Thermal Engineering Consulting & Research

Hard Apple Cider Pasteurizer
I designed a novel, space-saving plate heat-exchanger pasteurizer for a client. This project leveraged my heat-exchanger expertise to create a four-section unit: a regenerator for heat recovery, a heater, a pasteurization holding tube, and a cooler. Hot water supplied the heater, while chilled ethylene glycol cooled the final product. Considering the critical space and cost constraints, I reviewed the process (suggesting modifications), designed three plate units, and engineered the pasteurization tube. This project demonstrates my ability to innovate within tight parameters.

Reverse Engineering Sanity Check

I developed a "Reverse-Engineering Sanity Check Method" to verify heat-exchanger (HE) viability for a petrochemical client. This method assists project engineers, who lack specialized HE design expertise, in evaluating vendor quotes. By working backwards from vendor data sheets, engineers can compare calculations to industry standards. Acceptable ranges indicate likely functionality of the HE. This methodology empowers project engineers with a practical tool to assess HE suitability.

Retrospective Lifecycle Analysis

I drafted a technical article evaluating the 30-year lifecycle of novel modular shell-and-tube heat exchanger (MSTHE) systems in South African gold elution processes. My analysis drew on firsthand experience with MSTHE design, tracing its implementation from the initial stages of gold mine elution to final process recovery for maximizing gold yield from tail dumps.

Modular S&T Heat-Exchanger

I possess extensive experience with modular shell-and-tube heat exchangers (MSTHEs) dating back to 1988. As a Thermal Design Engineer, I spearheaded the development of unique design and selection software for a South African manufacturer. MSTHEs' versatility captivated me – their modularity allows configuration for diverse process needs, akin to a heat exchanger "Meccano set." They boast rapid assembly using readily available components.

These heat exchangers incorporate distinct features like a spiral cage assembly, elastomeric seals, and an air gap separating the tube-side and shell-side fluids. 

Ensuring Optimal Cooling Performance

This study assessed the performance of a large finned-tube heat exchanger for a platinum smelter water cooler in Northam, South Africa. The analysis considered historical climate data including high summer temperatures and high humidity winters. Simulations were conducted using reputable software to determine the effectiveness of the heat exchanger design across varying water inlet temperatures and air inlet temperatures. The findings revealed that while the design achieves a 10°C water temperature drop at a proposed inlet temperature of 55°C, it under-performs during months exceeding an air temperature of 27.5°C. This translates to limitations for 5 out of 12 months.

HPGR Comminution Review Report

I drafted a concise scoping report on High Pressure Grinding Rolls (HPGR) in mineral processing. The report leveraged my technical library (books, 49+ academic sources) and was enhanced through an iterative process. I first drafted the report, then utilized an AI system for review and suggestions. Based on the AI's feedback, I incorporated additional information, focusing on maintaining a concise overview. While further details on modern fluid flow and grinding theory could have been included, the report aimed to serve as a framework for the client to build upon. This project highlights my ability to leverage technical resources and explore the potential of AI for knowledge refinement.