In a recent computational engineering with Dieffenbacher, aixprocess assessed and
Independent Process Optimisation & Fuel Switch Engineering for O&G / Petrochemicals
Reduce CO₂/fuel costs, mitigate NOx emissions, and de-risk fuel switching (e.g., to H₂)
Page last modified
October 22 2025
Operators of industrial furnaces, reactors, and boilers in the Oil & Gas and Petrochemical sectors face dual pressures: meeting stringent emissions legislation (NOx, CO) while simultaneously navigating the risks of decarbonisation strategies, such as fuel switching to hydrogen or electrification. Operational challenges, including process bottlenecks or efficiency losses, often have an unclear 'root cause'.
aixprocess GmbH is a specialised, supplier-agnostic engineering consultancy providing data-driven decisions for high-temperature process optimisation. With over 20 years of experience, we do not sell hardware; we utilise advanced 'Computational Engineering' (e.g., CFD, DEM) and 'Digital Twin' models to analyse, troubleshoot, and optimise your specific process, identifying the objectively best solution.
Our services provide clarity and de-risk capital-intensive modifications.
Core Service Scope:
- Decarbonisation & Fuel Switch Engineering: Analysing the impact of H₂, biofuels, or other alternative fuels on your existing assets (burners, furnaces) regarding safety, performance, and emissions.
- Emission Mitigation Studies: Root cause analysis and optimisation to reduce NOx and CO emissions.
- Safety & De-Risking: Simulating hazardous scenarios or process changes to ensure operational safety.
- Debottlenecking & Root Cause Analysis: Identifying and resolving efficiency losses or bottlenecks in complex systems (e.g., reactors, cyclones, flue gas systems).
- Furnace Electrification & Thermal Management: Modelling the impact of switching to electric heating on your process and materials.
Pros & Limitations
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Completely Supplier-Agnostic: Our advice is 100% objective, focusing on the best technical and economic solution for the client, not on selling specific hardware.
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Quantifiable Cost & CO₂ Reduction: Typical projects identify 5-15% fuel cost and CO₂ reduction through combustion process intensification.
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Proven Emission Mitigation: We provide clear pathways for emission reduction, with projects achieving up to 90% CO and 40% NOx reduction.
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De-Risk Major CAPEX: We use 'Digital Twins' to validate the performance, safety, and operational impact of fuel switching or electrification before significant capital investment is made.
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Deep Niche Expertise: We leverage over 20 years of specialised experience in complex high-temperature processes (combustion, pyrolysis, gasification) with a scientific foundation from RWTH Aachen.
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Engineering Service: Our deliverable is an expert engineering service (e.g., a simulation study, optimisation report, or digital model), not a physical hardware product (With the exception of cyclone technology )
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Data-Dependent: The accuracy and value of the analysis depend on the availability of sufficient operational data and technical drawings (e.g., P&IDs, CAD models) from the client.
Our Expertise
| Expertise Title | Expertise Description |
|---|---|
|
Oil & Gas
|
Design & procurement of decoking gas cyclones
CFD Digital twins for multi-phase operations Fluid Catalytic Cracking-FCC - Burners & furnaces - Polymerisation reactors - Heat exchangers - Phase separators Advanced data analytics Feasibility & design studies |
|
Chemicals
|
CFD Digital twins for multi-phase operations
- Gassed stirred reactors - Dynamic/static mixers - High-temperature equipment Solids operations - Fluidized bed reactors - Nano-particle synthesis - Solids mixer - Dryer - Mills - Cyclones Fluid-structure interaction / Stress calculation Thermal management Fluid-structure interaction / Stress calculation Thermal management |
|
Cement & Minerals
|
Comprehensive data acquisition with detailed processes and plant audits
Data audit of historians Multilevel modelling: real-physics cement CFD Flowsheet model offline & online Conceptual Engineering Mill PILOT & Kiln PILOT: Digital Real-Time Optimiser |
|
Steel
|
CFD Digital twins for multi-phase operations
- Blast furnace PCI - Pneumatic dust conveying & quenching - Melt injection lances - Fume & dust suction system Design & procurement of swirl separators for spark & coarse grain de-dusting Dust and fume dispersal measurements |
|
Pharmaceutical
|
Pre-defined digital twins
- Stirred reactors - Crystalliser - Blender & Mixer - Mills - Dosing and tableting equipment - Spray dryer - Fluidized beds Tailored digital twin development Virtual DoE to reduce Cost of Goods and analytics efforts Development, scale-up and tech-transfer support Technological consulting |
|
Power
|
Subject matter expertise in multi-fuel gasification and combustion
- Pulverised fuel boilers - Fluidised bed equipment - Grate furnaces Digital twins for green hydrogen generation and utilisation |
|
Thermo Process
|
CFD Digital twins for:
- Aeration tanks & basins - Burners - Furnaces - Airflow & distribution - Heat exchangers Tailored process models for long-term operations |
|
Water
|
CFD digital twins for:
- Aeration tanks & basins - Sedimentation - Sludge separation - Sludge fermenters - Agitated digestion towers - Ozonation and trace element elimination |
Specification
| Title | Description |
|---|---|
| Theme/Discipline | Process EngineeringUtilities & Heat TransferDesign & Concept Select |
| Core Tech | Process EquipmentDigital TwinConsultancy |
|
Technical Areas
|
Oil & Gas
Petrochemicals Chemical Industry Cement & Lime Steel & Non-Ferrous Metallurgy Environmental Technology |
|
Fields of Expertise (Applications)
|
Multi-Fuel Burners & Furnaces
Pyrolysis, Gasification & Combustion Reactor & Boiler Systems Flue Gas Systems Fluidised Beds Cyclone & Separator Technology (e.g., FCC) Chemical Recycling Hydrogen Technology Rotating Machinery |
Latest Updates
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Technology Readiness Level
The Technology Readiness Level (TRL) indicates the maturity level of novel technologies. Learn more about the TRL scale used by us.
[9/9]
Development
Technology demonstration
Mature / Proven
aixprocess is a German technology consulting company specializing in process simulation, optimization, and digitalization. They use advanced computational tools and process expertise to help industrial customers optimize operational investments, accelerate new product development, and reduce risks. The company was founded in the late 1990s at RWTH Aachen University and originally focused on applying simulation technology to process industry challenges. Over 20+ years they have developed a suite of simulation, modeling, data analytics, and AI tools tailored for industries like chemicals, cement, metals, renewable energy, pharmaceuticals, refining, and water treatment. Their mission is "de-risking operational investments" by leveraging digitally-generated knowledge to solve real-world engineering problems. They aim to combine deep process knowledge with leading-edge simulation technology to generate value for customers far faster than traditional methods.
Country of Headquarters
Germany
Contact:
+4924141344920
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