Accelerating Carbon Capture Innovation with Mixed-Salt Process

EPIC Systems partnered with SRI International and the National Carbon Capture Center (NCCC) to design, build, and integrate a modular pilot plant for testing the innovative Mixed-Salt Process (MSP) carbon capture technology. By validating process assumptions, optimizing for a small footprint, and delivering turnkey automation and controls, EPIC helped accelerate realworld testing and scale-up of this energy-efficient CO₂ capture solution.

Speak to an engineer
Hygienic Process System Design

Project

Overview

  • Industry: Environmental
  • Location: USA
  • Customer Use Case: Carbon Capture, Modular Design

Customer’s

Challenge

SRI International (SRI), a renowned research institute, developed the Mixed-Salt Process (MSP) – a novel aqueous solvent system using ammonium and potassium salts designed to reduce energy requirements and enhance carbon capture efficiency. SRI were selected by National Carbon Capture Center (NCCC) to host a pilot demonstration of this promising technology using flue gas from coal-fired power generation.

However, the project presented multiple challenges:

  • Aggressive Timeline: A compressed schedule required rapid design, fabrication, and installation.
  • Footprint Limitations: The NCCC test bay offered limited physical space for the pilot system.
  • Unverified Assumptions: Some early design assumptions provided by the client were found to be inaccurate and needed to be quickly re-evaluated.
  • Operational Complexity: The novel nature of the MSP technology demanded sophisticated controls and instrumentation to ensure accurate testing and data collection.

To meet these challenges, SRI needed a partner with deep process knowledge, hands-on engineering capabilities, and a strong track record of building pilot plants for emerging technologies.

Epic

Solution

EPIC Systems partnered with SRI and the NCCC to bring the MSP pilot system to life—successfully overcoming engineering challenges while remaining aligned with the project’s aggressive timeline.

Key Contributions: 

  • Process Engineering Review: EPIC validated the process design and identified critical inaccuracies in some baseline assumptions. EPIC’s team proposed engineering alternatives that enhanced system feasibility and improved reliability.
  • Modular System Design: To accommodate the limited test bay footprint, EPIC developed a skidmounted, modular system, allowing the entire unit to be fabricated off-site and rapidly deployed with minimal onsite construction.
  • Instrumentation & Controls Integration: EPIC selected, configured, and integrated the full instrumentation suite to support real-time testing and evaluation of the MSP system. EPIC’s automation team provided the PLC programming to ensure the system could operate under various scenarios defined by the research team.
  • Project Management & Start-Up Support: From front-end design through commissioning, EPIC served as project manager, coordinating fabrication, logistics, and on-site installation. The team also supported system start-up and troubleshooting to ensure a smooth transition into the testing phase.
  • SRI Advanced Carbon Capture CAD Model

    3D Design: modeling all piping and components, checking interference for fits / connections, and verifying for practical use.

  • SRI Advanced Carbon Capture Fabrication Scan

    3D Fabrication Scans: fabricated modules are assembled virtually, and connection points / piping fits are reviewed and validated.

  • SRI's Mixed Salt Process

    Site Installation: fabricated module is assembled and commissioned on site in line with designed, scanned model for smooth installation.

Project

Impact

  • Accelerated Deployment: Modular design allowed for faster on-site installation, keeping the project on schedule despite initial design challenges.
  • Reliable Test Operation: Accurate controls and instrumentation enabled high-fidelity testing under realistic flue gas conditions.
  • Improved Design Integrity: EPIC’s early process engineering input helped avoid downstream problems and enhanced system reliability.
  • Scalable Pilot Platform: The modular approach and industrial-grade automation provide a strong template for future scale-up and commercialization efforts.

unlock your manufacturing potential

Connect with an EPIC engineer to discuss how our solutions can revolutionize your business.

Speak to an Engineer
« Return to Case Studies

More Client

Success Stories

Multi-Skid Process System for a New Time-Release Fragrance Technology

Multi-Skid Process System for a New Time-Release Fragrance Technology

EPIC’s innovative solutions and meticulous project management enabled the successful design, fabrication, and delivery of multi-skid systems, addressing many challenges faced by the consumer fragrance company and ensuring seamless production of their new product.

Read Case Study
No results found.

Our Solutions

EPIC Systems is a multidisciplinary engineering integrator specialized in industrial automation for process manufacturers. We deliver solutions in the following areas:

Process Systems

Learn More

Machine Vision

Learn More

Robotics

Learn More

Industrial Automation

Learn More