Process engineering · scale-up · decision support

Turn complex process technologies into decision-ready engineering.

ONB Engineering provides process modeling, reactor scale-up, FEL studies, equipment design, and techno-economic analysis for chemical, energy, mining, and manufacturing technologies.

  • Ph.D. & P.E.-led
  • 25+ R&D projects
  • Concept-to-Scale-Up Support
  • Global client support

What ONB Engineering does

Engineering work that reduces uncertainty before the next commitment.

Technology teams need more than a simulation or a report. They need a traceable engineering basis that clarifies performance, scale-up risk, equipment requirements, economics, and the next evidence to collect.

ONB Engineering combines process and reactor modeling with practical engineering judgment to support laboratory-to-pilot development, preliminary engineering, investment review, manufacturing decisions, and process optimization.

About ONB Engineering

Core services

Four ways ONB Engineering helps move a technology or process forward.

Each engagement is scoped around the decision the client needs to make—not around producing analysis for its own sake.

01

Process & Reactor Modeling

Develop and validate fit-for-purpose models that define performance, operating windows, and key sensitivities.

  • Process flowsheet model (e.g. Aspen Plus, Aspen HYSYS or other)
  • Kinetics and parameter estimation
  • Sensitivity and uncertainty analysis
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02

Reactor Scale-Up & Engineering Packages

Translate laboratory or pilot information into a practical scale-up basis, preliminary equipment definition, and next-stage engineering package.

  • FEL-1 and FEL-2 studies
  • Mass and energy balances
  • Equipment sizing and datasheets
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03

Techno-Economic & Sustainability Analysis

Quantify cost, commercial sensitivities, and environmental performance before additional capital or development effort is committed.

  • CAPEX and OPEX estimates
  • TEA, DFMA, TCO, and LCA
  • Scenario and cost-driver analysis
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04

Technical Due Diligence & Optimization

Evaluate technical claims, scale-up readiness, process risks, manufacturing constraints, and improvement opportunities.

  • Independent technical review
  • Debottlenecking and value walks
  • Manufacturing and process redesign
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Typical deliverables

Engineering work that ends in a usable decision package.

The exact deliverables depend on project stage, data quality, required accuracy, and the client’s decision.

Documented process or reactor model
Mass and energy balances
Operating-window and sensitivity analysis
Scale-up risks and data gaps
Equipment sizing and preliminary datasheets
Process flow diagrams and engineering basis
CAPEX, OPEX, and cost-driver model
Decision memo and prioritized next steps

How an engagement works

A focused process from open question to engineering recommendation.

Define the decision

Clarify the technical or commercial decision, available data, required accuracy, timeline, and project constraints.

Build and validate the analysis

Develop the appropriate model, engineering basis, or assessment while documenting assumptions, uncertainty, and data gaps.

Deliver engineering and next actions

Provide the agreed deliverables, conclusions, and prioritized recommendations for testing, scale-up, procurement, investment, or further engineering.

Representative engagement types

Common situations where ONB Engineering adds leverage.

These are examples of how an engagement may be structured. Project scope is tailored to the client’s technology, evidence, and decision.

Industries and domain expertise

Deep process-engineering capability across complex industrial systems.

ONB Engineering supports chemical, energy, oil and gas, mining and critical-mineral, and manufacturing technologies. The analytical methods are selected to fit the physical system and decision—not forced into a generic template.

  • Gasification
  • Pyrolysis
  • Fischer-Tropsch
  • Multiphase reactors
  • Hydrogen generation
  • CCUS / CCU
  • Catalysis and reaction engineering
  • Specialty chemicals
  • Computational fluid dynamics
  • Advanced manufacturing
  • Process optimization
  • Critical minerals

Principal engineer

Omar M. Basha, Ph.D., P.E.

Dr. Basha leads ONB Engineering and supports technology developers, manufacturers, and investors with process modeling, reactor engineering, scale-up, preliminary engineering, techno-economic analysis, and technical decision support.

His work focuses on converting complex technical information into documented assumptions, fit-for-purpose models, and practical development or investment recommendations.

Start with the decision

Have a process, scale-up, or investment question to de-risk?

Schedule a 30-minute project-fit call. Bring the available process description, project stage, timeline, and the decision your team needs to make.