expertise in action

Process Engineering and Design

Process Engineering and Design

At HRL we offer unique process and engineering design capability to assist you in optimising the output and efficiency of existing processes, identifying the root cause of process and problems, and developing innovative process technologies and solutions.

We work with you closely to understand your particular commercial needs and develop tailored solutions.

Our process engineering and design services are applied to wide-ranging applications, with a strong focus on energy industries with high demand for steam, power and natural gas, and processes which operate at high pressure and / or high temperature such as combustion, gasification and pyrolysis.

What sets us apart is our in-house analytical laboratory, the ability to construct and operate pilot-scale rigs to simulate industrial processes, advanced desktop modelling tools, and plant performance testing capability.

How can we help

Our process engineering and design services include:

  • Resource characterisation and evaluation particularly for solid fuels such as coal, biomass, and waste
  • Process development, scale-up  and owner's engineer support from process concept through to implementation
  • Bench and pilot scale process simulation using in-house or purpose-built equipment - examples include gasification, pyrolysis, activated carbon production, hydrothermal dewatering, briquetting, and pelletisation
  • Process modelling and optimisation using advanced desk-top process simulation (Thermoflow) and computational fluid dynamics (CFD - Fluent)
  • Process and equipment design and troubleshooting
  • Technical and economic feasibility studies including capital and operating cost estimation
  • Energy efficiency auditing and optimisation
  • Front End Engineering Design (FEED) studies
  • Turnkey implementation of innovative process solutions

Meet the expert


Sam has over 14 years of experience in energy efficiency, fuel switching and the implementation of cost saving options from the findings of energy efficient audits on large industrial plants. Sam has extensive experience in evaluation of upgrading and utilisation options for gas, biomass and other fuels. His experience includes material/fuel characterization, practical research and demonstration, techno-economic assessments, and detailed feasibility studies.

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What Our Clients Say

"For certain alleged foreign matter complaints in our products we need not only the analytical services provided by the lab there at HRL, but particularly the expert opinion of scientists such as Greg Richards to give an independent opinion on the ...

Andrew Penncuick
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Ready to transform your business performance?

Contact our technical consultants on -
+61 3 9565 9888
or to get started today.

Our Certifications


NATA accredited AtS/NZS ISO 17025, AS/NZS ISO 17020NATA Accredited Laboratories number 561

ISO 9001 Quality Management

ISO 9001 Quality Management certified by BSI under certificate number FS605116.