Technology

How a plant gets deployed.

Six capabilities decide whether a bio-CCU plant is a science project or an asset: how the reactor is made, how the gas is conditioned, how the process is engineered, how it is controlled, how it is monitored, and where the carbon comes from when there is no stack nearby.

TRL 7 to 8

Platform maturity

Flue, effluent, air

Carbon sources handled

Continuous

Sustained operation

01 / Extrusion and fabrication

Four steps. The reactor is made where it runs.

The extruder travels, not the tube. Raw stock goes in at the site and a commissioned photobioreactor train comes out. Use the rail to follow the build.

Stock and extruder on site

Modified PMMA stock and aluminium framing arrive as raw material. The co-developed extruder is set up at the site itself, so no finished tube is ever freighted.

Modified PMMA stock, aluminium framing

Draw the tube

The line runs continuously and cuts to length. Tube geometry is fixed by the reactor design, not by what a supplier happens to stock.

Continuous line, cut to length on site

Flange and rack

Tubes are joined with aseptic flanges in the same material, then racked into the aluminium frame as independent modules that can be added one at a time.

Modular trains · stepwise capacity

Commission and run

Medium in, carbon in, CO2 recycle loop closed. Telemetry goes live on Intrinsic Pulse and the train runs continuously under industrial conditions.

Train commissioning · continuous run validated

02 / Preconditioning

Industrial gas, taken as it is.

Flue gas arrives hot, dusty and variable. The preconditioning section brings temperature, particulates and flow into the window the culture needs, without a purification train in front of it. Carbon Banking then stores the CO2 as bicarbonate and carbonate in the medium, so capture no longer has to happen at the same moment as growth.

Carbon Banking: patent pending, App No. 202531093012

What the section handles

01Thermal conditioning before the culture loop, with a co-axial jacket system on the reactor side

02Particulate tolerance for cement dust and mixed industrial gas

03Compressed air sparging architecture for mass transfer

04Alkalinity control, storing 3,600 g CO2 equivalents per cycle

05Extremophilic strains selected for high temperature and variable CO2

03 / Process engineering

Designed at the conservative number.

Every mass balance is drawn at a conservative design basis, not at the performance we have validated on site. Two phase cultivation induces the target fraction, and the downstream cascade is sized for what the culture actually delivers over months of running.

Conservative

Design basis

Validated on site

Pilot on real gas

Continuous

Operating mode

Under NDA

Performance figures

04 / Automation

Plant grade control, not lab rigs.

Control sits on Siemens S7-1200 PLCs, the same class of hardware the host plant already runs. Dosing, circulation, thermal setpoints and harvest triggers are sequenced in the controller, with predictive thermal control keeping the culture inside its window through the day.

Telemetry over MQTT with TLS · cloud historian

05 / Intrinsic Pulse

One dashboard for every train.

Pulse is our web and mobile layer over the control stack: live monitoring, alerts, sensor auto discovery, and a single view across reactors, sites and cycles. Operators see the culture; we see the fleet.

Live monitoringAlertsSensor auto discoveryCycle history

Intrinsic Pulse screens: formula manager with variable management, and a client dashboard showing system health, temperature, pH, dissolved CO2, carbon abatement and harvest charts for the Hazaribagh pilot plant. — Intrinsic PulseFormula manager, sensor auto discovery and the client dashboard, as an operator sees them.

06 / Direct air capture

When there is no stack next door.

DAC clusters let a plant run on ambient air, so cultivation is not held hostage to one emitter's shutdown calendar. The same reactor family runs on bottled CO2, direct air, or industrial flue gas, and Carbon Banking lets the plant switch between them without stopping the culture.

Bottled CO2Controlled runs, strain work, commissioning

Direct airStandalone sites and pilots without a point source

Industrial flue gasCo-located plants at cement, steel, power and ethanol

Size it for your site.

Pick a reactor, set the carbon source, and we will come back with a deployment plan for your plant.

Customize your reactor See the portfolio