Process System Design
Chemical Process System Design, Turnkey Systems, Consulting, Engineering Design, and Major Equipment
CG Thermal is a leading chemical process system design manufacturer of heat exchangers, absorbers, and process equipment OEM with strong technical capabilities in thermal and mechanical design. We combine our extensive heat/mass transfer knowledge and fabrication capabilities with design and process expertise to deliver optimal, proven processing technology while incurring the lowest possible capital and operating expenses (CAPEX/OPEX) for the customer. Our team has a knack for understanding emerging markets and developing prototypes, as well as offering complete design and fabrication of pilot plants and modular plant systems with novel requirements.
We understand that the engineering specifications for industrial process equipment are as different as the customers themselves, so we are dedicated to working within your framework to provide the custom services that your job requires.
CG Thermal offers many options to address the needs of our customers including:
- Turnkey Packaged and Modular Plant Systems — Custom designed skid package system may include instrumentation, PLC, HMI, piping, electric and platforms, ladders, and other safety features per job requirements
- Consulting Services — Trouble-shooting, optimizing, and evaluating of existing plant operations
- Engineering Design Package — Complete engineering and operations design and documentation including Haz-Op review on customer site, and controls and control instrument loops
- Major Equipment Package — Exchangers, vessels, pumps, filters, controls, drums, tanks, etc.
Areas of Expertise
CG Thermal has extensive experience with chemical process system design and heat and mass transfer with particular focus on aggressive acids such as hydrochloric acid, sulfuric acid, hydrofluoric acid, phosphoric acid, nitric acid, and bromine. Our team of experts will assist you in designing the optimum solution for the application at hand. Our expertise extends to system designs such as:
- Dilution. Properly designed dilution systems work to address exothermic reactions and control product quality in industries like chemical processing, steel, refining, battery manufacturing, and more. CG Thermal manufactures skid-mounted, sulfuric acid dilution systems that can be custom-designed to address a variety of process requirements. We use Umax Advanced Ceramic or Impervite ® impervious graphite heat exchangers for their outstanding resistance to corrosion and thermal efficiency.
- Synthesis. Responsible for combustion, cooling of gas, absorption, and solution cooling, the synthesis process works to extract and optimize the ideal properties from reaction products. Synthesis minimizes environmental impacts and improves production safety and efficiency. At CG Thermal, we offer a unique burner design that results in an optimal CAPEX/OPEX solution.
- Scrubbers. Scrubbers control air pollution by removing particulate matter or gases from the air in chemical processing, steel production, and other industries. CG Thermal offers a variety of solutions and process system approaches to accomplish this, including sour gas stripping, stream conditioning, and VOC stream stripping.
- Absorption. The absorption process increases acid concentrations for feedstock, either isothermally or adiabatically. The absorption method impacts the maximum concentration of acid that can be maintained in a liquid, as well as the temperature at which the process can be carried out.
- Desorption. Thermal desorption systems use heat to increase contaminant volatility — often AHCL in gas or liquid form — so that it can be removed from production for reuse or disposal.
- Recovery. Acid waste is one of the most hazardous manufacturing byproducts — and also among the most expensive in terms of disposal. Recovery and reuse of these chemicals can reduce operating costs and improve environmental sustainability. With a complete line of fluoropolymer-lined components, our vacuum recovery systems concentrate H2S04 using a single- or multiple-effect arrangement.
- Azeotrope breaking. A required process when producing AHCL from HCL, azeotrope breaking (distillation) involves adding components to create a heterogeneous lower-boiling azeotrope. At CG Thermal, we can design vacuum-pressure or positive-pressure azeotrope breaking systems.
- Temperature control. Temperature control is vital in chemical milling, pickling, and other applications in which thermal precision is necessary to maintain product quality. Our team can produce a complete nitric acid skid-mounted system that includes the essential components — pumping, piping, and controls — to accurately moderate temperature and maximize production.
- Defluorination. Our team of experts provides defluorination process design and technology for the removal of HF from purified acid streams and hydrometallurgy, as well as manufacturing and design of DF columns.
Control Panels & Automation Services
In addition to complete process systems, CG Thermal offers standalone control panels and automation services to support a wide range of industries — from complex, process-critical operations in chemical manufacturing to specialized applications like bell tower automation.
Our electrical and control systems capabilities include:
Panel Building
Control panels serve as the interface between process operations and automation logic. They house power distribution, instrumentation, and control hardware needed to manage system performance. CG Thermal designs and fabricates custom panels tailored to project-specific requirements — including corrosive environments — for both new installations and system replacements.PLC/HMI Programming
PLC and HMI software coordinates field instrumentation and system logic to ensure safe, efficient, and adaptable operation. We develop application-specific programs for both legacy systems and new builds, with expertise in Allen-Bradley, Siemens, and AutomationDirect platforms.Retrofitting
Retrofitting extends the life and performance of existing systems by replacing outdated automation components. Our retrofit solutions improve functionality, replace obsolete hardware, and boost reliability — with minimal disruption to ongoing operations.System Expansions
Modern PLC-based control systems are modular and easily expanded to incorporate additional processes or equipment. Our team helps clients cost-effectively scale their systems by leveraging existing infrastructure and hardware.Troubleshooting
Reliable diagnostics are critical where aging hardware or outdated logic may impact performance. We provide troubleshooting support for relay-, pneumatic-, and PLC-based systems — including legacy applications such as bell tower automation — through loop tuning, logic revisions, and system optimization.Repair Services
When systems fail, quick and accurate repair is essential. CG Thermal delivers responsive repair services for control panels, PLC logic, and field instrumentation — isolating faults and restoring functionality across modern and legacy platforms.Whether as part of a complete turnkey system or a standalone solution, CG Thermal’s control and automation services are built on the core principles of safety, reliability, and flexibility.
Transition Metal Oxides (TMOs) – Precision Powders for Advanced Materials and Catalysis
CG Thermal offers custom-manufactured transition metal oxide (TMO) powders for specialty chemical, energy, and electronic applications. Our TMO program supports high-growth sectors such as catalysis, battery materials, fuel cells, polishing compounds, ceramics, and environmental technologies.
We specialize in thermal processing and spray pyrolysis to produce TMOs with precise control over purity, particle size, and phase composition.
Our Processing Capabilities Include:
- Spray pyrolysis and flame synthesis of mixed-metal oxides allow for efficient producion and fine control over surface area, morphology, and oxidation state
- Calcination furnaces for phase stabilization, crystallinity control, and high-temperature solid-state reactions
- Custom blending of chloride, nitrate, or organometallic precursors
- Small-batch and pilot-scale production of research and commercial oxide powders
- Material testing and certification: BET surface area, XRD phase ID, and particle morphology
Partner With Us – Sample Development and Technology Licensing
TMO Products and Capabilities
We support both undoped and doped formulations, and can tailor materials to meet specific surface area, crystal phase, or reactivity requirements. We have the capabilities to manufacture and formulate high-quality oxide powders including:
- Cerium Oxide (CeO₂) – for glass polishing, automotive catalysts, and solid oxide fuel cells
- Manganese Oxide (MnO₂, Mn₃O₄) – for batteries, supercapacitors, and wastewater treatment
- Silicon Dioxide (SiO₂) – for coatings, thermal insulation, and porous catalyst supports
- Nickel Oxide (NiO) – for fuel cells, hydrogen production, and semiconductor devices
- Doped Alumina (Al₂O₃) – for catalytic membranes, wear-resistant coatings, and chemical separations
- Cobalt Oxide (Co₃O₄) – for Fischer–Tropsch catalysts, battery cathodes, and gas sensors
- Zirconium Oxide (ZrO₂) – for advanced ceramics, dental materials, and oxygen sensors
- Vanadium Oxide (VO₂, V₂O₅) – for smart windows, thermochromic coatings, and electrochemical storage
Partnership Model
Beyond material sales, we offer a partnership model that includes:
- Sample production to support your formulation or R&D efforts
- Technical collaboration to scale production or fine-tune oxide behavior
- Optional technology licensing, allowing you to internalize production after successful validation
This model supports customers in:
- Electronics, clean energy, catalyst R&D, and custom ceramics
- Reducing supply chain risk and cost through localized production
- Maintaining IP control on next-generation materials
Applications and End-Use Industries
Our TMOs are used across industries including:
- Battery manufacturing (NiO, MnO₂, Co₃O₄)
- Catalysis and environmental remediation (CeO₂, Al₂O₃, ZrO₂)
- Optical and smart coatings (VO₂, SiO₂, doped oxides)
- High-performance ceramics and membranes (ZrO₂, Al₂O₃, CeO₂)
- Polishing and surface finishing (nano CeO₂, Al₂O₃)
Whether you need gram-scale samples or a long-term technology partner, CG Thermal is here to support your oxide material innovation. Contact us today!
Prototypes and Pilot Plants
Let our engineering team make your prototypes and pilot plants into a reality!
Combining our knowledge of heat and mass transfer along with our high-temperature design expertise, we’re equipped to provide innovate solutions to your unique reliability challenges. Our team of chemical, mechanical, and controls engineers are experts in reliable and cost-effective designs to achieve your desired result. Technology used in our heat exchangers and piping design are time-tested, and optimized for the high-temperatures experienced in many emerging markets.
Partner with CG Thermal for Optimal Plant Productivity
CG Thermal customers rely on our expertise in chemical process system design for thermal modeling, material selection, installation, and maintenance. We have developed close relationships with industry experts in every field that we work within. We collaborate with these partners to enhance our complete system process design and system build capabilities.
We pride ourselves on transparency, encouraging an open dialogue between our internal teams and our customers to inform the development of an optimal solution. We listen closely to our customers and anticipate their needs. This spirit of continuous improvement, fosters innovation in all of our products and services to develop ideal solutions that maximize the competitive positions of our customers.
We offer enhanced corrosion resistance to minimizing CAPEX on all our products as a central part of our company mission. To this end, we work closely with our technology partners and design team to recommend the most appropriate material for your process conditions, including standard and special metal alloy alternatives.
For more information on our process technologies, contact us today.
Technical Documents & Resources
