Carbon Capture Internship

June - Sept. 2023

I participated in Heirloom Carbon's internship program as a mechanical engineering intern. I worked as part of the research engineering team and closely with the research science team.

NOTE: an NDA was signed

Pneumatics
Product Design
3D printing

Goals:

Build a vertical forced air setup to study its affects on carbonation rate of calcium hydroxide
Design a minimally disruptive sampling tool for the research science team
Test a new method of powder conveyance to explore its pressurized behavior

What I did:

Built a vertical forced air carbonation setup with a VFD to vary vacuum strength, a vacuum gauge, and a powder/water trap for easy cleaning. Results:
- 90% reduction in carbonation time
- 20% increase in carbonation extent
- 80% reduction in water usage
- Increase in 28 W electrical power usage

2. Designed a sterilizable, easy-to-use tool for the research team to consistently pick up a vertical 0.12 g sample of powder without disturbing the powder bed
- Tested many methods of powder collection through rapid prototyping and selected a working design
- Designed an ergonomic grip and made 6 tools for the research science team
- Make it out of plastic and metal for easy manufacturing and cleaning (important for sampling)

3. Tested a new method of powder conveyance
- Determined it provided a mixed mass-funnel flow
- Verified it had no difficulties with our most problematic material
- Identified that it was not a great pressure break, only being able to hold 0.3 psi.
- Provided the team with a number of tests I would like to have run if I were to not end my internship and leave for school

4. Upgraded the company's 3D printers (in down time)
- Built a third 3D printer to increase prototyping capabilities
- Implemented remote monitoring and control to all printers to enhance team productivity and safety

Some piping and supports (can't show the rest of the system)

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Zoom in final design of tool

Iterations on the tool development

Tool in hand showing use movement

Zoom in final design of tool

1/4

Built a 3D printer (Prusa) for the team

Implemented remote control and monitoring to all existing printers

The video feed of printers in initial operation before adjusting to center of printing platform

Built a 3D printer (Prusa) for the team

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What I learned:

I excel in brainstorming and prototyping, but still need to work on knowing when it is time to slow prototyping and work on refining a final design
How to spend more money (compared to the $150 project budgets I'm used to for class projects)
Learned a lot more about piping, tubing, and filtration
Recognized the importance of an EHS team and workplace safety precautions
Practiced making assembly drawings for the machine shop to make (more specifically welding symbols)
How motivating and energizing it is to work with like-minded coworkers