Reactech Consulting Projects
Containerized Microwave Based Pyrolysis Units
Project based on university research in waste to fuel applications. The team worked with the client to take the project from conceptual idea of a containerized 1 TPD plastic waste to diesel pilot unit and deliver a fully functioning system with process safety at the top of mind.
The pilot system was rigorously tested and iterated to scale up to a full size 5 TPD containerized unit. Conceptual layouts were provided within a custom 40’ container frame.
Services
Interpret fundamental research to scale system with appropriate heat and mass balance calculations
System level design with HAZOP and FMEA
Electrical and control system design
Reactor design with RF components
Assembly and component level mechanical design
Establishment of basic MRP database and CAD file storage structure
Supplier contact list, component sourcing, and procurement support
Assembly and commissioning support
Process performance data analysis and design iterations
Client
Resynergi, Inc.
Year
2017 - 2025
Additional Industry Experience
World’s Largest Methane Pyrolysis Unit
Reactech’s core members have cut their teeth developing the world’s first successful methane pyrolysis and clean carbon black unit from pilot scale to full commercial scale. The cumulative experience spans the full range of technology, business, and operations development from small beginnings to world leader over several 10+ year tenures.
The journey to commercialize a primary process is the definition of “hard tech” in every sense of the phrase. A lifetime of experience in a few short years is the reward.
Highlights
Total process scale-up of over 200X from lab to pilot to commercial
World’s largest operating commercial plasma torch (>16 MW)
Greenfield plant construction and EPC management - initial site grading through commissioning
Engineering team management: organizational design, performance based promotions / terminations, cross-functional workflow development
DoEs to map process space and carbon black grade ranges.
Fundamental research in particle morphology levers and applications at scale
Deep understanding of advanced composites, refractory metals, and ceramics in harsh environment / ultra-high temperature applications
Deep understanding of machining and fabrication methods for both advanced and traditional engineering materials
Mastery of machine design for both fixed and rotating equipment
High power electronic system design, development, and operation
Process performance data analysis and design iterations
Software tool development to support operations and engineering
High temperature instrumentation design and development
Development of advanced CFD and FEA setups to simulate reactor performance under all system states to inform design iterations
Control scheme conceptualization, implementation, and continued development
Company-wide document control system creation and maintenance
International and domestic supply chain management
On-site support for operations, maintenance, and contractors.
Investor / Board presentations
Techno-Economic Analysis
Business development: technology pitches, site selection, public relations, customer relations
Bioreactor Systems
Haematococcus algae is cultivated to produce the carotenoid astaxanthin for the pharmaceutical and cosmetic industries. The lab-scale bioreactor was designed as a loop reactor to maximize Photosynthetically Active Radiation availability.
The Haematococcus species is especially sensitive to mechanical action needed to propel fluid around a loop reactor due to the fragility of its two flagella. The loop bioreactor was designed to propel fluid with no moving parts, minimizing fluid shear and preserving the integrity of the cells.
Highlights
Conceptualization of loop reactor pumping mechanism
Prototype reactor design, fabrication, and assembly
Inoculation, operation, and cleaning procedure development
DoE development to determine system viability and maximize culture growth rate
Biolab work to study cell density, bacterial contamination levels, astaxanthin yield, etc.
High-Precision Fluid Measurement Systems
Small Volume Provers (SVPs) are an essential measurement tool of the Oil&Gas and wider chemicals industry. These machines have been developed to calibrate many types of continuous liquid flow meters for custody transfer and process applications.
Each machine is customized for the customer’s specific measuement application, from lab settings to the harshest environments.
Highlights
Pressure vessel design from 150# to 1500#
Class I Div II electrical system design
Design for highly corrosive environments, i.e. off shore platforms
Internal flow components designed for hot and abrasive fluid handling, e.g. bitumen form tar sands
Cryogenic applications with inert gas purged linear motion components and thermal isolaiton
Trailer and truck mounted options - custom designed trailers with hydraulically actuated or spring assisted loading arms
Additional Coriolis meters and pycnometer balls for density measurements with passive flow elements
Additional activities - material review and defect disposition with inspection department, machine shop support, assembly and testing support
Consumer Electronics
In the early 2010s consumer grade FDM 3D printers had found their moment in the public’s imagination. Robo 3D was born from a Kickstarter campaign that achieved unprecedented success offering the public a unique, reliable product at affordable prices.
The success led to the immediate challenge of manufacturing a product in large volumes to fill the growing order book. This was achieved by establishing a partnership with international contract manufacturers and establishing a working production line.
The R1 printer, a certified best seller on Amazon, was the first to offer automatic bed-leveling to make printing easy and accessible for all skill levels.
Highlights
Design of injection molded components for high-volume manufacturing
International supply chain management
Full design package of component drawings, assembly drawings, and source control documentation for contract manufacturer compliance
Presenter at CES 2015
Development of the R2 and R2 Mini prototypes to show at the CES booth
Costco Road Show - Sales and consumer education at several Costco locations around the greater San Diego area
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