Founded in 2018 by Nicolas Myers, James Urquhart, Anthony Balladon, and Michelle Chao, Phoenix Tailings is a startup committed to revolutionizing the metals industry through sustainable practices. Based in Boston, Phoenix Tailings focuses on transforming mining waste into valuable resources by developing innovative, environmentally friendly methods for extracting metals such as aluminum, iron, and rare earth elements. The mission is to eliminate the harmful environmental impact of traditional mining, reduce the global carbon footprint, and create a circular economy that benefits both industry and the planet.
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Phoenix Tailings was my second work experience, a 6-month co-op under the role of R & D Mechanical Engineering.
Most of my work at Phoenix is under an NDA, here's what I can share.
I developed my skills and understanding of pressure vessels. Pressure reactors are commonly used at Phoenix, but face critical issues including pressure loss. The first task was to create a safer and more stable environment for these reactors.
The custom fittings from the manufacturer were replaced with NPT and Swagelok fittings ensuring a leak-proof system
Using the CNC mill, the ports were drilled and tapped to accept NPT fittings resulting in a sealed system
At Phoenix, many harsh acids and chemicals were regularly handled, and one of my ongoing tasks involved rapidly prototyping and 3D printing chemically compatible materials, often for HVAC fittings. To the left is a trio of PVDF fittings, which were meticulously designed to ensure leak prevention. These fittings were quickly developed and printed to maintain uninterrupted operations while ensuring safety.
Phoenix utilized a mixer-settler farm with over 200 units, arranged in sets of ten per tray. A load-cell, Arduino-powered system, connected to a relay that controlled the pumps, acted as a fail-safe mechanism. In the event of a leak, the system automatically shuts off the pumps to prevent further issues.
I designed and fabricated a water recirculation and filtration system for a wet sieve application. The system featured two pumps working in tandem to ensure efficient water flow, a filter to remove particulates, and a custom-welded stainless steel reservoir to ensure chemical compatibility and durability in harsh environments. The entire setup was securely housed in a robust 8020 aluminum frame, which provided modularity and easy access for maintenance. This design allowed for continuous water circulation, reducing waste and improving filtration efficiency.
One of my favorite projects was designing and building an Arduino-powered pressure and temperature monitoring system for high-pressure acid filters. The system utilized four pressure sensors: one for the input and one for the output of each of the two filters, along with a temperature sensor for each filter. Every component was carefully selected to be acid-compatible, ensuring long-term durability in harsh chemical environments. The system featured a display board with a seven-segment display, an LCD screen, and a rotary switch, allowing users to toggle between different readouts, including pressure, pressure differential, and temperature. This project involved extensive soldering, coding, and electronics work, and required precise calibration to ensure reliable monitoring of the filters under demanding conditions. The result was a robust, user-friendly system that enhanced the safety and efficiency of the filtration process.
Carbonation test fixture - 8020 frame and individual flow meters.
TIG welding for a liquid metal siphon
HAAS CNC machining for liquid metal siphon
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