快播

A team of 快播 chemical engineering seniors is addressing an operational challenge at Steel Dynamics La Farga Copperworks through their senior design project, developing a more efficient soot recovery system tailored to the facility鈥檚 expanding needs. 

Lydia Randolph of Jefferson, Ohio, Marshall Beebe of Nappanee, Indiana, and Joshua Scott of Ossian, Indiana, focused their capstone work on enhancing filtration performance at Copperworks, where recent plant growth has exceeded the capacity of the existing system. 

Their project combined design innovation with hands-on testing to propose both immediate upgrades and long-term solutions for improving soot removal. 

鈥淭his project gave us the opportunity to explore multiple facets of engineering鈥攆rom lab testing and vendor coordination to in-plant experimentation and system design,鈥� said Randolph. 鈥淭hat diversity made it especially engaging.鈥� 

From the lab to the line 

The students worked closely with Copperworks staff throughout the year. 

After establishing a project direction that included both system optimization and new equipment design, the team ran extensive small-scale lab tests to identify improvements such as better filter paper and flocculant performance. Flocculants are additives that help promote clumping of fine particles into larger aggregates, aiding in their separation and removal.  

The lab results were later scaled up and evaluated through plant trials conducted on-site. 

鈥淐opperworks gave us the independence to manage much of the project,鈥� Randolph explained, 鈥渂ut they remained closely involved, helping us secure materials and offering feedback through regular updates and plant operator input. That collaboration shaped our decisions and gave us practical insight into plant operations.鈥� 

Copperworks Process Engineer and Industry contact, Roger Chase, was impressed with the group鈥檚 problem-solving ability. 

鈥淭he Trine design team was able to effectively navigate not only the technical aspects of the project, but also the unforeseen complications that come with testing on an active production line and complete a financial analysis,鈥� he said. 

The team鈥檚 proposed improvements include implementing a more durable turbidity meter, optimizing flocculant dosing and designing a new hydrocyclone-based filtration system to better fit the plant鈥檚 spatial constraints. These recommendations are expected to reduce maintenance demands and operational costs while boosting efficiency. 

鈥淭his project provided Copperworks with cost-saving enhancements to their current system and a scalable path forward through the hydrocyclone design,鈥� said Scott. 

Design and experimentation 

Throughout the project, students balanced experimentation with engineering design鈥攁 unique element of their work. 

鈥淲e weren鈥檛 just handed a single objective,鈥� said Beebe. 鈥淲e had the freedom to explore different directions, whether that meant testing new flocculants or designing a completely new system. It really felt like we were doing engineering work.鈥� 

The project also reinforced concepts learned in the classroom. 鈥淲e applied principles of fluid dynamics, safety analysis and process design,鈥� said Scott.  

All three students also participated in undergraduate research projects during their time at Trine, which provided them unique insights on troubleshooting experimental testing.  

鈥淭hese academic experiences played a vital role in guiding us toward cost-effective, data-driven solutions," Scott added. 

Implementing recommendations 

Copperworks is in the process of implementing many of the team鈥檚 recommendations, including the purchase and installation of new process monitoring equipment and completing additional plant trials for the new filtration method.  

鈥淚 don鈥檛 know of a way to express the value of working with this design group better than actively pursuing the recommendations made by the team,鈥� concluded Chase, who plans to continue working with Trine for future projects.  

All three students are launching full-time engineering careers after graduation鈥攖wo with Abbott Nutrition and Randolph continuing her work with Copperworks. Their involvement in the project gave them valuable early experience in tackling complex challenges and working in professional environments.  

鈥淭his project gave me a head start on identifying improvements and developing practical solutions鈥攅xactly the kind of problem-solving I鈥檒l be doing at Abbott,鈥� summarized Scott, who will join the company as a Utilities Engineer. 

鈥淎s I begin my role as a project engineer, this experience helped me build confidence in collaborating with vendors and people outside of our direct organization to get quotes and information to conduct our design. It strengthened my ability to evaluate areas of continuous improvement and form meaningful professional relationships along the way,鈥� said Beebe. 

Randolph added, 鈥淥ur in-plant testing revealed both progress and challenges. As I return to Copperworks, I鈥檓 excited to build on what we鈥檝e done and help drive future improvements.鈥�