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From craft breweries to steel manufacturing plants, many industrial facilities rely on cryogenic gases for processes such as cooling, materials testing or energy transport.

But before those gases can be used, they must be vaporized with electricity-intensive equipment that can cost companies tens of thousands of dollars each year.��

A team of seniors in the Paul M. Rady Department of Mechanical Engineering are working on a new solution. For their senior capstone project, the group is developing a heat-exchange device that captures waste heat circulating through refrigeration systems.

The project could help facilities drastically reduce energy consumption and operating costs, providing them with a sustainable new alternative.

“Think of a local business with a small facility like Avery Brewing. We found that they spend over $20,000 a year just to heat those cryogenic gases electrically,” said test and systems engineer Zachary Weiner. “Our device would cut that cost completely and recovering waste heat makes for a great green energy alternative.”

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Members of the team chatting with local brewing industry professionals during a research visit.

However, the idea didn’t come together overnight. As part of the��Senior Design program’s Engineering for Social Innovation (ESI) track, the team was responsible for developing their own project from scratch without being assigned to industry-sponsored prompts.

After extensive research, the team decided to explore waste heat recovery in the brewing industry. It wasn’t until they visited some local breweries and distilleries that the project truly came into focus.

“All the engineers we met with on our visits were so interested in our early concept and that’s what really inspired us,” said manufacturing engineer Ian Mcleod. “Some of these small and mid-sized businesses are trying to cut costs and be more sustainable so they can prevent them from closing down. Our passion in this project is about helping them save energy and remain open.”

The problem is simple: cryogenic gases are liquefied and stored at extremely low temperatures to maximize storage and enable easier transportation. In order to be used in industrial facilities, though, they must be vaporized into gas.

To do this, most places today use an energy-intensive electric pressure builder that draws directly from the power grid. But the group’s new heat-exchange device is different.

Instead of using electricity, the device takes in a hot, refrigerant liquid called glycol. In breweries, glycol is already being chilled and circulated through cooling systems to keep tanks and other equipment at safe temperatures.

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Test and systems engineer Zachary Weiner working on the senior design project in the Idea Forge.

By using glycol, the team says the device can repurpose its existing heat rather than relying on new energy from the grid.

“We are essentially saving energy that would be taken out anyway through the glycol cooling process,” said project manager Gavriel Fox.

The group is currently working on a test article for their heat exchanger model. They plan to showcase the small-scale design and validate their simulations at this year’s��Engineering Expo event in April.

But Engineering Expo is only part of the journey. The team will also be competing in the��New Venture Challenge (NVC), where they will refine their business model and pitch the technology as a scalable solution for multiple industries.

“Our device is relevant wherever there is bulk gas that needs cooling. It can be oxygen in hospitals, nitrogen in oil and gas industries or even argon in commercial steel facilities,” said logistics manager Asaiah Gifford. “We see breweries as our market entry space. If the device works in breweries, then we know we can expand from there to much larger industries.”

If selected to compete at the NVC finals in April, the group will have capped off a year-long project with an exciting finish. And while the process has been stressful, the team says the experience has been equally rewarding.

“We have a great team and this project has pushed us to become independent thinkers with agency,” said Fox. “We’ve even become better engineers with a strong foundation of business knowledge.”