1. James Berejkoff
Chemical Engineering Intern– Smelter
Projected Chemical Savings of $200,000
Mentor: Ray Walker
Filter Plant T-Floc Dosing Correction
Key Personnel
Name Company Role in Project
Jim Westfall KUC-Superintendent Idea generator and ops support
Ray Walker KUC-Process Engineer Feasibility and Tech support
Chad Glover KUC- Electrical Engineer Control systems
Dave Gearhart KUC-Operations Spill protection/ safety ideas
Eric ‘Nacho’ Bray KUC-Operations Location/application methods
Kambiz Pezeshki Hychem-Vendor Chemical Properties
Dustin Tucker Davidson Sales Pump specs
Entrapped Particle
RO System Tracking
How it works
• Uses a series of Membranes
• Creates ultra pure water
Context Results
Plan Forward
• Usage trends
• Filter bag life analysis
• Filtrate turbidity
• Integrate pumps into DCS
• Level Control
• System Optimization
Context
• No Tracking method in place
• Feasibility study
• Membrane use and waste
• Chemistry
• Random dosing eliminated
• Improve effectiveness
• Lower usage
• Redirect usage trends
Data
Results
• PI Manual entry
• Data tables for RO A and B
• Normalization spreadsheet
0.00
1.00
2.00
3.00
4.00
5.00
6.00
26-May 31-May 5-Jun 10-Jun 15-Jun 20-Jun 25-Jun 30-Jun 5-Jul
%
Date
Salt Passage
• Plots show a return to near original dP after cleaning
• Cleaning had no effect on Improving Salt Passage
• Further testing necessary for membrane damage
tracking
• SWI in progress so analysis can continue
Hearth Sounding
Group Intern Project & Kaizen
• Under the Furnace
• Hearth conditions
• Sensor
• Signs
o Ordering
o Drilling
o Installing
• Grid
o GPS points
• RFID (Active and Passive)
o Vendor Meetings
o Feasibility of use