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Home › Mechanical Engineering Services › Air Pollution Control Equipment Design
For scrubber, oxidizer, and baghouse OEMs and the plants that run them
Meet your permit without oversizing. Free assessment and roadmap.
The challenge
New rules and permit renewals push emission limits below what your system was built for.
Review: Permit review
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What changes
Our air pollution control design models capture in CFD, sized to the limit you face.
How: Environmental CFD →
The challenge
Poor flow through ducts and scrubbers lowers capture and wears parts unevenly over time.
Review: Stack test
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What changes
Fluid flow simulation balances ducts, hoods, and scrubbers so every part does its job.
The challenge
Oversized fans and ducts waste power every hour the system runs, for its whole life.
Review: Energy cost
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What changes
Pressure drop is modeled through the system, so fans are sized to what the flow needs.
How: CFD Services →
The challenge
Adding controls to an existing plant means new equipment in space that was never planned.
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What changes
Ducts, supports, and equipment are designed in CAD around what is already in place.
How: Machine Design →
Scrubber, oxidizer, and baghouse OEMs: we act as your engineering team on abatement units and ducting.
Your extra design team.
Get Your Free RoadmapPlants with permitted emissions: we define and design the controls you need, then work with your builder.
Your permit, our design.
Get Your Free RoadmapPlant and abatement OEM in one loop, so capture, flow, and fan power are designed to your permit together.
One loop, both sides.
Get Your Free RoadmapBring your own manufacturer, or work with our partner network. We take the designs we engineer as far as you need. We don't manufacture, so we never compete with the OEMs we partner with.
Facts about how we work, not project results. One team engineers your product from analysis to delivery, and calculations carry a PE stamp where required.
01
An abatement design with the capture and flow model behind it, ready for your builder to quote.
02
CFD and pressure drop results you review and approve at each gate, before anything is built.
03
You own the IP by default. When an OEM or partner manufacturer is involved, the contract spells out who owns what.
04
If we missed it in our QC, we fix it. If your supplier can't make the part within three years, or supply dries up, we fix that too.
You send
What we need to start
Permit limits and current emission data
Process data: flows, temperatures, and loads
Drawings or CAD of the plant and system
Current equipment and its problems
Targets: limits, power, or schedule
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You get
What you hold at the end
Design: CAD and drawings ready to build
CFD results for capture and flow you approved
Fan and duct sizing with pressure drop
Fabrication package, ready to quote
Support through install and stack testing
We price to the value we deliver, not the hours we log. If the value isn't there for you, we'll say so in the assessment.
Model capture, dispersion, and stack plumes, so your controls are sized to the permit limits you face.
Sized to your limit.
Used For
Capture
Dispersion
Stacks
Balance flow through ducts, hoods, and scrubbers, so capture is even and parts wear at the same rate.
Even flow, more capture.
Used For
Ducts
Hoods
Scrubbers
Pressure drop, heat, and flow modeled across the whole system, so fans are sized to what the flow needs.
Right-size the fans.
Used For
Pressure Drop
Fans
Heat
Design scrubbers, ducts, and supports that fit your plant, with fabrication managed through our partners.
We manage the build.
Used For
Scrubbers
Ducts
Supports
Public benchmark
CFD-guided flow fixes cut a 350 MW unit's precipitator dust emissions by more than half (Vinča Inst., 2024).
What it means for you
The team measured the flow, built a CFD model that matched it, and then redesigned the devices that turn and spread the gas. We use the same steps on abatement equipment: measure, model, change, and check. Each design is built on your real flow, not on a guess.
The public record shows what the method can do. What it does for your equipment depends on your constraints, and the free assessment tells you.
Plant, OEM, or both: we set the model, the builder, and the hand-off.
Scope, limits, priorities, and approval gates.
CFD and design on the system, checked in our QC.
Drawings, fan and duct sizing, and a package ready to quote.
Install support, stack testing support, and later changes.
You approve the design at every gate, so nothing that affects function surprises you. If we missed something in our QC, we fix it. If a supplier can’t make a part within three years, we fix that too.
Permit renewal coming up? Send the emission data. Free roadmap.
Turbines, heat exchangers, and plant equipment studied for heat, flow, and fatigue before an outage.
Fewer forced outages.
Applications
Turbines
Exchangers
Piping
Kilns, mills, and coolers that run hot, dusty, and nonstop, engineered for heat, wear, and long uptime.
Fewer surprise stops.
Applications
Kilns
Mills
Coolers
Aerospace to data centers: see how one engineering team solves hard constraints across ten industries.
Find the one like yours.
Industries
Aerospace
Mining
Data Centers
Fixed scope for one project. A lower-risk place to start when you want to see our work on your data.
Start with one project.
Fits When
One Project
Fixed Scope
From $35K
Scheduled monthly engineering for recurring needs: drawing updates, ASME calcs, or FEA for each sale.
Work on a set schedule.
Fits When
Monthly
Recurring
From $15K/mo
A dedicated PPS team working your program daily, built for long, multi-year development and testing.
Your program, every day.
Fits When
Daily Work
Multi-Year
From $800K/yr
Gold · One project: a scrubber, collector, or duct system that must meet a new limit.
Platinum · Ongoing work: engineering support across permits and plant changes.
Diamond · A long program: a dedicated team for a major control system retrofit.
FEA, CFD, CAD, DFMA, and testing under one roof. Engineering is a team sport, and you get the whole team.
One team, every skill.
Under One Roof
FEA
CFD
CAD
DFMA
Testing
Veteran-owned SDVOSB status gives defense and federal buyers a set-aside path to proven engineering.
Verify our SDVOSB status.
Credentials
SDVOSB
VOSB
CAGE 8ZK73
NAICS 541330
Missed something in our QC? We fix it. Supplier can't make the part within three years? We fix that too.
Support for the long run.
We Fix
Our QC Misses
Supplier Gaps
Supply Chain
We price to the value we deliver, not hours logged. You buy a design that works, not more iterations.
Pay for the result only.
Collections
Gold
Platinum
Diamond
What does your air pollution control design cover?
Our air pollution control equipment design covers the engineering behind the systems that keep your plant inside its permit: scrubbers, collectors, oxidizers, ducts, and fans. Most plants feel the limits as uneven capture, high fan power, or a retrofit that won't fit the space. Each starts in the design. Poor flow through ducts and scrubbers lowers capture and wears parts unevenly. Oversized fans waste power every hour the system runs. Controls are costly to own: the EPA's Air Pollution Control Cost Manual sets out how to estimate costs for scrubbers, fabric filters, and precipitators. A design that misses on flow costs you for its whole life.
Environmental CFD models capture, dispersion, and stack plumes. Fluid flow simulation balances ducts, hoods, and scrubbers. Pressure drop analysis sizes fans to what the flow needs. Our mechanical design engineering services then fit the equipment into your plant, new or retrofit. Drawings come as a package your fabricator can quote. You approve the data at each gate. We support the work through install and stack testing.
Can you help us meet a new emission limit?
A new emission limit often lands on a system built for an older, looser one. Our air pollution control equipment design starts from the limit you must meet and the data you already have. That is industrial emissions consulting tied to real equipment, not a report on a shelf. Limits do move. The EPA's national air quality standards are reviewed periodically and sometimes revised. The usual answer is a bigger fan or another unit, and it is often the most expensive one. It adds power cost every year, and it may still miss the limit if flow is the real problem.
CFD shows how your current system performs, where capture is lost, and which changes would close the gap. Sometimes better flow through the existing system is enough. Sometimes a new unit is right, sized to the limit, not oversized. You see each option with its cost and its effect before you decide. Stack results also depend on operation, but if we missed something in our QC, we fix it.
Can PPS work with our OEM or manufacturer?
Yes. Air pollution control equipment design from PPS fits the partnerships that are normal in emissions control projects. We work in one of three models. As your OEM partner, we act as your engineering team. Operator-led, we design the controls and work with the builder you choose.
When design, build, and test sit with different companies, problems pass back and forth. The builder works from an old drawing, and each party defends its own scope. The Department of Defense's IPPD Handbook organizes programs around integrated product teams for this reason. In a joint program, the plant and the OEM work with us in one loop.
We engineer the design and coordinate the builder in one loop. Bring your own manufacturer, or work with our network of fabricators, machine shops, and test labs. You decide how far we take the design, up to the start of production. We never run production, so we never compete with your OEM. NDAs cover every party, and you own the IP by default, set in your contract.
What do you need from us to start?
To start a project with our air pollution control equipment design, send what you have, in any format. That usually means permit limits and current emission data, process flows, temperatures, and loads, and drawings or CAD of the plant. Add current equipment and its problems, photos, and your targets for limits, power, or schedule. Stack test reports help too. Missing data is the most common reason engineering projects stall, because a model built on guessed inputs gives a guessed answer. That is why we don't start the work until every data set is in.
Once it is, the first step is a free assessment of your project scope. We confirm what the work can and can't answer, and tell you what is still missing. Then we send a roadmap proposal with scope, targets, and approval gates. Every project is scoped on its own, so the roadmap sets the schedule, not a stock promise. NDAs are available before you share any files. For gaps in material data, NIST material measurement data is a good first stop.
Who owns the design and the models?
You own the design, the drawings, and the models from your air pollution control equipment design project by default, as set in the contract. With an OEM involved, the contract says who owns what. Some firms keep the models, or license them back to you, so every later change sends you back to them. That locks your product to one vendor and makes design reviews harder, because your team can't open the evidence behind the decisions. You receive the native CAD, the drawings, the simulation model files, and the documented results. Your engineers can then check the work, rerun a load case, or hand the package to a supplier or customer.
We sign mutual NDAs before any of your data is shared, and your files stay in our controlled project folders while we work. If your program has export-control or customer data rules, tell us at the start and we will set up the data handling to match them. For defense programs, the State Department ITAR guidance sets the rules we follow.
What happens if a prototype fails in test?
If a prototype fails in test, we find out why and fix the design. Hard engineering carries unknowns on any project: real loads, material lots, and assembly effects never match a model perfectly. With air pollution control equipment design from PPS, you approve the data at each gate. A test result is then checked against predictions you have already seen, not a black box. A failure in test is data. It shows which assumption was wrong: a load, a material property, or a boundary condition. That data improves the model and the design.
When testing is in scope, we plan the test to confirm the margins that matter most. Then we correlate the model to the results, following ASME verification and validation practice. If the miss was ours, because something slipped through our QC review, we fix it. If the test uncovers a condition nobody knew about, we scope the change with you and update the roadmap. Either way, you get a clear answer and a path to a design that holds.
How is air pollution control design priced?
We price air pollution control equipment design to the value it delivers, not the hours we log. Hourly billing rewards extra iterations, so the cheapest quote often becomes the most expensive project once tooling, rework, and field failures show up. Our incentive is to get the design right the first time. We engage by fit, not as a ladder. Gold (from $35K): you have one project and need help with it. Platinum (from $15K/mo): you have recurring work at a steady rhythm. Diamond (from $800K/yr): you have a long development program, often multi-year.
Gold is never required, and some clients start at Platinum or Diamond. These are starting points, not quotes; your roadmap sets the price. We price to the value we deliver, not the hours we log. If the value isn't there for you, we'll say so in the assessment. Our engineering consultant pricing page explains how each collection works in more detail.
Emission limits tightening? Send your permit and the data.
Send your permit, emission data, and plant layout. We review your project scope in a free assessment and reply within one business day with next steps.
On-site assessments that require travel are quoted separately.