NESTEC Inc.
NESTEC Inc.
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Expertise and Responsibilities
Expertise and Responsibilities
▪ Knowledge pertaining to oxidative processes and air filtration within the air pollution filtration industry
▪ Increasing workplace efficiency
▪ 3D Modeling with the SolidWorks Software
▪ Design and fabrication
▪ Research for components for the Research and Development department
▪ Woodwork
▪ Metalwork
▪ Welding
Engineering Internship
Engineering Internship
RTOs and RCOs
RTOs and RCOs
Regenerative Thermal Oxidizers (RTOs) and Regenerative Catalytic Oxidizers (RCOs) are air pollution filtration systems designed to destroy volatile organic compounds (VOCs), and hazardous air pollutants (HAPs). RTOs operate by using thermal energy to oxidize pollutants at high temperatures, typically between 1,400 and 1,800°F. The process begins with polluted air being preheated in heat exchangers, which recover heat from the outgoing exhaust. A metal plate with high thermal conductivity separates the intake air from the outgoing exhaust. The preheated air then enters a combustion chamber where VOCs and HAPs are oxidized into harmless byproducts like carbon dioxide and water. The hot, clean air transfers its heat to the incoming polluted air through the heat exchanger, creating a highly efficient regenerative process with minimal fuel consumption. RTOs are commonly used in industries with high VOC concentrations, such as painting, coating, and chemical manufacturing, offering destruction efficiencies of 95-99%.
In contrast, RCOs combine thermal oxidation with catalytic processes, allowing them to achieve pollutant destruction at much lower temperatures, typically between 500 and 1,000°F. Like RTOs, RCOs preheat polluted air using regenerative heat exchangers. However, instead of relying solely on heat, the air passes through a catalytic media where the catalyst (usually platinum or palladium) facilitates oxidation at reduced temperatures. This results in significant fuel savings and lower operating costs. However, catalytic media does not last forever and must be replaced after a certain amount of time or volume of air has passed through it. The clean air then transfers its heat back to the incoming polluted air, maintaining energy efficiency. RCOs are ideal for applications with low to moderate VOC concentrations or where emissions are heat-sensitive, such as in printing, packaging, and electronics manufacturing.
While RTOs are more suitable for high VOC concentrations and simpler to maintain due to the absence of a catalyst, RCOs offer lower energy consumption and operational costs but require periodic catalyst replacement. The choice between these systems depends on factors like pollutant concentration, energy requirements, and long-term cost considerations. Both technologies provide destruction efficiencies of 95-99% and help industries meet strict environmental regulations effectively.
Regenerative Thermal Oxidizer
Regenerative Thermal Oxidizer
Simplified Drawing
Regenerative Catalytic Oxidizer
Regenerative Catalytic Oxidizer
Nearly identical to a RTO
Air Flow Demonstration
Air Flow Demonstration
This demonstration was created to simulate air flow in a Regenerative Catalytic Oxidizer (RCO). The high-powered fan in the middle starts the demo. The intake is vacuumed from the duct to the right and the air flows to the left. On the left end, a cube of catalytic media is attached to the system. The demonstration was meant to illustrate the loss of speed the air exhibits when passing through the media. This can cause problems such as built up heat in the media, higher energy consumption, potential mechanical failures, and increased degradation of materials. The experiment highlighted the importance of choosing the optimal cell density in the media, which refers to the quantity of holes/cells per cubic inch. While higher cell densities increase the surface area available for catalytic reactions, it also causes a larger decrease in air flow. Finding the optimal cell density for air flow and catalytic reactions is an important step in creating an energy-efficient RCO.
Welding Cart
Welding Cart
The welding cart project was an ambitious and long endeavor that aimed to create a practical solution for organizing and mobilizing welding equipment in the metal shop. The objective was to design and build a durable, mobile cart capable of securely storing and transporting a wide range of welding tools and accessories, ultimately improving efficiency in the workspace. This project was the result of extensive discussion, planning, and collaboration during my internship, reflecting the importance of thorough preparation before undertaking such a hands-on task.
Before we could begin constructing the welding cart, gaining welding experience was a critical prerequisite. This involved a comprehensive training process to ensure a solid understanding of welding techniques, materials, and safety protocols. We underwent formal training sessions, which included welding exercises, safety practices, and the proper handling of equipment. Additionally, we became certified in welding safety, which further qualified us to complete the project and maintain a safe work environment.
Once we were equipped with the necessary skills and certifications, we moved on to the planning and preparation stages of the project. Every detail of the welding cart was carefully mapped out to meet specific requirements. We began by drafting schematics to determine the dimensions, layout, and functionality of the cart. The design was tailored to store welding equipment, including a tool chest, shielding gas tanks, spools of solid wire, grinders, and personal protective equipment (PPE). This planning phase also involved creating a detailed list of materials required for the build, ensuring nothing was overlooked. Starting from scratch, we selected raw metal materials, which were measured with precision and cut in the metal shop, adhering to tolerances we deemed appropriate. Each piece of metal underwent sanding and grinding to remove rough edges, burrs, and imperfections, preparing them for welding. This step was crucial for ensuring strong, clean welds that would contribute to the cart’s durability and stability.
During the assembly phase, the metal pieces were initially tacked together. Tack welding allowed us to position and secure the components temporarily, ensuring they were aligned correctly before committing to full welds. Once the framework and structure were confirmed to be accurate, we proceeded with the complete welding process, reinforcing each joint and seam for maximum strength.
Over 50 custom metal "pegs." were created to hold the tools in place. These pegs were individually cut, sanded, and welded onto the cart to serve as holders for various tools and accessories. This required precision and attention to detail to ensure that the pegs were not only functional but also aesthetically aligned with the overall design.
The cart was still a work in progress when the internship ended, as the workshop users had not made final decisions on which tools they wanted on the welding cart. However, the only step remaining was to weld the pegs on the cart and distribute them in a way that was efficient and followed the aesthetic design. The layout was intentionally designed to maximize storage capacity and ease of access. The necessities were mapped out, like the tool chest, spools of metal wire, and gas cylinders, along with some tools. The addition of smooth-rolling wheels further enhanced the cart’s mobility, making it an indispensable asset in the shop.
Reflecting on the project, the welding cart was more than just a practical tool; it was a testament to teamwork, skill development, and problem-solving. It served as a valuable learning experience, combining theoretical knowledge with hands-on application. From gaining welding expertise to overcoming challenges in construction, this project was an incredible opportunity to grow both technically and professionally.
Preparation
Preparation
In Progress
In Progress
Final Product
Final Product
Warehouse Reconfiguration
Warehouse Reconfiguration
This project allowed me to use my skills in Industrial Engineering. Reconfiguring the warehouse was a basic exercise in a streamlining process. The items stored in the warehouse were organized via random SKU order numbers. All of the items were fairly similar in importance, so slot allocation based on priority ranking was not relevant. After this evaluation, the decision to keep the prior slot allocation was deemed appropriate. The main objective after this was to organize the warehouse in a way that the workspace was properly separated from the storage space without occupying the areas in front of the bay doors. In the image, the spaces that should not be occupied are marked with an X. The shelves are represented by the narrow rectangles, and the entire warehouse surface area was divided by the concrete slabs the warehouse resided on. Ultimately, the aisles were extended and set in an array that occupied one side of the warehouse, up until the bay door section was reached. In front of the bay door, there needed to be space for the telescopic handler. The workspace was assigned to the space opposite to this bay door. The other bay door and the entrance filled the remaining spaces.
Side Projects
Side Projects
Paint Cabinet (Left image, back of photo)
The NESTEC Inc. facility had recently undergone major renovations when I started my internship. Due to this, there were excess materials from the renovation, which included many large paint cans. We were given the capacity required for the paint cabinet and specific instructions on the design. After framing the paint cabinet to its desired measurements, we sanded the edges, put on 3 coats of polyurethane on the inside of the cabinet, and painted the outside gray. We also decided to add features of our own design, including caster wheels for mobility, and shelves on the inside of the doors for paint brushes and other utilities.
Drill Bit Cabinets (Left image, quantity of 3)
One of the main issues in the metal shop was the organization of the drill bits. The drill bits were originally in a large bin, completely mixed together. To combat this, we designed a cabinet to organize the drill bits with a 3D design software known as SolidWorks. Within SolidWorks, we also modeled a bracket of our own design that was meant to not only hold the shelves of drill bits, but also rotate for ease of access and visibility. After the design phase, came the organization phase. Every drill bit was categorized by the material it was designed to drill, and the type of bit that it was. After separating them into these categories, I labeled each bit with its engraved size for better visibility. If the engraving was rubbed off, I took a precise measurement with calipers and put the measurement down on the label. For the implementation phase, we planned to build the frame of the cabinet out of wood, 3D print the brackets and shelves, and insert the drill bits into press-fit holes in the shelves. After framing the cabinets, we finished them by sanding the edges and putting on 3 coats of polyurethane.
Utility Trays (Top right image)
Something we noticed as interns was the constant use of the same tools throughout the workshops. The tools we found to be used the most were tape measures, pencils, chalk, and carpenter's squares. All of these tools were in the same tool chest in the corner of the metal shop. Every time a tool was needed or misplaced, workers would have to walk a sizeable distance to retrieve the tools. To mitigate this, I designed and created several Utility Trays to be placed around the workshops. In each Utility Tray were the most frequently used tools. By placing these trays throughout both workshops, workers would no longer have to traverse around the work shops when they needed a tool. These trays also decreased the frequency in which these tools were misplaced, as they had a designated spot to return to.
Utility Carts (Bottom right image)
As a fun, small side project using scrap materials, we crafted small, mobile Utility Carts to help us in the wood shop; these closely resembled a box on wheels. Oftentimes, we would find ourselves working on projects on our hands and knees, and constantly moving throughout the room to retrieve tools and materials such as drills and screws. The Utility Carts solved this problem; acting as both a seat and a container. The Utility Carts were low to the ground, which allowed us to work on projects without crawling on the ground. As for the lid, we tested two different versions. One of the carts had a slit in which you could reach inside of the box, which contained all of the tools and materials you need, while you were sitting on it. The other cart had a hinge that allowed the lid to slide so you could decide when to keep the slit open. Unfortunately, if you were to slide the lid so the slit was open, you could sit on the unsupported part and fall. Another issue we found in the slotted Utility Cart was that screws would scatter inside when the cart was in motion, which negated the need for the slit in the first place. For future creations, we decided it was best to have a recessed area for small materials such as screws on the top of the Utility Cart, and the lid should open like a door. This would prevent users from sitting on an unsupported area, while still having access to smaller materials.
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