Via Separations Achieves Decarbonization Technology Goals With AutoCAD and the Plant 3D Toolset | AutoCAD Blog


In the pulp and paper sector, a single step in the Kraft pulping process that converts wood into wood pulp is responsible for nearly 1% of global greenhouse gas emissions. Via Separations, a venture-backed climate tech company that is an indirect investee of the Autodesk Foundation portfolio through Prime Coalition, is using its technology to transform industrial separations through an innovative membrane filtration solution – with the goal of eliminating 80-90% of the energy currently used in thermal separations while creating value for industrial customers.

Via Separations uses Autodesk AEC solutions like AutoCAD and Revit to develop pumps, pipes, valves, and control systems that augment or replace fossil-fuel-powered thermal separation process units with energy-efficient, electrified filtration systems. They recently completed construction and commissioning of a 10,000 square-foot facility at a pulp mill, aimed at proving their decarbonization technology at scale to the manufacturing sector. Their work is a prime example of how technology can be leveraged to create economic, sustainable solutions for pressing environmental challenges, highlighting the power of design in driving sustainable innovation.

Via Separations project

Separation Process

Typically, pulp and paper are created from fibers which are extracted from a variety of sources, often from forestry products, and converted to pulp. During this extraction process, pulp must be separated from other byproducts like lignin, chemicals, and water, which facilities recover for re-use in the process. This is where the most greenhouse gases end up being produced.

Via Separations is helping to transition away from expensive, energy-intensive thermal separations to more efficient mechanical separations, reducing the load on evaporators used during the process. Their technology has several benefits, namely energy and chemical savings, operational flexibility, and debottlenecking production.

Via Separations’ Black Liquor Concentration System uses a process similar to reverse osmosis, which directly removes hot, clean water from weak black liquor. Their filtration system uses proprietary membranes, which efficiently concentrate valuable liquor solids at high-temperature, corrosive conditions outside the typical operating window of other separation technology.

Via Separations utilizes AutoCAD, in addition to other Autodesk solutions, for its robust and flexible features – allowing them to design and modify their filtration systems with precision and ease. By using AutoCAD, Via Separations can visualize their designs, simulate real-world performance, and identify potential issues before the manufacturing stage. This not only enhances the quality of their filtration system, but also saves time and reduces costs.

Specifically, they leverage the Plant 3D toolset, an extension of AutoCAD which provides specialized tools for creating, managing, and sharing plant design projects. With the help of the Plant 3D toolset, Via Separations can create intelligent piping and instrumentation diagrams (P&IDs) and then integrate them into their 3D plant design models.

“I’m kicking myself for not using Plant 3D earlier.”

Steve Zaloudek, Principal Engineer, Via Separations

This comprehensive approach allows Via Separations to streamline their design process, maintain consistency in their designs, and improve collaboration across their teams. The ability to visualize their designs in 3D also helps Via Separations optimize their designs, ensuring maximum efficiency and reliability of their filtration systems.

Learn More

Meet other leading innovators and entrepreneurs collaborating with the Autodesk Foundation to support the design and creation of innovative solutions to the world’s most pressing social and environmental challenges.

Sustainable Set Design With AutoCAD Takes Center Stage for Opera North and OC Theatrical | AutoCAD Blog


Stage with large ensemble and throne made of deer antlers.

Opera North’s production of Verdi’s Falstaff. Photo credit Richard H. Smith.

Opera North’s recent season hit all the high notes of thrilling drama, powerful arias, and the moving moments expected during an opera performance. But they also made a new impact beyond the stage.

Opera North, a national opera company based in Leeds, United Kingdom, performed its first fully sustainable season in an ambitious undertaking guided by the Theatre Green Book. With a collaboration between Buro Happold and a wide swath of the UK theatre community, the Theatre Green Book’s three volumes provide new goals, guidance, and sustainability standards for theatre productions, buildings, and operations.  

For Opera North’s “Green Season,” all three operas—Falstaff, La Rondine, and Masque of Might—shared scenic elements with a focus on reducing material use and creating new designs that were both distinctive and a similar aesthetic for continuity. All sets, props, and costumes were sourced from previous productions to adapt for reuse or purchased second-hand. Everything was brought to life in a reimagined and sustainable way.

Opera singers on a stage with large white panels
Opera North’s production of Puccini’s La Rondine. Photo credit Tristram Kenton.

“We wanted to take this ambitious next step for sustainability by creating our first fully Green Season of three operas,” says Richard Ashton, Operations Director, Opera North. “The result was an incredible season of productions for our audiences with a reduced impact on the planet and many learnings for our continued journey to a more sustainable future for the industry.”

Discovering Past Sets to Inspire New Designs

OC Theatrical is a consultancy based in the UK specializing in theatre and events. Owner and founder Oli Cooper has worked on a vast array of drafting and engineering projects over his long career, ranging from the National Theatre in London to touring productions of Hamilton, Six: The Musical, and many more. But helping to create a completely “green” set design was a first.

“Since everything was a recovery from another show or a secondhand purchase, it was particularly challenging on the drafting side,” Cooper says. “Normally I would be given a project, pick materials suitable to the construction of the object, and work out how and where to cut or weld.”

Large ensemble of opera singers on stage
Opera North’s production of Puccini’s La Rondine. Photo credit Tristram Kenton.

It was understood that there wouldn’t be massive, unique set structures. A core goal of the three-show season was to use the same set pieces but reimagine them with different configurations for each show. By reusing existing sets from their warehouse and sourcing existing materials, a new level of sustainability was reached.

The process itself started like any other typical show where Cooper received a 1:25 scale model from the designer. The designer went around Opera North’s storage to see what pieces were existing, and he provided recommendations to be sure and include. “It was up to us to come up with solutions to create that vision,” Cooper says.

Two level set design with man walking down stairs
Opera North’s production of Puccini’s La Rondine. Photo credit Tristram Kenton.

Drafting Scenic Elements With AutoCAD for Sustainable Set Design

Cooper visited Leeds and did several visits of Opera North’s warehouse space and storage to see what scenic pieces had been put aside and saved.

“For the beams of the structure, we found material going to scrap and were able to purchase it,” Cooper says. “The rest of the structure was used from materials in storage. I measured and surveyed pieces that would potentially work and then generated a 3D model in AutoCAD. From that, we could piece together the structure like LEGO and add in the components that were already existing and on hand.”

Screenshot of AutoCAD
Opera North set design in AutoCAD. Courtesy of OC Theatrical.

For other set pieces, some reference drawings were on hand and could be easily reimagined in AutoCAD. One of these set pieces included 20-foot high, period window frames that were originally static, but then transformed with a different truck base to wheel it on and off the stage. “We were able to take the original drawings in AutoCAD and modify the bases and braces by simply adding them on,” Cooper says. “It was a far more efficient process.”

One of the show-stopping scenes in Falstaff featured an enormous throne covered with deer antlers. The chair was modified from a previous show and the antlers were obtained from recovery in local parks. After the season ended, they were put in storage for reuse in future productions.

Man sitting on large throne of deer antlers with two people singing in front
Antler throne in Opera North’s production of Verdi’s Falstaff. Photo credit Richard H. Smith.
Screenshot of throne frame in AutoCAD
Design for antler throne in AutoCAD. Courtesy OC Theatrical.
PDF of assembly for throne
PDF of assembly for antler throne. Courtesy of OC Theatrical.

“Working on the ‘Green Season’ for Opera North brought an entirely new way of thinking about fabrication, appreciating reuse, and approaching the drafting process,” Cooper says. “In the end, I delivered 110 drawings for 14 different elements, and it only would have been possible with AutoCAD.”

“One of the most important parts of AutoCAD is its flexibility. You don’t always need to necessarily know what you’re drawing before you draw it. You can add, remove, and carve away. It’s far more organic and dynamic than other software and gives you more flexibility.”

Oli Cooper, Owner and Founder, OC Theatrical

Communicating and Collaborating With AutoCAD

The documentation for the design and fabrication of Opera North’s season was both in DWG and PDF formats. Everyone was encouraged to view PDFs on tablets to save paper and keep in the green theme. These drawings were crucial for coordination, but the collaboration and communication extended far beyond a final set of drawings.

Shared Views in AutoCAD is important in all the work with my clients,” Cooper says. “It allows me to put things in 3D and anyone can go through the design. It’s so simple.”

“One of the biggest parts of my job is communication,” he continues. “I’m there to communicate ideas and many of my stakeholders are very creative, visual people. Having that ability to do it in 3D with AutoCAD with different levels of details is important.”

Courtesy of OC Theatrical.

Cooper also often uses AutoCAD on the web and on mobile for markups, quick sketches on site, or to review designs with a stakeholder. “If I’m just doing a survey of an area or need to draw something simple, I have my MacBook with me and I can just quickly knock it out then and there with AutoCAD on the web,” Cooper says. “It’s a powerful tool.”

For Cooper, AutoCAD is a critical component to his success.

“When you’re in a specialized field, it’s really hard to find a program that does everything,” he says. “I love how much you can customize with AutoCAD. I have many plugins that enable me to do what I do because it’s a base that you can add to. It’s like a pizza with anything you want to add and make it your own.”