrification pathway assessment
- Operational scenario analysis
Test decarbonization pathways before making the investment.
Process modeling and techno-economic analysis quantify trade-offs across decarbonization pathways and evaluate their performance under uncertainty.
- 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
Get an independent view before relying on someone else’s assumptions.
Vendor materials, engineering studies, and simulation chains are reviewed to reveal hidden assumptions, assess technical claims, and strengthen the basis for your decision.
- Evaluation of vendor materials, models, and assumptions
- Reconstruction or simplification of complex process models
- Focused technical audits
Working Approach
We deliver high-quality technical 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 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 technical and investment decisions.
Download the GH‑CC Capabilities Overview (PDF)
About
Gerhard Hofer, PhD
Founder & Technical Consultant 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-emission technologies
He has more than a decade of experience in supporting industrial and research clients with process modeling, system optimization, and techno-economic analysis.
Technical experience includes DWSIM, IPSEpro, MATLAB, and custom modeling workflows.
Engineering Thinking
Holistic Engineering
Does a solution still work once the system interacts with the world around it?
Expanding the System Boundary
Why shifting the boundary often changes the engineering solution.
Plant Health
Why operational performance is rarely determined by a single variable.
Contact
Discuss your project
We currently take on a limited number of engagements to ensure focused, high-quality technical work.
If you are evaluating a technology upgrade, questioning assumptions in a proposal or vendor model, exploring what a digital twin could reveal, or comparing 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.
