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Project Experience

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Energy Projects


Biosolids Dryer

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Client: City of Kingston, NY

Phase: Full commercial operation

The City of Kingston, NY, partnered with V1 team members, succeeded in developing a new and innovative system for managing wastewater treatment plant solids residuals in an economical and environmentally sound manner. The first system of its kind in the world has successfully been in operation at the Kingston Wastewater Treatment Plant since April 2007. Waste biogas is captured from the plant's digesters and utilized as the only required fuel to turn 10 wet tons per day of municipal wastewater sludge into two tons per day of an EPA recognized "Class A" EQ pelletized usable biosolid.

The drying technology selected was previously proven in large scale dryers in Brugges and Antwerp, Belgium, and in Baltimore, Maryland. V1 team members initiated an energy evaluation of the overall plant operations and integrated this solution to the existing plant. The entire system then needed to be scaled down to meet the needs of the smaller Kingston operation. The operating system also needed to be updated to allow for automated operations. Since startup, the plant has hosted many tours of the new operational model.

Measurable environmental benefits of this innovative project include:
• Removing a 6-8 ft. high arc burning methane, sulfur and mercaptan compounds. Biogas is now burned in a furnace and used as a heat source for the drying process;
• Reducing tens of thousands of yards or tons of "Class B" waste solids from being landfilled annually;
• Reducing truck traffic by 70 trips per year;

Key Skills:
scouting, problem/need identification market analysis
technology development
industrial innovation
proof of concept testing
business creation
legal
permitting
fundraising
technology design
sales and marketing public/private partnership fabrication
construction
operation and maintenance


Landfill Gas Control

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Client: Casella

Phase: Pilot Demo

Design and prototype development of a wireless monitoring and control system for landfill well gas collection system. Design included innovative sensor implementations, and advanced wireless mesh implementation, with innovative modeling of the landfill gas production process.

Key Skills:
modeling
sensor systems
non-metal fabrication
wireless technology


Energy Harvesting

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Client: New York based startup

Phase: Pilot Demo

Designed system for harvesting energy from braking vehicles on roadways. Product designed to be self-powered, wireless, and integrated with remote data acquisition and realtime cloud based visualization. Fabricated early proof of concept designs, iterated on promising solution, and and fielded a demonstration unit in upstate NY. 

Key Skills:
technology design
technology development
proof of concept testing
modeling
fabrication
energy generation
sensor and parts integration
wireless communication


Plasma Gasifier

Client: Spec

Phase: Concept

Design of a universal waste processing system for big-box retail stores, to move toward the zero-fuel, and zero-waste goals of large retailers

Key Skills:
energy systems
fabrication


Microturbine Cogeneration

Client: Spec

Phase: Concept

Design of small scale turbine generation and cogeneration for distributed electric generation at the household level

Key Skills:
energy systems
turbines
cogeneration


Thermo-hydraulic test cell for heat-pipes

Client: CRS Engineering

Phase: Pilot

Design and fabrication of a test cell for evaluation of laboratory-scale optimization of heat-pipe wicking elements.

Key Skills:
modeling
fabrication
control systems


Plastic packing materials for CO2 capture

Client: ConocoPhillips

Phase: Research

Research into efficiency of various materials considered for CO2 capture from amine scrubbing systems.

Key Skills:
chemical engineering
modeling
prototype development


Electrowetting-driven thermal management

Client: Spec

Phase: Concept

Design and early analysis of the potential for electrowetting techniques to be used for improving the heat transfer capacity of heat-pipes.

Key Skills:
modeling
electronic design
control systems


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Manufacturing and Industrial Projects


Microfluidics Manufacturing

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Client: Singapore Institute

Phase: Pilot

Design and fabrication of a very low cost benchtop manufacturing system for microfluidic chips. The system is designed to be used for small-run microfluidic manufacturing, or design and development efforts.

Key Skills:
metal and non-metal fabrication
manufacturing
control systems
automation


Microcontact Printing

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Client: NSF

Phase: Pilot

Design, fabrication, and demonstration of hardware and control systems for contact printing of micro-scale electrically conductive elements onto microfluidic chips.

Key Skills:
modeling
manufacturing
control systems
automation


Roadway-Vehicle Interface Testing Equipment

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Client: NY based startup

Phase: Equipment Fabrication

Designed and fabricated a custom testing rig to measure forces generated between a vehicle and the roadway. Test equipment was outfitted with sensors and attached to a laptop for experimental data capture. Test equipment automated for use in fatigue testing of new products under development.

Key Skills:
control system design
fabrication


Automotive

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Client: Various

Phase: Various

Team members have been involved in many elements of automotive design, fabrication, repair, restoration, etc. Vehicles include on- and off-road vehicles, motorcycles, custom vehicles, and industrial and construction vehicles.

Key Skills:
design
fabrication
engine build
suspension
bodywork
control systems


Roll Straightener

Client: Alcoa

Phase: Pilot Test in Plant

Design of a 3-roll extrusion straightening machine to automatically remove any residual curvature from annealed aluminum extrusions.

Key Skills:
modeling
control system design


Configurable Die Press

Client: GM Corp

Phase: Pilot

Design and fabrication of a prototype automated configurable die press. The configurable die consisted of a set of die matrices formed by rows and columns of 1/4” rods which could be quickly set to any shape, then locked into the shape for forming sheet metal.

Key Skills:
fabrication
hydraulics
control system design


Packaging for Empire Parallel Processing Engine

Client: IBM

Phase: Proof of concept

Design of electronics hardware packaging to house, power, and cool 100 CPUs and associated memory, storage, and power systems. This prototype computer system for general purpose, massively paral- lel processing was designed to be scaled to 1000 processors.

Key Skills:
modeling
advanced control systems
thermodynamics
sheet metal fabrication


Plastics Mixing Container

Client: Saunders Foundry Supply

Phase: Commercial Product

Fabrication of large stainless steel mixing pots for batch processing of molten plastics. Design of the mixing pots required special fabrication techniques to guarantee purity of various batch recipes.

Key Skills:
fabrication
toolmaker


Brushless DC Motor design

Client: Rotron

Phase: Commercial Product

Design of patented improvements to brushless DC motor design to be used in motor-fan combinations.

Key Skills:
patent
electronics
design


High-Reliability Motor/Fan

 

Client: IBM

Phase: Commercial product

Design of a specific motor/fan element to replace units that were failing prematurely in the field.

Key Skills:
patent
electronics
design
electronics fabrication


Factory Automation

Client: Rotron

Phase: Commericial Implementation

Redesign of factory flow process for manufacturing of consumer commodity motors and fans. Oversee construction of the factory through startup.

Key Skills:
project management
design
construction


Recording Studio Design

Client: Mosaic Ministries

Phase: Full Commercial Operation

Design and construction of an audio recording studio in an existing building. Key elements included acoustic isolation, power, cooling, wiring, and assembly and installation of all recording equip- ment. Also design and fabrication of a portable sound system for live sound applications and remote multi- track recording

Key Skills:
acoustics
automation
fabrication
woodworking


Restaurant Acoustics

 

Client: Cracker Barrel

Phase: Full Commercial Implementation

Measurement of sound levels throughout the restaurant and store to study noise problems for a normal operating day. Analysis of the noise patterns, and objectionable noise frequencies, and suggest modifications to the restaurant area to reduce cross-noise levels to improve customer experience.

Key Skills:
acoustics
modeling
construction


Pilot plant testing of ceramic membranes for oil-water separation

Client: ConocoPhillips

Phase: Research

Design of a testing program and procedures for analyzing various membranes considered for oil-water separation in pipeline operations.

Key Skills:
testing
analysis
modeling