Building on our earlier work with Powerhouse’s Thermal Conversion Chamber (TCC), we supported the company in designing a hydrogen recovery plant to utilise syngas produced from their gasifier. The aim of this project was to create an efficient process for separating hydrogen while minimising CO₂ emissions and energy losses. Our team carried out full process modelling in Aspen Plus, implementing a calcium looping scheme in which carbonation captured CO₂ as CaCO₃, and calcination regenerated CaO, releasing a high-purity CO₂ stream. This looping system was tightly integrated with heat recovery, allowing excess energy from exothermic reactions to drive steam generation and support overall plant efficiency. Downstream of this, we designed a multi-stage pressure swing adsorption (PSA) unit to purify hydrogen to high specifications.