Daniel Hocheimy

Project 01

High Performance CO2 Capture Module

2023 / Experimental Systems / Thesis

Minimizing the energy required for post-combustion CO₂ capture is critical to reducing the cost of industrial decarbonization. Conventional capture technologies, including absorption, membranes, and packed-bed adsorption, face challenges related to high energy demand, temperature requirements, scalability, and site dependence. Adsorption offers a lower-energy alternative, but conventional packed beds suffer from poor heat transfer and often rely on electricity-intensive vacuum regeneration. This study develops and demonstrates an adsorbent-coated microchannel heat exchanger designed for rapid, heat-driven CO₂ capture and regeneration. The system uses aluminum microchannel plates coated with Zeolite 13X and interlayered with uncoated microchannel plates carrying a heat-transfer fluid. A coating formulation using xanthan gum as a binder was developed to provide strong adhesion while preserving adsorbent porosity. The dehydrated coating contained 97.6–98% Zeolite 13X and 2–2.4% binder, with SEM imaging showing minimal impact on the characteristic zeolite pore structure. The final system contained seven coated plates with 21.84 g of Zeolite 13X, paired with 1 mm heat-transfer plates and custom headers and silicone gaskets for independent gas and liquid flow. CO₂ capture experiments were conducted using a 20% CO₂/80% N₂ gas mixture and a Raman laser gas analyzer. Regeneration was achieved by circulating 50–65°C water through the heat-transfer channels - temperatures equivalent to low grade waste heat from numerous industrial sectors. System performance was evaluated based on CO₂ adsorption capacity, adsorbent mass, bed volume, and thermal energy required for regeneration. The results demonstrate the potential of coated microchannel architectures to provide a compact, scalable, and low-temperature approach to adsorption-based CO₂ capture, resulting in 3 times faster desorption rates.

Role

Thesis

Tools

Fusion 360 / Python / LabVIEW / COMSOL / Water-jet / Laser Cutter / Standard machining

System

Thermal / Experimental

Year

2023

• Thermal Systems
• Experimental
• Energy
• CO2 Capture

Project 02

Hydrogen Sulfide Removal Skid (GCS)

2025 / Gas Processing / Engineering Lead

Hydrogen sulfide removal is a critical step in landfill gas processing because H₂S can cause severe corrosion, damage downstream equipment, and create significant safety and emissions risks. This project involved the development of a modular H₂S removal skid designed to process approximately 1,200 SCFM of landfill gas as part of a larger gas conditioning system. As the lead mechanical engineer, I owned the skid design from initial concept through detailed design and design for manufacturing. This included process equipment layout, vessel and component integration, piping and valve routing, instrumentation placement, structural packaging, service access, and mechanical interfaces with adjacent subsystems. The skid was designed within a constrained trailer-mounted architecture, requiring optimization of footprint, maintainability, pressure-rated piping, assembly sequence, and fabrication complexity. I also led the DFM effort, simplifying fabrication, reducing unnecessary part complexity, standardizing components, and improving assembly and serviceability. The final design delivered a compact, manufacturable H₂S removal system capable of conditioning a 1,200 SCFM landfill gas stream for downstream processing and field deployment.

Role

Engineering Lead

Tools

Inventor / AutoCAD / PYTHON

System

Biogas H2S Removal

Year

2025

• Gas Processing
• SKid

Project 03

Landfill Gas Clean-up System (GCS)

2026 / Energy Systems / Mechanical Design & Fabrication

The Gas Conditioning System trailer integrated multiple process skids, utilities, and support systems into a single mobile platform for field deployment. The system brought together H₂S removal, water knock-out, biogas compression, interstage processing (thermal recuperation), adsorption and membrane separation, controls, and supporting mechanical infrastructure within a tightly constrained trailer footprint. I led the mechanical integration design for the complete trailer, coordinating skid placement, piping and utility interfaces, structural packaging, service access, and subsystem integration. The design focused on creating a compact, manufacturable, and maintainable platform that could be assembled efficiently and deployed reliably in the field. This system is the initial point to service the Gas-to- Methanol technology, and made it possible to turn landfill gas into methanol.

Role

Mechanical Design & Fabrication

Tools

inventor / autocad

System

Mechanical

Year

2026

• Mechanical Design
• Manufacturing
• Prototyping

Project 04

Syngas Conditioning Skid (GTM)

2024 / Gas Processing / Engineering Lead

The syngas conditioning skid was developed to prepare raw syngas for downstream processing by controlling gas temperature, removing contaminants and condensables, and maintaining stable process conditions across the system. I led the mechanical design and integration of the skid, including equipment layout, piping, heat exchangers, separation hardware, valves, instrumentation, and interfaces with upstream and downstream equipment. The design focused on compact packaging, pressure and temperature management, serviceability, and manufacturability within a modular skid architecture. The skid was also refined through DFM and system-level integration work to simplify fabrication, improve accessibility, and support reliable field operation as part of the broader gas processing platform.

Role

Engineering Lead

Tools

Inventor / AutoCAD / Python

Year

2024

• Thermal Systems
• Manufacturing
• SKID
• Gas processing

Project 05

Syngas Compressor Skid (GTM)

2024 / Auxiliary Systems Integration

Led the mechanical design and integration of the auxiliary systems supporting a Knox Western compressor package, including the drivetrain, cooling system, purge system, and oil pump circuit. The skid was developed as a compact, serviceable package with close attention to component layout, piping, structural support, and interfaces between the compressor and supporting systems. I also supported the full compressor skid design and system integration, coordinating auxiliary hardware with the core compressor package and broader process system. My work included component selection, routing, packaging, DFM, assembly support, and resolving mechanical integration issues through the build process.

Role

Auxiliary Systems Integration

Tools

Inventor

Year

2024

• Compressor Systems
• Skid

Project 06

Methanol Synthesis Skid (GTM)

2024 / System Design & Integration

The methanol synthesis skid was designed to convert conditioned syngas into methanol within a compact, modular process system. The skid integrated the reactor and associated heat management, piping, valves, instrumentation, and downstream methanol collection hardware required to control the synthesis process and recover the product. My work focused on the mechanical design and integration of the skid, including equipment layout, piping and valve routing, component selection, thermal and mechanical interfaces, instrumentation integration, and packaging within the overall system architecture. I also supported DFM, fabrication, assembly, and system integration, ensuring the skid could be manufactured, serviced, and integrated cleanly with the upstream syngas conditioning and compression systems.

Role

System Design & Integration

Tools

Inventor / AutoCAD / Python

Year

2024

• Reactor
• Skid

Project 07

Gas-To-Methanol System (GTM)

2024-2026 / Process & Mechanical Engineering

The GTM system is a modular, trailer-mounted process platform designed to convert gas feedstocks into methanol through an integrated sequence of gas conditioning, compression, catalytic conversion, heat management, and product recovery. The system combined multiple process skids into a single field-deployable architecture, with significant emphasis on compact packaging, thermal integration, maintainability, and reliable operation. My work centered on mechanical systems integration across the full GTM platform. I designed and coordinated subsystem interfaces, piping and utility routing, equipment packaging, structural integration, and service access between the major process skids. I also supported DFM, fabrication, assembly, and commissioning, helping take the system from detailed engineering through build and field operation.

Role

Process & Mechanical Engineering

Tools

aspen / autocad / inventor / python

Year

2024-2026

Project 08

Spring loaded Ferry access

2020 / Machine Design / Mechanical Engineer

This project involved the design of a custom spring-assisted access gangway for a ferry servicing Martha’s Vineyard. The system was developed to provide safe, reliable passenger access while accommodating changing vessel position and dock height during loading and unloading. The structure used a lightweight aluminum frame, grated walking surface, integrated handrails, and a spring-loaded support mechanism to reduce the effort required to raise and lower the gangway. The design focused on structural strength, corrosion resistance, operator ergonomics, and durability in a marine environment, while remaining practical to fabricate, install, and maintain.

Role

Mechanical Engineer

Tools

Inventor / autocad

Year

2020

Project 09

Disney World, Magic Kingdom, Ferry Gangway Hydraulics & Controls

2021 / Machine Design / Hydraulics

Supported the design and integration of the hydraulic and control systems for a ferry gangway serving Disney World’s Magic Kingdom transportation system. The system was designed to safely raise, lower, and position the gangway during passenger loading and unloading while accommodating changes in vessel position and operating conditions. My work focused on integrating the hydraulic power unit, actuators, valves, sensors, and control hardware into the gangway assembly. I supported system layout, component selection, hydraulic routing, control interfaces, and design validation, with emphasis on safe operation, reliability, maintainability, and smooth passenger access in a high-use environment.

Role

Hydraulics

Tools

Inventor

Year

2021

Project 10

Thermal Systems Packaging - Weather Radar System

2024 / Thermal Systems / Design & Assembly

Supported the mechanical packaging and integration of a high-performance thermal management system for a radar platform, where cooling hardware, fluid routing, structural supports, and service access had to be engineered into a tightly constrained envelope. The work required balancing thermal performance, pressure drop, weight, accessibility, vibration tolerance, and manufacturability while maintaining clean interfaces with the broader radar assembly. My contributions included developing packaging concepts, integrating heat exchangers and fluid hardware, refining component layouts, validating thermal and mechanical calculations, and supporting design reviews through release. The result was a compact, serviceable thermal architecture designed to protect high-power electronics and maintain reliable operation under demanding system conditions.

Role

Design & Assembly

Tools

SolidWorks / MATLAB

Year

2024

• Cooling Systems

Project 11

Plank

2025

Site commissioning companion, and emotional support.

Year

2025