Global Engineering Solutions for Complex Industrial and Mining Projects
PegasusTSI and Pares&Alvarez, engineering services companies from USA and Chile, respectively, are combining their expertise and resources to create SynertekPPA.
About SynertekPPA
With a solid background in process engineering, SynertekPPA brings over 90 years of experience developing industrial projects around the world. From concept through feasibility, basic and detailed engineering, and supported with full procurement, project, construction and commissioning management services, we can offer a complete range of project delivery services.
Services & Capabilities
SynertekPPA provides end-to-end support across the project lifecycle:
Front End Loading
We support early project definition by integrating technical, operational, and commercial considerations to reduce risk and improve certainty. Our approach includes structured project planning, technology selection, laboratory testing, financial and risk analysis, and the application of industry best practices such as PDRI and VIP. We develop clear execution strategies through robust documentation, Project Execution Plans (PEP), and well-defined procedures to enable successful project delivery.
Engineering
Construction Management (EPCM)
Why SynertekPPA
With a team of more than 1,100 people who have expertise in all engineering disciplines and design and operating backgrounds, SynertekPPA has the experience to deliver innovative and tailor-made solutions delivered with the highest standards of quality and collaboration.
Markets & Regions
Together we offer our vast combined experience in multiple industrial sectors:
Pegasus TSI: polymers & chemicals, mining & minerals fertilizers, water/wastewater, power and consumer products.
Pares&Alvarez: Mining, oil & gas, energy, wood products, infrastructure and industrial manufacturing.
Throughout our joint history, we have worked in different corners ofall over the world in The Americas, Europe, Middle East, Africa, Asia and Australia, including Argentina, Peru, Chile, Brazil, Ecuador, Venezuela, Colombia, USA, Mexico, Spain, Germany, Turkey, Israel, Saudi Arabia, Qatar, UAE, Malaysia, Australia, and Japan.
Experience
Our teams have delivered complex industrial and mining projects for leading global clients as well as independent, entrepreneurial clients .
Talabre dam
Rare earths project
New LPG storage terminal for northern Chile
Expansion of existing port facilities
PTX plant for e-methanol and e-gasoline production
Boron SX plant
Arboris Sterol Plant Profile
Takreer Green Diesel Project Profile
Taminco DMAPA Project
Syntroleum GTL Fuels and Catalyst Regeneration Project Profile
Ma'aden Magnesite Mining & Processing Project
Talabre dam
Engineering for Operational Continuity
Client: Codelco VP
CAPEX: US$503 MM
Solution: Detailed Engineering delivered with BIM and AWP
Location: Calama, Chile
Duration: 24 months (2024-2026)
Scope
- Detailed engineering for hydraulic barriers, power supply, centralized monitoring and control, tailings conveyance and deposition systems, and water recovery and recirculation.
- On-Site engineering for electromechanical works
- All designs were delivered applying BIM and Advanced Work Packaging (AWP) methodologies.
The Talabre Tailings Facility currently operates in Stage VIII, receiving tailings from the Ministro Hales and Chuquicamata concentrator plants. Stage IX of the project adds an additional capacity of 290 Mm³ and includes the raising of the perimeter embankments to elevation 2,500 m.a.s.l., as well as new works for the transport, conveyance, and deposition of tailings.
Additionally, the project includes reclaimed water pumping stations, a new network of monitoring wells, and the implementation of updated control systems.
Rare earths project
First Ree Processing Plant In Chile
Client: Aclara Resources (Ree Uno SpA)
CAPEX: US$255 MM
Solution: Feasibility Engineering and technical report in accordance with the Canadian NI 43-101 standard for the disclosure of mineral projects.
Location: Penco, Chile
Duration: In progress
Scope
- Design of a hydrometallurgical plant with a processing capacity of 320 t/h of ionic clays.
- Development of the plant layout considering complex topography and access constraints.
- BIM execution with multidisciplinary integration.
- Integration to the 15 kV medium-voltage electrical supply, with an installed capacity of 13.6 MW.
- Class 3 CAPEX estimate and procurement support.
The project aims to produce approximately 1,800 t/year of lanthanide concentrate. The processing plant comprises ore preparation and classification, leaching, solid–liquid separation, precipitation, washing, water recovery, and disposal of processed clays, delivering a wet-blended REE carbonate as the final product.
This pioneering initiative introduced a technological innovation in Chile by adapting established hydrometallurgical processes to local conditions for the country’s first rare earth processing project.
New LPG storage terminal for northern Chile
Client: Oxiquim
CAPEX: US$27,5 MM
Solution: Detailed engineering, project management.
Location: Mejillones, Chile
Duration: 15 months (2019-2021)
Scope
- Detailed engineering (civil, mechanical, and instrumentation).
- Cathodic protection and flare radiation studies.
- Design of the storage sphere, pipeline, and auxiliary systems.
- Fire protection and gas detection systems.
- Support to project management and mechanical and instrumentation ITO.
- Document control and construction supervision.
Oxiquim developed a new maritime LPG storage and dispatch terminal in Mejillones, Antofagasta Region. The terminal includes a 10,000 m³ semi-refrigerated storage sphere, a 2,000-meter submarine and onshore pipeline, refrigeration systems, truck loading facilities, and industrial safety networks, enabling a strategic point for the direct reception of liquefied gas in northern Chile.
The project helps reduce truck traffic from central Chile and strengthens the energy independence of the country’s northern region, commencing operations with the arrival of the first LPG vessel from the United States.
Expansion of existing port facilities
Minera Centinela Development Project
Client: Antofagasta Minerals
CAPEX: US$92 MM
Solution: EPC
Location: Mejillones, Chile
Duration: In progress
Scope
- EPC for the expansion of the port sector: engineering, procurement, construction and erection, pre-commissioning, technical assistance to commissioning, and ramp-up.
Minera Centinela has operated an oxide line since 2001 and a sulphide concentrator since 2011, both based on open-pit mining. Starting in 2017, the company optimized its cathode plant by sending PLS solutions from the Encuentro Oxides dynamic leach pads.
The project includes the design and construction of a new concentrator plant to process ores from the Esperanza Sur and Encuentro deposits, along with a new molybdenum plant. The additional concentrate will be transported to the port through the existing concentrate pipeline, which will be upgraded.
PTX plant for
e-methanol and
e-gasoline production
Client: HIF
CAPEX: US$38 MM
Solution: DIA permitting, basic and detailed engineering
Location: Punta Arenas, Chile
Duration: 10 months (2021–2022)
Scope
- Processing of the Environmental Impact Declaration (DIA) for the project.
- Development of basic and detailed engineering for the Balance of Plant (BoP) of the MtG system.
- Multidisciplinary engineering in mechanical, piping, structural, electrical, and instrumentation & control disciplines.
- Design of the MtG building tank farm, electrical system, and interconnections with the methanol plant.
- Engineering of truck loading systems and associated services for the MtG areas and tank farm.
HIF led the development of the Haru Oni demonstration plant, one of the first PtX projects worldwide. The plant integrates wind energy, water electrolysis, and CO₂ capture to produce e-methanol, which is subsequently converted into e-gasoline through the Methanol-to-Gasoline (MtG) process.
This pioneering project demonstrates how e-fuels can contribute to carbon neutrality by reusing CO₂ and leveraging existing infrastructure to enable an effective energy transition.
Boron SX plant
Expansion Of The Lithium Carbonate Plant
Client: Tenova
CAPEX: US$380 MM
Solution: Detailed engineering
Location: Salar de Cauchari, Argentina
Duration: 2018
Scope
- Detailed engineering for the SX Plant across all disciplines.
- Development of 3D models for construction and assembly.
- Engineering in mechanical and piping, structural, electrical, and instrumentation & control disciplines.
In 2018, Minera Exar -a joint venture between Lithium Americas (49%) and Ganfeng Lithium (51%)- promoted the expansion of its lithium carbonate plant in the Cauchari Olaroz Salar to increase production by 15,000 t/year, from 25,000 to 40,000 t/year.
The project included the addition of nine new evaporation ponds and the development of a new Boron SX Plant associated with the brine purification process.
Tenova commissioned Pares&Alvarez to develop detailed engineering for the SX Plant, including 3D modelling for construction and assembly, in a challenging context marked by pandemic restrictions.
Syntroleum Corporation
Marathon Oil Company GTL Fuels and
Catalyst Regeneration Plant
Scope:
- Gas-to-Liquids (ultra-clean) fuels demonstration plant, 70 barrels/day.
- Syntroleum GTL technology
- Partial funding by DOE
Facts/Figures/Statistics:
- 151 New pieces of equipment
- 37 existing / relocated pieces of equipment
Technical Challenges:
- Grassroots site
- New modular process units
- Relocation and re-assembly of existing modular process
PegasusTSI Expertise:
- Modular unit design
- Value engineering services (15% cost reduction)
Success Factors:
- 240,000 field hours (no lost time)
- OSHA site inspection (no violations / citations)
- Met demonstration production requirements for synthetic
Abu Dhabi Oil Refining Company
(TAKREER)
Green Diesel Project
Location: Ruwais, U.A.E.
Duration: March 2006 – April 2007
Scope:
- FEED
- Technology Integration HSEIA
- LSTK ITB Packages
Unit Operations
- Crude Distillation
- Vacuum Distillation
- Continuous Catalytic-Generation Reforming
- Hydrocracking
- Naphtha Stabilization
- Reforming
- Gas Oil and Kerosene Hydrotreating
- H2S Removal and Sulfur Recovery
- Sour Water Stripping
- Hydrogen Production
- Gas Condensate Distillation
- Lubricity System
- Utilities: Steam, Condensate, Boiler Feed Water, Cooling Water, Fuel Gas, Fuel Oil, Potable Water, Instrument Air, Nitrogen and Caustic
- Hydrocarbon and Acid Gas Flares
- Drainage and Sewage Systems
- Wastewater Treatment
- Fire Protection System Intermediate and Product Storage
Scope:
- Front End Engineering & Design (FEED)
- Project consisted of the reconfiguration and optimization of TAKREER’s Ruwais and Abu Dhabi refineries to meet the new Ultra Low Sulfur Gas Oil concentration standard of 10 ppmw sulfur, as well as cetane number, back- end distillation temperatures, density, cold flow properties and poly- aromatics or total aromatics content, by the year 2010.
Facts / Figures / Statistics
- US$1.2 Billion capital investment
- 456 Major Pieces of Equipment
Technical Challenges
- FEED Schedule
- Feeds, Effluents and Energy Integration
- Steam optimization
- Integration with existing refinery units
- Integration with an adjacent plant
- Coordination with Multiple Technology Licensors
PegasusTSI Expertise
- Process Knowledge
- Project Management and Coordination
- Utility Definition
- Project Estimating
Success Factors
- Achieved aggressive FEED Schedule
- Integration of all Process and Utility Facilities
- Integration of new facilities into existing refinery
- Coordination and interface management of multiple international Licensors
- Incorporated ‘Open Art’ and Licensed Unit designs into FEED Package
Arboris
LLC Sterol Plant
Scope:
- Pilot plant scale-up to commercial production facility; grass roots engineering, procurement, and construction of food grade sterol production facility
Facts:
- Solvent dissolution, crystallization, filtration, solvent drying, distillation, and product
- Included warehouse, product loading, fire protection
- 46,000 ft of pipe, 120 equipment items, 150 ft high process structure and 700 tons of steel
Technical Challenges:
- Pilot Plant Commercialization
- Fast-track timeline
- Specialized vendor packages use of thin film evaporation
- 24 months from pilot to commercial operation
- 9 months duration for
PegasusTSI Expertise:
- Commercialization of pilot plant studies
- Process engineering capabilities for all unit operations
- Fast-track project design
- Stress engineering
- HAACCP review & facilitation
Success Factors:
- On schedule/budget
- Technology and design proven
Saudi Arabian Mining Company (Ma’aden)
Magnesite Mining & Processing Project
Scope:
FEED
- Design Basis
- Capital Cost Estimate
- Project & Procurement Mgt Planning
Detailed Engineering , Design & Procurement
- Technology Package & Equipment Integration
- Overall Project Management
- Construction Packages
- Procurement – Full Services
- Project Controls
Construction Management
- Multiple Contracts
- Safety & QA/QC
- Cost & Schedule
Commissioning Services
- Operating Manuals
- Training
Facts/Figures/Statistics:
- $90MM TIC
Technical Challenges:
- Multiple Hearth Furnace Package
- Vertical Shaft Kiln
- Sinter Blending System Package
- Magnesia Mill
- International Client, Vendors & Standards
PegasusTSI Expertise:
- Inorganic Chemical Process Experience
- Solid Material Handling
- Project Management & Coordination
- Project Controls
- Middle East Experience
- Commissioning Experience
Success Factors
- Integration and Coordination of diversity of International Technology Suppliers
- Coordination and Communication on an International Project for the Client, Technology Suppliers and Local Engineering Company
Taminco Higher Amines, Inc.
Dmapa project
Scope:
- The project included installation of the reaction system for production of DMAPA along with the retrofit of the existing P47 distillation system for purification of the crude
Facts:
- ISBL Facilities:
- New six level braced galvanized steel structure, two bays wide and one bay deep
- OSBL Facilities:
- Unloading and loading pumps
- Storage tanks
- Piping tie-ins to existing facilities
- Modifications to existing modular MCC
- Equipment Piece Count – 29
- Nearly 16,000 ft – Piping
- 65 Tons / Steel
Technical Challenges:
- ISBL structure fixed into tight area with no shared column lines
- Piping and equipment layouts resulted in tight work spaces
- Approximately 130 tie-ins; many double block and bleed type arrangements to allow for segregating other plant facilities for campaigning of products
- Existing Honeywell TDC3000 together with and existing Fail Safe Controller System to be used in the project, with Class 1 2 Areas requirements.
PegasusTSI Expertise:
- Project Management & Coordination
- Team Chartering / Teambuilding
- Project Controls
- 3D PDS Modeling
- Control Systems and Instrumentation in DCS systems
Success Factors:
- On schedule and under budget
- Over 80,000 safe man-hours (Zero accidents/ Zero recordable incidents)
- Trouble free start-up
- Minimal time from start-up to on spec product
- More than 300 instruments successfully purchased and installed
- More than 200 IO’s wired and properly tested
Lynas USA, LLC
Seadrift, TX
Rare Earth Processing Facility
Scope
- Full Scale plant based on similar design of existing facility, green field design including all utility and wastewater treatment systems.
- Process included Dissolution, Liquid / Liquid Extraction, Precipitation, Drying.
- Procurement and Construction management were the next steps of the project.
Facts
- Raw Material Dissolution including small scale and large-scale batches, material handling of dry raw material included.
- Liquid / Liquid solvent extraction including design of support equipment.
- Precipitation of final product, including reactor design and mixing profile evaluations.
- Product finishing including product filtration, drying / calcination, and dry goods packaging with technology selection.
- Utility System design and a Minimal Liquid Discharge Wastewater Treatment process included.
- Process Hazard Reviews as well as Value Engineering Challenges conducted.
Technical Challenges
- New technologies within a new industry within the USA, design considerations and adaptation to US Codes and standards.
- Specialized vendor packages in multiple areas (Filtration, Drying, Calcination, Reactor mixing).
- Confidential IP in certain process areas.
PegasusTSI Expertise
- Process Engineering capabilities for all unit operations.
- Fast-track project design with large discipline-specific teams.
Success Factors
- Flexibility and adaptation to the evolving process/project design.
- Expertise in specific discipline areas.
- Strong vendor relationships to help drive technology selection and testing.
Haldor Topsoe
Ammonia Plant OSBL (SIPCHEM)
Location: Jubail, KSA
Duration: September 2006 – April 2007
Scope:
- FEED (Utilities and Process)
- Technology Integration (Ammonia Licensor)
- LSTK ITB Package
Scope
- Front End Engineering & Design (FEED)
- Ammonia Plant OSBL Storage and Utilities
- Infrastructure (Buildings, Roads, Sewers)
- FEED PHA
- Permit Application Package
- Project Estimate and Schedule
- ITB Package for LSTK Bids
Facts / Figures / Statistics
- $271MM TIC
Technical Challenges
- Schedule for FEED Completion
- FEEDS & Effluent Integration
- Integration with existing plants
- Technology Licensor Coordination
- Ammonia (HALDOR TOPSOE Process)
PegasusTSI Expertise
- Process Knowledge
- Project Management and Coordination
- OSBL and Utilities Definition
- Project Estimating
Success Factors
- Schedule Compliance
- Facilitation of Milestones for Technology Provider
- Communication and coordination on an International Project for Owner and Technology Provider
HyProMag USA
Rare Earth Magnet Recycling Facility
Location: Forth Worth, Texas
TIC: $130 MM
Scope:
Bankable Feasibility Study
- 80 Major Pieces of Equipment
- 7 MW Installed Power.
- Hard Drive Magnet Recovery Technology
- HPMS Technology
(Hydrogen Processing of Magnet Scrap) - Permit Road Map
- Site Selection
Global Reach
Leadership Team
Ronal Sepulveda
Board Manager
Mr. Sepúlveda is a Chemical Engineer with more than 30 years of experience in engineering and project management across multiple industries, including specialty chemicals, fertilizers, minerals, consumer products, and petrochemicals.
As General Manager, he leads the strategic vision and business development of the organization, ensuring both short-term performance and long-term growth.
Throughout his career, he has held senior project management roles, directing multidisciplinary teams and overseeing projects from feasibility and FEED through detailed engineering, construction, commissioning, and start-up. His international experience includes projects in the United States, Saudi Arabia, Morocco, Chile, Brazil, Finland, and other regions.
He holds a Bachelor’s Degree in Chemical Engineering from the University of Concepción, Chile.
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Karl Ibadulla
Board Manager
Mr. Ibadulla serves as President of PegasusTSI and Manager of HSE & Management Systems, leading the organization’s strategic and financial performance while overseeing the development of project execution systems and processes.
He drives continuous improvement and best practices in project development, focusing on organizational growth, client satisfaction, and employee engagement. His responsibilities include the design, implementation, and monitoring of company-wide quality, HSE, and performance management systems, ensuring scalable and sustainable project execution across all offices.
He also leads the standardization of procedures, compliance monitoring, and internal training programs to strengthen operational consistency and efficiency.
Mr. Ibadulla holds a Bachelor of Science Degree in Chemical Engineering from the University of Leeds (UK) and is a member of the Institution of Chemical Engineers (IChemE).
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Víctor Contreras
Board Manager
Chief Executive Officer of Pares&Alvarez since January 2017, Mr. Contreras joined the company in 1998 as Head of Processes and was later appointed Engineering Manager in 2000, a position he held for 16 years, where he led multidisciplinary teams, optimized resources, and ensured the delivery of departmental objectives.
With over 38 years of professional experience -26 of them at Pares&Alvarez- Mr. Contreras has developed strong technical, managerial, and commercial capabilities, playing a key role in the company’s growth, diversification, and strategic development.
Mr.Contreras holds a degree in Chemical Engineering from the University of Concepción and is a former member of the Chilean national rowing team, having competed in the 1984 Los Angeles Olympic Games. He has led and contributed to more than one hundred engineering projects across a broad range of industrial sectors.
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Stuart Singleton
Board Manager
Senior commercial leader with over 40 years of experience in engineering, project delivery, and business development across the chemicals, fertilizers, petrochemicals, and gas processing industries. As Commercial Director of PegasusTSI, he leads commercial strategy, financial performance, and international growth, while serving as Executive Sponsor on key projects to ensure strong client engagement and strategic project outcomes.
Mr. Singleton holds a degree in Chemical Engineering from the University of Bradford (UK) and is a member of the Institute of Chemical Engineers (IChemE).
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Andrés Jara
Board Manager
A Chemical Civil Engineer from the University of Concepción and an MBA from the Pontificia Universidad Católica, since 2017 has leading the Business and Marketing area, from where he consolidated the company’s presence in the mining sector and promoted the internationalization of Pares&Alvarez with the opening of offices in Peru and Australia.
With more than 28 years of experience, Mr. Jara began working at the company in 1997 as a Process Engineer. During his career he has assumed distinct roles associated with engineering, consulting, and projects, until reaching his current position. Between September 2012 and June 2013, he was project manager of the “Expansion of the CMPC Plywood Plant” (EPCM engineering, construction management and procurement), with an investment of USD$125 MM.
Mr. Jara has developed and directed more than four hundred projects, related to evaluation, market research, cost estimation, process optimization, basic and detail engineering, contract development and administration, tender development, and negotiation.
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Ricardo Sepulveda
Business Development
Prior to his business development leadership roles, Ricardo developed extensive expertise in process design, product development, and EPC project delivery, supporting major capital projects across the refining, energy, and manufacturing industries. He has a proven track record of advancing organizational growth, including successfully scaling company revenues from USD 7 million to USD 70 million within three years.
Mr. Sepúlveda holds a Bachelor’s degree in Chemical Engineering from the University of Concepción and an MBA from the University of Chile. He is a Registered Professional Engineer in Florida, Georgia, Kentucky, and Alabama.
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The Partners Behind SynertekPPA
Pares&Alvarez (P&A)
Founded in 1994, Pares&Alvarez is a Chilean engineering services company with expertise in environmental services, consulting, engineering, procurement, project management, and EP/EPC/EPCM contracts.
We develop industrial solutions for the mining, energy, chemical, desalination, wood-derivatives, oil and gas, manufacturing, and infrastructure sectors, and have executed more than 5,600 engineering projects in Chile, Argentina, Peru, the United States, Europe, and Asia.
We operate offices in Santiago, Concepción, and Calama (Chile); Tampa, Florida (United States); Lima (Peru); and Perth (Australia). Today, the company has over 1,000 professionals across multiple disciplines, enabling an installed production capacity exceeding 136,000 workhours per month.
PegasusTSI, Inc.
Based in Tampa, Florida, our team has a long history of working together, formerly as The Badger Company and subsequently as Raytheon Engineers & Constructors and Mustang Tampa, Inc. Over years of significant and steady growth, we are proud to have built a global reputation successfully serving the needs of the oil refining, petrochemical, fertilizer, chemical, pharmaceutical, municipal, consumer products and industrial facilities industries. Now, as we look to the future, we have the team and talent in place to elevate our company even higher.
We are committed to ensuring your success by delivering services and products that meet or exceed your requirements for quality and value. PegasusTSI works as an extension of your resources, maintaining a true team concept. Our proven expertise, accountability, and fierce dedication to personal service have resulted in long-term client relationships across the globe.
News
Press Release
Meet us at PDAC in Toronto 1st-4th March 2026