Process Systems Engineering & Operations Research

Expert Modeling for Process Innovation

Zynstace bridges the gap between R&D and operational scale by integrating high-fidelity steady-state and dynamic modeling directly into your decision-making loop. We provide the custom modeling, parameter estimation, and conceptual design expertise needed to translate complex process physics into actionable decision metrics, helping engineering teams compress design cycles and de-risk the path to production.

Core Capabilities
Process Simulation
Dynamic & steady-state modeling
Simulation
Model Calibration
Parameter estimation & design of experiments
Validation
Custom Model Development
Built around your specific process chemistry
Custom Build
Scale-Up Support
Bench to pilot to commercial
Scale-Up
These capabilities span renewable chemicals, biochemicals, critical minerals, and water/wastewater treatment — wherever your process needs rigorous modeling, we adapt to your specific challenge.

Your Growth Is Our Commitment

Who We Serve

Delivering value across industriess

We go beyond standard simulation, transforming process models into reliable engineering strategies that optimize operational costs and maximize throughput.

We integrate rigorous first-principles engineering with physics-informed machine learning, ensuring your models accurately capture complex system behaviors where traditional empirical methods fall short.

Whether you are scaling critical minerals processing, designing advanced wastewater treatment systems, or optimizing chemical manufacturing, we deliver the custom simulation tools needed to reduce scale-up risk, optimize operations, and accelerate time-to-market.

Service 01 — Chemical & Biochemical

Chemical & Biochemical Process Development

Dynamic & steady-state simulation for novel process scale-up

Accelerate development of specialty chemicals, renewable chemicals, and bio-based products with custom process models built from first principles. We handle the novel reactors, unconventional separations, and hybrid processes that off-the-shelf simulators can't model rigorously.

What You Get

  • First-principles models validated against your experimental data
  • Multi-variable optimization for yield, selectivity, and cost
  • Hybrid physics-ML models for complex or poorly understood systems
  • Heat integration and process intensification opportunities
  • Pilot-to-commercial transition planning with risk quantification
Industries Served
  • Specialty chemicals
  • Petrochemical Process Optimization
  • Biorefinery & bio-based chemicals
  • Hydrogen production & purification
  • Carbon capture & utilization
  • Continuous manufacturing
Process Types
  • Novel reactor configurations
  • Reactive distillation
  • Membrane-based separation
  • Catalytic processes
  • Fermentation & biocatalysis
  • Solvent-based extraction
Modeling Capabilities
  • Equation-oriented process optimization
  • Reaction kinetics parameter estimation
  • Thermodynamic property modeling
  • Dynamic simulation & control
  • Flowsheet synthesis & screening
  • Process safety & operability analysis
Service 02 — Critical Minerals

Critical Minerals & Rare Earth Element Processing

Custom process modeling for sustainable resource development

Navigate complex extraction and processing challenges with rigorous, custom-built process models tailored to your specific feedstock and target minerals. We help you optimize yield, reduce environmental impact, and deliver credible techno-economic analysis for investors and partners.

What You Get

  • Validated process models for your specific feedstock and target minerals
  • Multi-scenario optimization to identify the most economically viable flowsheet
  • Environmental impact analysis and sustainability metrics
  • Defensible techno-economic analysis for funding applications
  • Scale-up guidance from bench to pilot to commercial
Unit Operations
  • Leaching & extraction
  • Solvent extraction cascades
  • Ion exchange & adsorption
  • Precipitation & crystallization
  • Roasting & calcination
  • Electrowinning
Feedstock Types
  • Hard rock ore deposits
  • Coal ash & byproducts
  • Mine tailings
  • Electronic waste
  • Phosphogypsum
  • Geothermal brines
Analysis Capabilities
  • Custom flowsheet optimization
  • Techno-economic analysis (TEA)
  • Life cycle assessment (LCA)
  • Sensitivity & uncertainty quantification
  • Multi-objective optimization
  • Process intensification studies
Service 03 — Water Treatment

Water Treatment & Desalination Technology

Custom simulation for data-driven treatment train design

Design and optimize water and wastewater treatment systems with rigorous, custom process models built for your specific source water and treatment targets. Whether you're developing novel treatment processes or optimizing existing facilities, we deliver the modeling rigor investors and regulators expect.

What You Get

  • Optimized treatment train configurations for your water source and targets
  • Levelized cost of water (LCOW) analysis with sensitivity studies
  • Energy consumption optimization and cost reduction opportunities
  • Regulatory compliance verification and permitting support documentation
  • Pilot-to-commercial scale-up guidance with de-risking analysis
Treatment Technologies
  • Reverse osmosis (RO)
  • Nanofiltration & ultrafiltration
  • Ion exchange systems
  • Advanced oxidation (UV, ozone)
  • Membrane distillation
  • Biological treatment
Source Waters & Sectors
  • Seawater & brackish water
  • Industrial wastewater
  • Municipal water reuse
  • Produced water (O&G)
  • Agricultural drainage
  • Power plant cooling water
Analysis Delivered
  • Custom flowsheet optimization
  • LCOW calculation & breakdown
  • Energy intensity analysis
  • Recovery rate optimization
  • Brine management strategies
  • Capital & operating cost models
Service 04 — Operations Optimization

Manufacturing & Business Operations Optimization

Custom optimization models for measurable operational improvement

Unlock hidden efficiency in your manufacturing and business operations with mathematical optimization models that deliver improvements in throughput, cost, or service level — without capital investment. Enterprise-grade analytical capability at SME-compatible economics.

What You Get

  • Custom optimization models you own and can run internally
  • Practical interfaces your team can actually use (Excel, dashboards, scripts)
  • Measurable improvements in efficiency, cost, or throughput
  • Data-driven decision support, not gut-feel or guesswork
  • Rapid deployment — see results in weeks, not quarters
What We Optimize
  • Production scheduling
  • Capacity planning
  • Inventory management
  • Supply chain flow
  • Resource allocation
  • Workforce planning
  • Equipment maintenance scheduling
What You Measure
  • Throughput increase (15–30% typical)
  • Inventory holding cost reduction
  • Production cost per unit
  • On-time delivery rate
  • Equipment utilization
  • Defect & waste reduction
  • Service level maintenance
What We Deliver
  • Custom optimization models
  • Excel or dashboard interfaces
  • Documented solution procedures
  • Training for your team
  • Success metrics & KPI tracking
  • Implementation support
  • Post-deployment validation
How We Work

A structured process designed for results

01

Understand

We start by deeply understanding your process, constraints, data availability, and decision criteria. No templates — every engagement begins with your specific challenge.

02

Design

We design the modeling approach, select the appropriate frameworks and methods, and define clear success metrics before writing a single line of code.

03

Build & Validate

We develop the model iteratively, validating against your data at each stage. You see progress in real-time, not after months of black-box development.

04

Deliver

We deliver validated models, clear documentation, and practical tools your team can use. Not equations in a report — actionable decision support.

05

Support

We provide training, implementation support, and post-deployment validation. Your success is our success — we stick around until the model delivers value.

Engagement Models

Flexible engagement models, ranging from targeted modeling projects to fully integrated R&D partnerships

Fixed-Fee Assessment

System Architecture & Scoping

Scoping study to evaluate process feasibility, define system constraints, and architect the optimal modeling approach. We analyze preliminary data and deliver a rigorous, phased roadmap before you commit to a full-scale simulation.

Ideal for: Early-stage R&D evaluation, conceptual process design, and defining technical requirements for scale-up

Fixed-Fee Project

Funding & Proposal Collaboration

Accelerate your grant applications and investor pitches with defensible technical backing. We provide the preliminary simulations and techno-economic analysis required to build a credible, rigorous narrative for high-stakes funding rounds.

Ideal for: DOE SBIR/STTR collaborations, venture due diligence, and competitive federal proposals

Project-Based

Model Development

Full-scope modeling engagements from problem definition through validated deliverable. Pricing scales with complexity, timeline, and deliverable scope. Includes model development, validation, documentation, and training.

Ideal for: Process development, scale-up projects, comprehensive TEA/LCA studies

Ongoing Partnership

Fractional Engineering Support

Continuous process modeling and optimization for your ongoing R&D and scale-up programs. Gain priority technical execution, flexible project scoping, and predictable costs with the agility of a month-to-month partnership.

Ideal for: Operations teams, R&D programs, companies with recurring modeling needs

Get In Touch

Schedule a technical consultation

Whether you're facing a complex modeling problem, seeking operational improvements, or exploring what's possible — we're here to help.

Connect With Us

Location
Pittsburgh, PA

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