Biomedical and Chemical Engineering and Sciences

Project Summary

Aging is the most significant risk factor for most human diseases. Several genetic pathways demonstrate the capacity to regulate aging, including the Heat Shock Response (HSR) controlled by heat shock transcription factor 1 (HSF1). Acetylsalicylic acid (aspirin) is an anti-inflammatory drug often used to reduce pain, fever, and the formation of blood clots. Aspirin is known to partially activate HSF1. Here, we test whether aspirin can affect lifespan using the model nematode Caenorhabditis elegans. 

Project Summary

Quorum sensing is a process by which many unicellular organisms coordinate behaviors such as bioluminescence, swarming, biofilm production, etc. This process is regulated by the exchange of chemical signals which serve as proxies for cell density. Recent studies have established that the photosynthetic algae Chlamydomonas reinhardtii regulates swimming speed through a largely uncharacterized QS process. However, this species displays significant phenotypic and genetic diversity suggesting QS may not be ubiquitous throughout all environmental isolates. Such variation could provide molecular tools for the identification and characterization of signals and molecular processes at work in this novel QS system. Here we focus on characterizing a non-motile variant of this species, CC4414. This variant of C. reinhardtii was isolated from high altitude lake samples in Breckenridge, Colorado and originally characterized as having a larger cell size than other wildtype C. reinhardtii strains, as well as being able to survive and grow at temperatures as low as 4°C. However, this strain has not seen significant use since its isolation nearly two decades ago and these claims have not been supported elsewhere. Here we evaluate the previously assigned characteristics associated with this variant, as well as its potential to engage in quorum sensing.

Project Summary

Of the approximately 250,000 new cases of invasive breast cancer diagnosed every year, an estimated 80% will have increased levels of the HSF1 transcription factor. Patients with both elevated HSF1 levels and increased HSF1 activity have significantly worse outcomes. We have performed a cell-based screen and identified three small molecule inhibitors of HSF1 expression. Here, we characterize the response of HEK293T cells upon 16-hour exposure to the small molecules on a genome-wide level using RNA-sequencing technology. The sequences from two of the inhibitors were filtered and graphically visualized to compare the differentially expressed genes and begin to understand the pathways. The goal is to identify the mechanism of action in order to further develop the potency of the small molecule and to minimize potential side effects.

Project Objective

We have identified 3 small molecular inhibitors of HSF1 expression. The goal of this research is to characterize the genome-wide response of human cells to these inhibitors using RNA sequencing technology in order to continue preclinical development.

Analysis

The processed RNA-seq data was filtered to eliminate low-count genes and genes above a p(adj) value of 0.01. RStudio, with the help of several packages (e.g. 'edgeR', 'tibble', 'tidyverse', 'dplyr'), was used to filter the datasets. Graphs were generated using 'ggplot2' and 'ComplexHeatmap' in R.

Future Works

Future work will define specific pathways and genes that contribute to the compounds’ responses and their connection to the down regulation of HSF1. The long-term goal is to identify interaction partners in order to improve potency and complete preclinical studies.

Project Summary

Mechanosensory neurons are responsible for sensing touch, relaying mechanical force into electrical signals. Critical to the function of these neurons are microtubules, which are involved in touch detection and act as the support system of the long axons of these cells. Destabilization of microtubules is linked to several neurodevelopmental and neurodegenerative diseases, but the cellular, genetic, and molecular mechanisms involved are not well understood. Tau, a protein expressed in the nervous system, functions to help stabilize microtubules. A specific mutation of the Tau gene, TauV337M, causes familial Frontotemporal Dementia. Aggregation of Tau forms neurofibrillary tangles, but this is a late-stage disease symptom. Understanding Tau’s role in neurons, and how mutations affect Tau’s functions, will be important throughout life, including development. Uncovering the genetic pathways involved in the complex process of neuronal development will be important for future diagnostics and therapeutic treatments. This study proposes to examine two questions by assessing the morphology of C. elegans ALM neurons: 1) How does the disease-associated TauV337M affect microtubule stability during neuronal development? and 2) What genes does Tau interact with to affect these processes? Using combinatorial genetics, pharmacology, and fluorescence microscopy, we show that the TauV337M mutation causes ALM mechanosensory neurons to grow an ectopic neurite (Fig. 1), which is linked to reduction in microtubule stability. Unexpectedly, we show that strongly reducing microtubule stability through pharmacological manipulation completely prevents formation of the defect. We also show that the ubiquitin ligase, rpm-1, functions downstream of Tau to regulate the development of the ectopic neurite. These results reveal a new genetic pathway between Tau and rpm-1 that provides potential targets for therapeutics for neurodevelopmental disorders and neurodegenerative diseases. This project was partially supported by the Beta Beta Beta Research Scholarship Foundation.

Project Summary

The microgravity environment aboard the International Space Station (ISS) poses significant challenges to both animals and plants which have evolved with gravity as a generally constant parameter over millions of years. These stressors limit potential agricultural yields in this environment while potentially changing normal biological interactions in unknown ways. On Earth, Plant growth promoting (PGP) microorganisms are common companions to many plants, having evolved over millions of years. We hypothesize that such PGP microorganisms can be leveraged in space, to improve agricultural yields in the microgravity environment, while also learning about how plant-microbial interactions may change in this environment. However, such interactions are not limited to a single microbial species at a time, but often require mixed cultures to maximize potential benefits. Here we have taken microorganisms isolated from plants growing on the ISS and previously screened for PGP properties to determine if they can be co-cultured and retain their PGP behaviors.

Project Summary

Advancements in industrial and agricultural sectors have rapidly increased the amount of heavy metal pollutants in the Earth’s environment. Many heavy metals are important in the essential mechanisms of plant growth in low concentrations, but if the necessary uptake of these ions is exceeded damaging effects will occur. Therefore, the remediation or removal of heavy metal pollutants from soil and groundwater is a crucial topic for research. There are also uses for this form of remediation in the future; if efforts are made to grow crops in a Lunar or Martian settlement, methods will need to be developed to work around the high metallic concentrations found in the local regolith. Cupriavidus metallidurans is a bacterium known for its adaptation to withstand heavy metal stress. This species is known to be genetically related plant pathogens. We hypothesize that C. metallidurans can help alleviate heavy metal stress in plants exposed to toxic levels of chromate​​ (CrO42-) and copper (Cu4-) because of its innate resistance to these stressors and its relationship to bacteria capable of interfacing with plants. Chromate and copper were chosen for this experiment because of C. metallidurans’ known resistance to these metals, the low concentration for these which is toxic to plants, and because both are present on the planet Mars and the moon. As stated previously, there are useful applications for heavy metal remediation currently on Earth, but the future implications of this research have been emphasized during the process of this project as the samples of C. metallidurans used come from a strain isolated on the International Space Station. ​​​​​​Potential future​​​​​​ avenues to explore for this topic would be the mechanism by which C. metallidurans reduces metal stress in plants or determining other heavy metals which this bacterium is effective against.

Project Objective

Evaluate the capacity for C. metallidurans to help alleviate heavy metal stress in plants exposed to toxic levels of chromate​​ (CrO42-) and copper (Cu4-).

Project Summary

The phenomenon of quorum sensing (QS) allows unicellular organisms to coordinate phenotypic switching based on cell density, optimizing specific behaviors to high or low cell densities as appropriate. Originally thought to be limited to prokaryotes, QS has been observed in a small number of eukaryotes, including the model unicellular green algae Chlamydomonas reinhardtii. In the wild-type strain cc124, swimming speeds are positively correlated with cell density, nearly doubling as cell density increases by two orders of magnitude. However, within this species, there is significant genetic and phenotypic variation and evidence suggests this may extend to QS behavior also. Therefore, understanding how quorum sensing responses vary across strains of one species could provide tools for identifying the relevant signal molecules as well as the molecular mechanisms associated with QS. Here we will investigate the QS responses of two C. reinhardtii wild-type strains - cc1010 and cc1690. Liquid cultures of each strain will be incubated for either 48 hours (for low cell density) or 96 hours (high cell density). Using the liquid cultures, videos of the cultures will be taken using a light microscope and the cells tracked using ImageJ and the TrackMate software package. Using the data exported after the TrackMate process, the swimming speeds of the tracks between the low cell and high cell density sample of the strains will be compared. Media swap experiments between low cell and high cell density cultures will provide additional evidence for the conservation or absence of QS in these geographically distinct wild-type isolates.

Project Objective

To characterize the phenotypic variation of quorum sensing responses across C. reinhardtii, specifically strains 1010 and 1690.

Manufacturing Design Methods

Cultures of cc1010 and cc1690 were grown from 24-96 hours to compare growth with cc124. For cc1010 and cc1690, low cell density cultures (below 2.0x106 cells/ml) were grown for 48 h, and high cell density cultures (at or above 2.0x106 cells/ml) for 96 h. Using FIJI and the TrackMate package, the track speeds were calculated and then analyzed in Excel.

Future Works

Further characterization of the other strains available and testing the effects of other strains.

Manufacturing Design Methods

Cultures of cc1010 and cc1690 were grown from 24-96 hours to compare growth with cc124. For cc1010 and cc1690, low cell density cultures (below 2.0x106 cells/ml) were grown for 48 h, and high cell density cultures (at or above 2.0x106 cells/ml) for 96 h. Using FIJI and the TrackMate package, the track speeds were calculated and then analyzed in Excel.

Project Summary

Plant growth promoting bacteria (PGPBs) are likely to play an important role in supporting food security during long duration space flight missions. For example, PGPB could help improve edible biomass yield and supplement life support over the 6-month long journey to Mars. Our lab has developed a pipeline for the discovery of PGPB isolated from the surfaces of plants grown aboard the International Space Station and are exploring these organisms for their potential benefits to space agriculture. At the core of our pipeline, is determining what these phenotypes are and how they are regulated. This would allow us to match specific microorganisms which may have compatible PGP phenotypes with host plants. Many of these plant beneficial processes are regulated by cell density, a phenomenon known as quorum sensing (QS), regulated by the synthesis, release, and detection of a variety of low molecular weight compounds. In Gram-negative bacteria, the most common signals are N-acyl-L-homoserine lactones (AHLs) and a variety of AHL-reporter systems have been identified to monitor the production of these regulators of bacterial behavior. The Gram-negative bacterias that are currently being tested are: Burkholderia multivorans, Burkholderia pyrrocinia, Cupriavidus metallidurans, Curtobacterium flaccumfaciens, Enterobacter cancerogenus, Methylobacterium luistanum, and Pantoea agglomerans. Here, we present a series of biological assays which determine which Gram-negative bacteria from our pipeline are capable of AHL-mediated QS as well as the likely identity of that signal utilizing thin layer chromatography (TLC). This approach will provide a cheaper alternative to techniques like high-pressure liquid chromatography (HPLC). The work presented here will focus on the development of our TLC approach.

Project Objective

Thin-layer chromatography (TLC) is used to study solutes by weight. TLC allows the AHLs to migrate up the plate and therefore distinguish the identity of which AHL is present. Here we are modifying a spot extract assay to better apply TLC to determine the identity of AHLs present.

Manufacturing Design Methods

Design methods includes our experimental designs for each step of the process. 1) Workflow for AHL extraction and concentration the AHLs from the different species samples. These species were previously identified as AHL producing. 2) TLC assay workflow. A ladder of stock AHLs are used to determine the identity of each extracted AHL. 3) Spot assay workflow, to support extract viability.

Analysis

Currently known AHLs (stock) were compared with extracts in the spot assay. AHLs were detected, not identified. The spot assay got us closer to a TLC plate which is continuing to be worked on. The issues that were encounter with TLC plate have been discovered and are now being fixed in order to get our first completed AHL TLC plate.

Future Works

Future studies will use high-performance liquid chromatography (HPLC) and more TLC tests. HPLC would yield results with fewer variables.

Manufacturing Design Methods

Design methods includes our experimental designs for each step of the process. 1) Workflow for AHL extraction and concentration the AHLs from the different species samples. These species were previously identified as AHL producing. 2) TLC assay workflow. A ladder of stock AHLs are used to determine the identity of each extracted AHL. 3) Spot assay workflow, to support extract viability.

Project Summary

In this project, we analyze fiber bundle formation in model proteins for Alzheimer’s Disease (AD). In the lab, we focused on: making hydrogels, which contain lysozyme in a glycine buffer with NaCl at a pH of 2.5, making different dilutions of the gel (10X, 100X, or 1000X), and finally viewing these under a light and confocal microscope. The purpose of this project is to better understand fiber aggregation by using lysozyme to simulate the plaques found in the brains of patients with AD. The major challenges that we encountered included finding the correct amount of time between centrifuging our samples and waiting for the hydrogel to solidify. We found that 1-2 days was an ideal time for gel formation by experimenting with a variety of different times. Our methods of data analysis included observing microscope images using light and confocal microscopy and determining where there were bundles in the different images. Through these images, we were able to determine which magnification and concentration of gel was ideal for getting the best results, which we found to be 10X dilution of gel and 40X magnification for light microscopy. For future studies on fiber bundle formation in AD, it would be beneficial to use different concentrations of lysozyme in the gel-making process to determine whether this would result in a difference in the bundles when viewed under the microscope. Overall, our project aims to get a closer look at the bundles that are present in those with AD, and how we can produce and view these bundles using lysozyme as a simulation.

Project Summary

Through the phenomenon known as quorum sensing (QS), unicellular organisms are able to couple phenotypic switching to cell density. In the model unicellular eukaryote, Chlamydomonas reinhardtii, QS establishes a positive correlation between cell density and swimming speed. This switch is due to a presently unidentified molecule, called the Chlamydomonas Swimming Speed Factor (CSSF). We have previously established that swimming speeds change depending on the cell density, however it is unknown whether or not QS affects the surface structure of the cells as part of this phenomenon. Imaging samples under high magnification allows for the surfaces of these cells to be observed for physical characteristics. Here we compare and contrast images of high cell density (HCD) and low cell density (LCD) samples to determine if there are phenotypic variations between these two populations as a result of QS in C. reinhardtii. A fixation procedure specifically for Chlamydomonas was followed; the surface area of cells and detailed observations of structural differences between LCD and HCD cultures of different strains was found. These comparisons will provide a refined understanding of how Chlamydomonas responds to the QS process as well as extracts containing the CSSF.

Project Objective

Imaging samples under high magnification allows for the surfaces of these cells to be observed for physical characteristics. The images of high cell density (HCD) and low cell density (LCD) samples can be compared to determine if there are phenotypic variations between these two populations as a result of QS in C. reinhardtii.

Manufacturing Design Methods

A procedure, specifically for Chlamydomonas, was followed to prep the cells for the SEM. This fixation procedure involved fixing, dehydrating, and drying the samples followed by mounting the sample on top a carbon-taped electron microscope stub. The sample dries over night and is then ready to be imaged and analyzed in the SEM.

Specification

2% glutaraldehyde and 1% osmium tetroxide in 0.1 M sodium cacodylate were both used to fix the cells. A series of ethanol dehydrations from 50% to 100% ethanol was done to dehydrate the cells. A series of ethanol:hexamethyldisilane (HMDS) was done from 1:0, 2:1, 1:1, 1:2, and finally 0:1 so the sample is being treated and chemically dried with 100% HMDS. The cells are then mounted onto a stub which goes directly into the microscope. The stub has double-sided carbon-tape on top so the cells can stick to the surface of the stub and dry in preparation for the SEM.

Analysis

The SEM images were analyzed with imageJ to obtain surface area measurements of cells throughout different samples. Excel was used to find averages and errors in the surface area measurments. The frequency of notable characteristics in different strains was found by counting cells in a sample and determining how many of those cells have specific structural characteristics. This data was put into an Excel table where the frequency was found for each strain and corresponding density.

Manufacturing Design Methods

A procedure, specifically for Chlamydomonas, was followed to prep the cells for the SEM. This fixation procedure involved fixing, dehydrating, and drying the samples followed by mounting the sample on top a carbon-taped electron microscope stub. The sample dries over night and is then ready to be imaged and analyzed in the SEM.

Project Summary

How plants balance resource utilization, competition, and growth provide valuable insight into ecosystem functioning, which can be leveraged to improve sustainable agriculture models. This is of particular importance given the United Nations’ estimates that current food production levels would need to substantially increase to satisfy the projected food demands of 2050, as well as to address the current 800 million people around the world experiencing hunger. Due to their sessile nature, plants have evolved complex responses to manage resource acquisition based on the identity of their neighbors. This includes the display of differential responses to members of the same species based on genetic diversity, which frequently relates to geographically distinct populations, known as accessions. Accession recognition in plants is often synonymous with the concept of kin recognition and is about optimizing inclusive fitness in co-existing species of plants. However, in the case of many plants, it remains unclear whether the responses between accessions are based upon theiArabidopsis thaliana is a model angiosperm for accession recognition research that grows quickly and easily, and for which a variety of accessions are readily available. We hypothesize that accession recognition is modulated by the extent of genetic relatedness between the accessions in question whenever plants of the same species are forced to interact. Prior studies have established that nutrient restriction can amplify accession recognition impacts, providing an additional tool for distinguishing between the random (unrelated) and genetic relatedness models. Here we evaluate accession recognition phenotypes between several well-established accessions Developing a deeper understanding of accession interactions between plants in terms of time and nutrient availability can facilitate the improvement of agricultural productivity by minimizing competition and maximizing cooperation between plants.

Project Summary

One significant consideration for the agriculture of the future, whether it is in space, on another planet, or in an urban warehouse is the number of human work hours required to produce an edible harvest. In high-stress and low-resource farming systems, like those we will need to establish off-world, it is vital that we explore ultra-sustainable methods of agriculture that both minimize resource use and maximize production output. One resource frequently ignored in these models is crew time, or the value of the hours worked by the inhabitants of a settlement. Automated farming systems provide an opportunity to potentially reduce crew time input while providing exact aliquots of expensive resources, such as nutrients, supplemental lighting, and water, in a targeted manner. The use of such automated systems in regolith, like on Mars, introduces new problems such as dust management, reliable communication through wireless access, and the erosion of machine parts; which will be considered alongside the benefits provided by the automation of growing. The Farmbot Genesis machine allows for the automatic sowing, watering, and weeding of a plot of land without human assistance, other than error correction, as well as providing methods of monitoring plant and soil conditions not limited by human schedules. We will investigate the time demand in building the Farmbot system, points of function that might be prone to failure or error (both in hardware and software), as well as the mechanical integrity of Farmbot’s motion and tool functions when used with Martian regolith as a substrate. Our next phase will evaluate the overall time requirements of automated versus traditional farming methods in both regolith and soil conditions, as well as examine the edible versus inedible yields of microgreen radishes from all our subs rates.

Project Summary

Microgravity environments create unique challenges for successful plant growth, as the distribution of nutrients and water is disrupted. Plant growth promoting (PGP) microorganisms can facilitate plant growth, improve nutrient uptake, and improve resistance to potential plant pathogens. We propose that a similar approach will be successful in the spaceflight environment as well as on off-world settlements. Deployment of such beneficial microorganisms will likely be easier if they already have spaceflight history (i.e., were identified in the spaceflight environment). Microbial isolates collected from the VEGGIE crop production system aboard the International Space System (ISS) are being evaluated in our lab with a series of biochemical assays to determine if they express PGP phenotypes. These assays are the first step in the development of a pipeline designed to create microbial mixtures in support of space agriculture. Here, an indolic compound production (ICP) assay was performed to determine if specific bacterial isolates produce auxin-like compounds, a plant hormone. A phosphate solubilization assay was also performed to determine if bacterial isolates could convert insoluble forms of phosphorus to a form that plants can uptake and utilize. Our findings are among the first steps in the development of an engineered microbiome for improving plant growth on spaceflight.

Project Objective

Microbial isolates collected from the VEGGIE crop production system aboard the International Space System (ISS) are being evaluated in our lab with a series of biochemical assays to determine if they express PGP phenotypes. These assays are the first step in the development of a pipeline designed to create microbial mixtures in support of space agriculture.

Manufacturing Design Methods

Here, an indolic compound production assay and a phosphate solubilization assay were performed to determine if the VEGGIE microbial isolates express PGP phenotypes.

Manufacturing Design Methods

Here, an indolic compound production assay and a phosphate solubilization assay were performed to determine if the VEGGIE microbial isolates express PGP phenotypes.

Project Summary

Background: Hydrogels are commonly used for biomedical applications, as they can mimic many soft tissues found throughout the body. Hydrogels are formed through the polymerization of a monomer solution, to which materials may be added in order to control their mechanical and metabolic properties. The hydrogels used in this study were fabricated to be used in wound healing, 3D printing, and tissue engineering applications, and tested via compression to determine similarity of Young’s modulus (stiffness) to native tissues. 9 different sample types were tested (6 samples each for compression and 8 samples each for Micro testing); composed of alginate hydrogels with concentrations of 1.5%, 2%, 2.5%, and 3%, crosslinked with +2 cation inclusions of 0.18, 0.27, and 0.36. The hydrogels were fabricated in two separate batches for two rounds of testing. Methods: Uniaxial Compression Testing: The Newton TestResources Universal Testing Machine was used on compression testing. Each sample was uniformly cut using a 3D printed blade holder to a cross sectional area of appx. 121mm2. The samples were compressed until failure, and the stress and strain given during testing and averages at 20% strain were used to calculate the Young’s modulus using Hooke’s law. MicroTesting: The hydrogels were cut into small samples with a cross-sectional area of approximately 4mm2 for a micro-compression test past 20% strain. This test was performed on the CellScale MicroTester. Force, surface area, and tip displacement raw data was used to calculate the stress, strain, and Young’s modulus for each hydrogel sample. Stress was calculated by the bending moment of the beam multiplied by the length of the beam divided by the moment of inertia. Strain was calculated by dividing the tip displacement of the platen by the initial height of the gel. These calculations were used with Hooke’s law to find the Young’s modulus. Discussion: Data across all tests indicates an overall trend of a higher Young’s modulus with increasing concentrations of both alginate and additives. The samples tested range in elastic modulus from approximately 3 - 50 kPa, which matches the range for many native tissues, including the brain, tongue, esophagus. Variation of Young’s modulus across samples and testing methods may be caused by batch variation and time sensitivity of samples, as Young’s modulus increases when the samples lose hydration. Future work: Inclusion of larger sample populations for more consistent statistical and error analysis, as well as performing a study of the effect of cross-linking over time.

Project Summary

The Echolynx device is developed to address many issues with the current electrolarynx devices on the market. Echolynx provides users with a hands-free device and a Bluetooth controller with dynamic pitch controls along with a reduction in excess noise. These device functions are validated through a series of tests including preliminary functionality tests, direct Echolynx user experiences, and an audibility and intelligibility study. Future improvements to the device include a reduced device size to increase the user’s comfort and improvements in manufacturing.

Project Objective

The main struggle of current electrolarynx devices is the excess external noise that masks the user's voice. Electrolarynx devices must be held against the user’s neck while holding down the volume controls, which limits the use of their hands. Another struggle includes the difficulty of making real-time pitch and volume adjustments due to the clunky design. Echolynx addresses these issues by introducing a hands-free model with vibrational insulation and dynamic controls.

Manufacturing Design Methods

The vibrational unit is designed to rest around the user’s neck like a collar. The unit will be controlled via Bluetooth connection with the controller. The volume and pitch input variations from the wrist controller directly adjust the vibrational unit through frequency and amplitude shifts of the motor. The vibrational unit is sufficiently insulated by internal silicone coatings and external cushioning materials. Device functionality tests such as vibration permeability tests are completed to ensure the necessary vibrations are achieved and comparison tests with an algorithm are used to validate the vocal accuracy of the user. First-hand user experience tests are used to gain feedback on the true functionality of the device through user testing and user intelligibility.

Analysis

After gathering insight from the intelligibility, vocal accuracy, and user experience tests the data will be analyzed and cross-examined to determine the actual functionality of the device. This analysis will provide an understanding of the long-term viability of the device along with areas of improvement when compared to current electrolarynx devices. Audibility is assessed through the listener study portion when the data are statistically compared.

Future Works

The Echolynx device can be further developed by improving the range of motion of the user by reducing the size along with a more streamlined manufacturing process.

Manufacturing Design Methods

The vibrational unit is designed to rest around the user’s neck like a collar. The unit will be controlled via Bluetooth connection with the controller. The volume and pitch input variations from the wrist controller directly adjust the vibrational unit through frequency and amplitude shifts of the motor. The vibrational unit is sufficiently insulated by internal silicone coatings and external cushioning materials. Device functionality tests such as vibration permeability tests are completed to ensure the necessary vibrations are achieved and comparison tests with an algorithm are used to validate the vocal accuracy of the user. First-hand user experience tests are used to gain feedback on the true functionality of the device through user testing and user intelligibility.

Project Summary

Nurses and certified nursing assistants (CNAs) play a critical role in healthcare. They routinely monitor patient vitals and are recommended to have a maximum of 4 patients in their care. At the height of the COVID-19 pandemic, hospitals were short-staffed, and there were not enough nurses and CNAs to monitor patients. This is especially a problem in intensive care units (ICUs) where patient vitals need to be frequently recorded, and their comfort is a priority. To assist these healthcare workers, smart mattresses can be used in patient rooms as a secondary source of monitoring. ElectroSense is a smart mattress with several sensors embedded within it for the most optimal monitoring and comfort of patients. It can monitor heart rate, pulse oximetry, and body pressure distributions with the ability to control temperature, alarm settings for patient bed exits, and pneumatic compression pumps for blood circulation. For streamlined patient care, the smart mattress corresponds to an IOS app where all parameters can be constantly monitored and controlled from the nurse's station. ElectroSense is composed of numerous circuits operating in parallel that are controlled by one Arduino module. The circuits responsible for heart rate, pulse oximetry, body pressure mapping, temperature, and bed exit sensing are continuously on. Oppositely, circuits responsible for heating the bed or blood circulation are controlled by a transistor to only be on when that app setting is selected. The future of healthcare is rapidly changing, and ElectroSense is here to assist it. With Bluetooth communication between the app and the bed, patient vitals can continuously be monitored. Nurses be notified of rapid changes in vitals to assess how best to assist the patient quickly. Currently, the projected use is in ICU rooms, but ElectroSense has the potential to expand to all areas of the hospital. The backbone of healthcare are nurses and their crucial role to patient care. Most mortality rates have been linked to the variation of nurse staff levels, especially in post operative care. A study in England found the probability of a surgical patient dying rises by 7% for every extra patient over four in a registered nurse's caseload. Our proposal to solve this problem is the implementation of smart mattresses in the hospital. Here, we have designed a mattress with numerous sensors and devices incorporated for intensive care. This will assist nurses and CNAs and reduce the workload they face and provide an elevated level of care and comfort for patients.

Project Objective

Our goal is to create a connected mattress capable of measuring and reporting patient vitals via a Bluetooth IOS application. Specifically, we aim to build a cost-effective smart mattress capable of measuring/modulating heart rate, pulse oximetry, body temperature, bed temperature, body pressure distributions, circulation pumps, heating pads, and bed alarms.

Manufacturing Design Methods

Sensor components were combined and connected to an Arduino Due. A 3D printed component houses the main circuitry at the base of the mattress. All sensors are located within the top layers of the mattress except for an elastic heart rate monitor with the option to be worn on the wrist and strapped onto the mattress. All components were tested initially with direct connections through Arduino code. One final code for all circuits operating at once was created and tested. Then, a Bluetooth module was added to allow for wireless communication between the mattress and IOS app.

Specification

Primary considerations for design specifications involved selecting sensors that would best benefit healthcare workers. Additionally, patient comfort and ease of use was also considered. This resulted in a 'touchless' mattress with all sensors and devices embedded within except for the heart rate sensor that requires direct skin contact.

Analysis

We have demonstrated a connected mattress with the ability to monitor crucial patient vitals and improve the comfort of patients in intensive care. All sensors and devices were individually tested and compared to known sensing devices. Then, all components were placed within the mattress for final testing. The final test combined all previous validation forms to ensure sensors were working properly.

Future Works

Future improvements involve better regulated compression pumps, wireless heart rate monitor, and completed bed frame.

Other Information

ElectroSense LinkTree: http://linktr.ee/electrosense

Manufacturing Design Methods

Sensor components were combined and connected to an Arduino Due. A 3D printed component houses the main circuitry at the base of the mattress. All sensors are located within the top layers of the mattress except for an elastic heart rate monitor with the option to be worn on the wrist and strapped onto the mattress. All components were tested initially with direct connections through Arduino code. One final code for all circuits operating at once was created and tested. Then, a Bluetooth module was added to allow for wireless communication between the mattress and IOS app.

Project Summary

Hundreds of thousands of people have conditions that affect their upper body movement, ranging from cerebral palsy to stroke rehabilitation patients to patients who had been in accidents that affected their upper extremities. This causes a disconnect between the patient's mind and body, which is extremely detrimental to the patient's mental health. The ExoArm is a myoelectric exoskeleton arm brace that utilizes an EMG sensor to collect the electrical signals from the arm muscles to control motors that move the brace to mimic the arm's movement. By using the patients' muscle signals to control the brace, the ExoArm is designed to be an extension of the arm that amplifies the patients' strength. The ExoArm uses machine learning to classify the motions of the patient's arm to accurately and quickly convert it into mechanical motion in the brace.

Project Objective

The objective of the ExoArm was to design and manufacture a myoelectric exoskeleton brace that amplifies a patient's arm strength to enable them to regain a full range of motion. The ExoArm sought to be completely customizable- from the setup code for the brace's movement so it is specified to its user to the brace's length. This brace aims to be comfortable enough for all-day wear and have all components completely wearable, without the need to be plugged in during use. Another goal of the ExoArm was to minimize the timing delay from the muscle activation to the brace's movement.

Manufacturing Design Methods

During the hardware testing stages, an initial design for the brace with drafted with consideration of the weight requirements, mobility, and comfort. The iterated designs were 3D printed and assembled for further structural integrity testing. The design cycled through multiple models; the most significant changes being to the hand to enable the patient to grip and to the elbow to ensure comfort and optimize the range of motion. The hand mechanism was altered so that the movement of the fingers was controlled by the wrist so that patients who have lost fine motor skills can regain their grip strength. During software testing, EMG data was collected from several participants to determine the patterns in the signal, and different methods were tested to determine the best signal-to-motion classification system. In the end, the brace will use machine learning to identify the motion from the signal and output a position to the brace. The brace is similar to some devices that are already on the market and FDA-approved, so our product is predicted to have high success with the various improvements made. The design was predominantly 3D printed for cost-effectiveness and customizability.

Specification

The specifications for this project include: being able to lift 50 pounds, having a less than 1-second delay between muscle and brace movement, being comfortable for long-term wear, being customizable for different patients, having a 160º range of motion, having accurate movements from the muscle signal data from EMG sensor, having an entirely wearable design, being more affordable than the competition, and having a lightweight design.

Analysis

The data analysis for the hardware was predominantly trying to simulate how the brace would be used in day-to-day life and determine what improvements would be necessary. With each adjustment and improvement to the design, force calculations, biomechanical motion range, and functionality of the user had to be re-examined. For the software, data analysis consisted of determining the best sensor type and placement, understanding the patterns of the EMG waveforms for different motions, and extracting features that have the most correlation to motion. A process of trial and error and visual patterns was used to determine the thresholds of the different features. The movement of the brace, as controlled by the code, was compared against a protractor to ensure the theoretical and actual movements were equivalent. Later, a position sensor was used to record real-time data while also getting the angle of the arm. This data was put into a machine learning model to test the accuracy of classification using XGBoost. With two motions, the accuracy of the predicted motion was 86%, while the accuracy with three motions was 77%. Feature Importance in machine learning was also used to determine the significance of the selected features to the motion results. Through this, it was determined that the bicep muscle was more significant than the tricep, and all features used had high correlations to the motion of the arm.

Future Works

Throughout our research and manufacturing process, we developed several different designs to improve functionality. In the future, several improvements could be made to the current design to better assist patients in day-to-day life. For software, advancing the machine learning algorithm will make the responses faster and more accurate. Additionally, including rehabilitation features to simulate a therapy session could aid in patients' recovery. Creating a Bluetooth connection and app would make the brace smarter and easier to use. For hardware, designing the brace to have more adjustable settings would make the brace more inclusive for all ages. Choosing more optimal biomaterials for the brace would increase its integrity and durability.

Other Information

Since the inception of the project, the ExoArm team has had a donation link for the cerebral palsy foundation and has raised over 400 dollars toward cerebral palsy research. Watch our Project Video: http://youtu.be/dXDNjwDAp0s

Manufacturing Design Methods

During the hardware testing stages, an initial design for the brace with drafted with consideration of the weight requirements, mobility, and comfort. The iterated designs were 3D printed and assembled for further structural integrity testing. The design cycled through multiple models; the most significant changes being to the hand to enable the patient to grip and to the elbow to ensure comfort and optimize the range of motion. The hand mechanism was altered so that the movement of the fingers was controlled by the wrist so that patients who have lost fine motor skills can regain their grip strength. During software testing, EMG data was collected from several participants to determine the patterns in the signal, and different methods were tested to determine the best signal-to-motion classification system. In the end, the brace will use machine learning to identify the motion from the signal and output a position to the brace. The brace is similar to some devices that are already on the market and FDA-approved, so our product is predicted to have high success with the various improvements made. The design was predominantly 3D printed for cost-effectiveness and customizability.

Project Summary

The idea for our project is to utilize hydraulically amplified self-healing electrostatic (HASEL) muscle-like actuators to create a prosthetic arm that will function better than those already on the market inspired by the current discontent amongst upper-limb prostheses users. Ultimately, we plan on creating a bicep as a proof of concept with the goal of lifting a water bottle. The project has coding in order to control the muscle, chemistry as part of manufacturing the necessary conductors, biomechanics to determine the forces necessary to generate, and high voltage circuit design to generate the proper response. It has not been an easy process, and we've faced challenges centered around circuitry and chemistry. During the chemical synthesis of the hydrogel, the two issues were getting to stay in the shape we need it to, and that the conductor originally used segregated from the hydrogel. For the circuitry, we had to learn entirely new software, and the voltage applied to the arm decreased the further it got from the source beyond the fact that working with high voltage circuitry is difficult. We also needed an electrode flexible enough to deform with the contraction, and the chemistry necessary to do so was incredibly complex. Multiple syntheses ended with the chemical components of the muscle segregating, or the synthesis ended up bonding to the sides of the cast if it did not end up leaking out of the sides. To solve the issue with finding an electrode stretchable enough for our purposes, we applied hydrogels to the muscles that will deform with them. For the chemistry problems, we used wax to ensure a tight seal with wax and an acrylic mold to create the desired hydrogel shape and granular LiCl instead of crystalline to fix the solubility. The issue with bonding to the cast was never solved, but addressed by simply cutting it free. Solving the issue of the decreased voltage was not entirely solvable, but was mitigated by changing the shape of the muscle. While the product has needed to be downscaled for feasibility and monetary concerns, it will be possible to make a full-functional bicep muscle that can lift 5 pounds.

Project Objective

The idea for our project is to utilize hydraulically amplified self-healing electrostatic (HASEL) muscle-like actuators to create a prosthetic arm that will function better than those already on the market. Our ultimate goal is to make a bicep that is able to lift a bottle of water and to move on command without any applied load.

Manufacturing Design Methods

There were two large manufacturing components within the project, first for the chemistry and then the PCB. The chemistry necessary for the project is Schlenk Chemistry, necessary to make the hydrogels due to the reactive components within the solution. The idea is to replace reactive gas with an inert gas, nitrogen, and to do the reaction under such conditions. This solution is then poured into an acrylic cast atop an elastomer and left to cure under UV light for a hour, and then cut from the cast using a butter knife. The PCB was then fabricated using the Circuitmaker software map out all the components, and then shipped to a PCB manufacturer to be processed. Once the PCB was received, all the components needed to be soldered and connected properly to control the muscle. Once these components were completed, it was mounted to the arm at predetermined locations, and connected to the wires. The arm itself was controlled with a Raspberry Pi at the advice of a professor, because it would allow multiple muscles to be controlled independently of each other when the design is scaled up to a full sized arm.

Specification

The prosthetic muscle, when applied to our makeshift arm, must be able to lift the weight of a bottle of water, have precision control enabled via an external microcontroller, and be able to hold the weight of a bottle of water for twenty seconds without failure.

Analysis

Circuit integrity will be validated with a multimeter to ensure that voltage is being properly delivered to the muscles, and there will be calculations performed to determine the amount of force it can lift once the arm has been tested.

Future Works

There remains much work to be done in order to translate this product from the bench to the market. For starters, a more thorough data analysis needs to be performed so the force can be quantified and mathematical rigor can be applied. This can be done via LabVIEW and ANSYS. The voltage required for actuation to ease the engineering constraints of the electric field of such a high voltage via improved chemistry, better insulation, or circuit design to receive a larger range of motion and more force per volt. Additionally, there remains further optimization to be done with regards to the shape and size of the hydrogel actuators with regards to the output force.

Other Information

More information can be found in our video, http://youtu.be/tVpBNy5oQe4.

Manufacturing Design Methods

There were two large manufacturing components within the project, first for the chemistry and then the PCB. The chemistry necessary for the project is Schlenk Chemistry, necessary to make the hydrogels due to the reactive components within the solution. The idea is to replace reactive gas with an inert gas, nitrogen, and to do the reaction under such conditions. This solution is then poured into an acrylic cast atop an elastomer and left to cure under UV light for a hour, and then cut from the cast using a butter knife. The PCB was then fabricated using the Circuitmaker software map out all the components, and then shipped to a PCB manufacturer to be processed. Once the PCB was received, all the components needed to be soldered and connected properly to control the muscle. Once these components were completed, it was mounted to the arm at predetermined locations, and connected to the wires. The arm itself was controlled with a Raspberry Pi at the advice of a professor, because it would allow multiple muscles to be controlled independently of each other when the design is scaled up to a full sized arm.

Project Summary

Atopic dermatitis, commonly known as eczema, is a chronic skin condition characterized by inflammation, irritation, and itchiness of the skin, and can include thick, scaly, dry patches of skin on the body. It occurs by a combination of gene-determined sensitivity and environmental irritants, causing an overactive immune response across the dermal and epidermal skin layers. Eczema affects nearly 31 million Americans, and children are more prone to develop it. There is no cure for eczema, so it is typically treated with corticosteroids, most commonly in topical form. Over time the body often becomes resistant, so increasingly more concentrated steroid creams are prescribed to manage symptoms. If a patient then tries to discontinue use of these steroids, due to quality-of-life issues or other factors, then the body is likely to go through severe drug withdrawal symptoms. For other drugs which commonly cause withdrawal symptoms, such as nicotine, the use of transdermal patches has been shown to reduce these symptoms. A transdermal patch delivers the same drug in a lower and controlled dose to help the patient taper off the effects of addiction and ease up the withdrawal symptoms. ReAction Patch aims to be the go-to corticosteroid transdermal delivery patch for the millions of people that experience withdrawal symptoms from topical steroid addiction. The patch is designed to release hydrocortisone (a commonly available steroid over the counter) over a period of 24 hours. The patch is composed of gelatin and an inclusion of hydrocortisone powder, which is then crosslinked with glutaraldehyde. To test the release rate of the hydrogel with the diffusion properties of skin, the team is using a glass apparatus called a Franz Cell. The Franz cell allows samples to be taken at specific times which can later be used to calculate the release rate of the hydrogel using a spectrometer and a calibration curve for reading concentrations. Hydrocortisone is diffused in the Franz cell through a skin-mimicking membrane, Strat-M™. In the future, our team would like to incorporate cell studies on skin cells which would give us a better understanding of the phenomenon of Topical Steroid Withdrawal. Our team was able to develop a patch which showed a sustained release of Hydrocortisone over 24h.

Project Summary

Due to the challenges presented in isolating bromides from the phosphine oxide byproducts, Silicaphosphine (Silphos) has been used as a filterable brominating agent for benzylic alcohols. Ordinarily, chromatography is necessary to separate the bromide from the byproducts, but with this method, quantitative yields have been generated with a vacuum filtration and extraction work-up. Moving past the bromination, a simple SN2 reaction is done to convert the bromide into the thiolacetate. This method is intended to be used in a complex carbazolopyridinophane sensor synthesis to detect trace amounts of hydrazine and other functional amines.

Project Summary

Our team will be simulating the conversion of carbon dioxide into ethylene and methanol, two highly in demand chemicals. Ethylene is used for producing materials like antifreeze, synthetic rubber, and foam insulation and methanol is used to produce materials such as clothing fibers and light-up displays as well as being used as a fuel. The process we are utilizing to complete these products are greener than the currently used process. Our process uses a photoelectrochemical cell, meaning it utilizes both light and electricity to push the reaction forward, resulting in a more environmentally friendly operation that uses less energy and has a higher efficiency.

Project Objective

The objective of this project is to simulate a viable carbon dioxide conversion plant utilizing photoelectrochemical cells as the reactor.

Manufacturing Design Methods

For this project we utilized Aspen Plus to simulate the carbon dioxide conversion plant. Costing and profitability were conducted via the Turton methodology.

Manufacturing Design Methods

For this project we utilized Aspen Plus to simulate the carbon dioxide conversion plant. Costing and profitability were conducted via the Turton methodology.

Project Summary

Our project encompasses the design of a chemical plant that produces propylene oxide in a two-step process. The first step is the auto-oxidation of fresh cumene, producing cumene hydroperoxide (CHP). The second step is the epoxidation of propylene with CHP to produce propylene oxide (PO). This second step utilizes a novel catalyst, silylated titanium containing silicon oxide treated with palladium loading (Pd/Ti-MCM-41), which provides a PO selectivity that approaches one hundred percent. This design was motivated by creating a greener avenue for PO production. Typical production processes utilize chlorohydrin, producing toxic by-products in a 40:1 ratio with the desired product. By using a peroxide, the harmful by-products are no longer an issue to be dealt with. There are four peroxides processes used for epoxidation, including the tert-butyl hydroperoxide process (PO/TBA), ethylbenzene hydroperoxide process (PO/SM), hydrogen peroxide process (HPPO), and cumene hydroperoxide process (PO/CHP). PO/CHP, as it is used in our process, provides for an elimination of by-products when the novel catalyst is used. PO/CHP is a relatively new process in the industry, but its benefits, both environmentally and economically, have proven themselves already. The combination of two processes, oxidation and epoxidation, into one continuous chemical plant process provided many challenges. The reactor configuration for cumene oxidation had to be modeled as 3 cascading CSTRs in our software, replacing the typical bubble column process used in industry. The exothermic nature of the cumene oxidation provided extra barriers, as many safety measures needed to be considered every step of the way to ensure the process did not produce a dangerous amount of heat or cause an explosion. Limits had to be placed on the reaction temperature and cumene conversion percentage. Fail-safe devices, such as cooling jackets and pressure vacuums, were introduced to the reactors, heat exchangers, and distillation column to get in front of any overheating that might occur. The market for PO is projected to increase due to the rising demand for polyurethanes. PO is a vital component in creating those polyether polyols required for the production of many plastics, resins, and elastomers. Polyurethanes are essential to the textile, automotive, and pharmaceutical industries. Ultimately, this process utilizes new green chemistry to produce a valuable intermediate, PO, while producing minimal by-products.

Manufacturing Design Methods

Aspen Plus V12.1 software was used to simulate the cumene oxidation and propylene epoxidation processes. The simulation was optimized through sensitivity analyses that displayed the changes in specific process parameters when other parameters were varied. The generated values, such as selectivity, yield, and conversion, were compared to similar processes found in literature. The parameters of all equipment and feed streams, given by the simulation or pre-set, were used to perform a cost analysis.

Manufacturing Design Methods

Aspen Plus V12.1 software was used to simulate the cumene oxidation and propylene epoxidation processes. The simulation was optimized through sensitivity analyses that displayed the changes in specific process parameters when other parameters were varied. The generated values, such as selectivity, yield, and conversion, were compared to similar processes found in literature. The parameters of all equipment and feed streams, given by the simulation or pre-set, were used to perform a cost analysis.

Project Summary

The capstone project objective is to design a process with a novelty aspect to existing or new technology. Aspen Plus simulator is required to generate processes and aid in calculating plant costing. The basis of this project is to design a methanol production plant using direct air capture (DAC) with solid adsorbent. One of the major challenges was to find a method of CO2 capturing which will be both profitable and sustainable. Based on available literature, two types of DAC were studied. Solid based DAC was utilized for this particular project, but alternative use of Liquid based DAC was proposed in literature. In Solid based DAC, carbon dioxide is captured from the atmosphere using an adsorbent (Zeolite 13X), regeneration process using vacuum temperature swing adsorption (VTSA) is performed to release the CO2 which is then sent to the methanol production part of the process. The methanol production and purification were modeled via the Aspen Plus Simulator while solid based DAC was treated as black box. The calculations related to solid based DAC were performed outside Aspen Plus simulation. The simulation environment led to the methanol production per year as well as costing and profit analysis of the production plant.

Project Summary

Most polymers have a Vinyl Acetate Monomer (VAM) component. VAM will only increase as we explore new methods to utilize new materials. Experts predict the market for VAM will exceed 1.9 billion by 2028. The problem with traditional production is that it emits a lot of CO2. Ethane is the primary source of ethylene used to make VAM. The process of converting ethylene to ethane is known as "cracking." Enormous amounts of heat are required to break carbon chains produced by burning and emitting CO2. Ethane cracking is the source of most CO2 emissions in this process. Building the plant in Texas was determined to be the best design because it gives the most accessible access to natural gas. Therefore, having close refineries is the best way to get pure ethane. With the accessibility to natural gas, we can just have a pipeline or quick train ride to get the necessary materials and reduce many transportation risks. The project focuses on reducing CO2, as most of the world wants to reduce greenhouse gas emissions. Reducing Carbon emissions is feasible by altering the process of Ethylene production. The aging process is the cracking of Ethane to create Ethylene. However, this process is Carbon emission-heavy and releases approximately 1.5 metric tons of CO2 emissions per ton of ethylene generated. A new suggestion for creating Ethylene from Ethane is using a membrane reactor like the process shown in Figure One. The method may convert up to 6 metric tons of CO2 into one metric ton of ethylene, recycling nearly all the CO2 captured. Figure 1: Membrane reactor used in the production of Ethylene Aspen Plus version 12 aided in the design of a majority of the project. The team built the Ethane to Ethylene process and the VAM Process separately and then added them onto a single simulation so that the whole process could run off of the primary feeds. The team simulated a Plug Flow Reactor (PFR) of the membrane reactor depicted in Figure One because Aspen allows for the addition of numerous stages to represent the catalysts within the membrane. The end of the simulation employed a distillation column to separate ethane from ethylene, and post-separation of 99.5 % pure ethylene moves to the VAM reaction.

Project Summary

This project is a design for a chemical plant producing styrene using two novel methods during the production process. The first novel idea is the conversion of ethanol to ethylene via dehydration, and the second novel idea is the substitution reaction between benzene and ethylene to create styrene. This approach is safer, easier, and greener than current industry standards. One of the major challenges overcome in the project was the cupric acetate regeneration. This loop is necessary to be profitable as the Cu(II) is oxidized in the second reaction and is very costly to buy. Thus we developed a pathway to regenerate the Cu(II) from the Cu(I) using crystallization. This was difficult because the simulation software does not have the Cu(II) compound we were using and is notoriously difficult to properly simulate solids. Styrene Is very important in the modern world as it is a key component for the creation of polystyrene and other plastics commonly used. With these advantages over the common industrial methods, this project can be developed further for future implementation by producers. Overall, this project shows that there is a greener, safer, and easier method for the production of styrene which can also be profitable for investors.

Project Objective

The objective of this project was to design a chemical plant that produces styrene while limiting carbon dioxide generation and maintaining profitability.

Manufacturing Design Methods

This project is mainly a simulation based on software known as ASPEN which can simulate an environment based on user inputs. This software does have some notable drawbacks which are apparent in this project; firstly, it does not have every chemical needed in its database, and secondly, ASPEN does not handle solids very well which normally results in the program crashing whenever it comes across them.

Future Works

This project is by no means ready to be immediately used in production, however, it can serve as a basis for a "green" initiative in styrene production.

Manufacturing Design Methods

This project is mainly a simulation based on software known as ASPEN which can simulate an environment based on user inputs. This software does have some notable drawbacks which are apparent in this project; firstly, it does not have every chemical needed in its database, and secondly, ASPEN does not handle solids very well which normally results in the program crashing whenever it comes across them.

Project Summary

The project aims to explore an innovative approach to ethanol production using carbon monoxide, hydrogen, and dimethyl ether. The proposed method involves a dual-bed multitube reactor filled with a unique combination of zeolite and metallic catalysts. The novel production process also includes a recycling stream that generates dimethyl ether from methanol produced during the process, eliminating the need for food crops and significantly reducing production costs. The project seeks to evaluate and compare annual and hourly ethanol production rates with the largest ethanol producer in the United States, using Aspen Plus software to simulate and optimize the proposed manufacturing route. Ultimately, the project's significance lies in addressing the growing demand for ethanol as a fuel additive by exploring alternative production methods that can be more sustainable and economically feasible.

Project Objective

The primary goal of this project is to investigate an innovative approach to producing ethanol that utilizes non-traditional means of carbon monoxide, hydrogen, and dimethyl ether. By utilizing a dual-bed multitube reactor, filled with a unique combination of zeolite and metallic catalysts, the proposed production process eliminates the need for food crops and significantly reduces production costs. Additionally, the process introduces a novel recycling stream that generates dimethyl ether from methanol, a byproduct produced during the process. The project also seeks to evaluate annual and hourly ethanol production rates and compare them to the largest ethanol producer in the United States, Poet Biorefining. Through the use of Aspen Plus software, the proposed manufacturing route was simulated and optimized to produce 45 million gallons of ethanol annually. The significance of this project lies in the exploration of alternative methods for producing ethanol, addressing the increasing demand for ethanol as a fuel additive while simultaneously mitigating environmental and economic concerns associated with traditional production methods.

Manufacturing Design Methods

The ethanol manufacturing process was simulated using Aspen Plus software. There, the multi-tube dual-bed reactor was modeled as two heat exchangers to simulate each bed. During the utilization of the Aspen Plus software, it is important to note that certain limitations may arise. One such limitation includes the intermittent cooling process within the reactor. However, this obstacle was successfully addressed by breaking down the reactor into multiple sections and implementing suitable cooling techniques within each section. Moreover, certain heuristics were applied to ensure the safety of the reactor.

Manufacturing Design Methods

The ethanol manufacturing process was simulated using Aspen Plus software. There, the multi-tube dual-bed reactor was modeled as two heat exchangers to simulate each bed. During the utilization of the Aspen Plus software, it is important to note that certain limitations may arise. One such limitation includes the intermittent cooling process within the reactor. However, this obstacle was successfully addressed by breaking down the reactor into multiple sections and implementing suitable cooling techniques within each section. Moreover, certain heuristics were applied to ensure the safety of the reactor.

Project Summary

5-Hydroxymethylfurfural (HMF) is an organic multi-use compound that is used in various industries. It is used to make bioplastics, which are a type of plastic made from renewable resources such as plant matter, making it biodegradable. It can be used as a food additive to provide a natural and healthy alternative to traditional sweeteners. Additionally, it is an antioxidant that helps prevent or slow down the process of oxidation in the body to avoid various diseases. HMF is a precursor to a high energy biofuel called dimethylfuran (DMF). Overall, HMF can be used in an assortment of ways and can also be produced with various carbohydrate feedstocks. The main carbohydrate feedstock used to produce HMF is fructose. Instead of fructose, our production uses waste paper which is a cellulose based feedstock. Waste paper is a low-cost feedstock that is abundant and widely available. It is also a renewable and sustainable resource that can be obtained from various resources such as a paper recycling plant. Using waste paper as a feedstock will also help reduce the amount of waste in landfills, making it a more environmentally friendly option. While cellulose can be a potential feedstock for the production of HMF, it cannot be directly converted into HMF like fructose. Therefore, the cellulose from waste paper will need to be converted into fructose. Cellulose is first converted into glucose through a process called hydrolysis. Cellulose is a biopolymer consisting of many glucose units which are connected through β-1,4-glycosidic bonds. Hydrolysis occurs when these bonds are broken by acids, resulting in glucose. The next step is the isomerization of fructose which is done by rearranging the atoms in the glucose molecules to produce fructose. The fructose is then purified to get rid of any impurities, such as enzymes or other byproducts. The finished product is sent into the Continuous Stirred Tank Reactor (CSTR) for the production of HMF. Along with fructose, the CSTR contains HCl as the catalyst, NaCl to help the dehydration process, and 2-butanol/MIBK as the solvent. The reactant mixture is heated to a constant temperature of around 180°C and stirring continuously. There are two phases in the CSTR which is the aqueous and organic phase. The aqueous phase is known as the reaction phase containing NaCl, HCl, water and fructose. This phase is where fructose is dehydrated to create HMF and quickly degrades to create levulinic acid (LA) and other byproducts, therefore it must be extracted into the organic phase. The organic phase is known as the Extraction phase containing a solvent mixture of MIBK/2-butanol and HMF. The two phases can be separated after settling inside of the CSTR, the organic phase is sent to be purified by an evaporator to isolate and recover HMF. The aqueous phase is also sent out to be purified by distillation to isolate and recover the second product, LA. Everything separated out of the distillation column is sent back to the CSTR as a recycle stream with a fraction amount purged to wastewater treatment. The software used to design the process is Aspen Plus V12.1 In conclusion, HMF can be produced by using a feedstock other than fructose for a more cost effective approach. Using waste paper as a feedstock will also help environmentally by decreasing the waste accumulated in landfills.

Project Objective

To create a reliable process for the synthesis of chemical intermediate HMF from a wastepaper feedstock.

Manufacturing Design Methods

Manufacturing is not possible due to the massive costs of creating a chemical plant so it was all simulated on Aspen Plus V12.1 with cost calculations completed on Microsoft Excel. The process was designed to maximize the profits and creation of the main product 5-Hydroxymethylfurfural(HMF) and secondary product Levulinic Acid(LA).

Specification

In order to cost out the profitability of the created products their purity had to be a specific degree. The HMF was required to come out at 97% purity and the LA needed to be at least 98% purity with higher purity increasing the price.

Analysis

It was shown through the results of our process that waste paper was converted into HMF and levulinic acid. The objective of producing 97% HMF and 99% of levulinic acid was met. The estimated cost of the plant was higher than ideal, and further optimization of the process is advisable to reduce cost.

Future Works

Future work for this project includes being able to rigorously design the process of turning waste paper into cellulose in Aspen Plus. This would allow for a more accurate process representation. Carrying out the described process in a laboratory scale would be optimal. This would allow for a better representation of a real process that is not limited to the approximated and idealized values that the simulation software produces. Finding methods of increasing the yield of cellulose is critical to the economic viability of the process.

Manufacturing Design Methods

Manufacturing is not possible due to the massive costs of creating a chemical plant so it was all simulated on Aspen Plus V12.1 with cost calculations completed on Microsoft Excel. The process was designed to maximize the profits and creation of the main product 5-Hydroxymethylfurfural(HMF) and secondary product Levulinic Acid(LA).