One notable project involved the design and construction of a mini biofuel production facility. For their capstone project, a group of senior chemical engineering students at the University of Illinois designed and built a small-scale system to produce biodiesel from waste vegetable oil. Their system was able to process up to 5 gallons of waste vegetable oil per day into biodiesel fuel. It included major process units like reactors, separators, pumps and storage tanks. The students designed the process flow diagram, engineered the system components, wrote safety and operating procedures, conducted testing and analysis. They presented their work at a regional engineering conference, where it received an award for its innovative application of chemical engineering principles to a sustainable energy problem. The detailed design process and hands-on construction provided invaluable real-world experience for the students.

Another successful project involved the development of a new filtration process for waste treatment. A team of students at the University of Texas engineered and tested a novel nano-membrane filtration system to remove heavy metals like lead, cadmium and mercury from acid mine drainage water. Acid mine drainage is a major environmental problem associated with mining operations. By developing ceramic nano-membrane filters with tailored pore sizes, the students were able to achieve over 95% removal of targeted heavy metals. They worked with an industrial sponsor and presented their work to the EPA. Their filter design research later led to the filing of a provisional patent application. The project demonstrated the students’ process design, experimentation and commercialization skills.

At the University of California, Berkeley, a capstone team took on the challenge of improving product quality for a food manufacturing plant. They studied production issues like inconsistent mixing, uneven heating and off-specification packaging that were affecting a major snack food company. Through plant site visits, sampling, testing and computer process simulations, the students developed targeted design modifications and process control strategies. Their recommendations focused on installation of in-line mixing and temperature monitoring equipment, automated packaging controls and standard operating procedure updates. Implementation of the student team’s proposals led to reduced waste, increased throughput, and financial savings for the industrial sponsor due to higher yields and quality. The project success demonstrated the students’ ability to conduct a real-world process troubleshooting and continuous improvement project.

Another exemplary effort involved the design of a pilot plant for monomer production. As their capstone project, chemical engineering seniors at Ohio State University worked with an petrochemical industry partner to engineer a small-scale reactor and distillation column system to produce a crucial monomer building block. Through collaboration with company engineers and extensive research, the students developed a detailed process flow diagram and 3D equipment designs. Their pilot plant was later built on campus and allowed for hands-on demonstration of various unit operations like reaction kinetics studies and purity evaluations. Operating data collected from the student-designed system provided valuable insights into scale-up issues. Several of the pilot plant designs pioneered by this outstanding student team were incorporated into the company’s full-scale commercial operations. Their project garnered recognition from both the university and industry for successfully bridging academic training with real-world industrial application.

These are just a few examples but they illustrate the types of impactful process design and problem-solving projects that chemical engineering students have undertaken. When done well in collaboration with industrial partners, capstone projects allow students to gain real-world work experience while also addressing challenges of interest to companies. The projects often produce results that have value beyond the classroom through intellectual property, continued research, incorporated plant designs, and other outcomes that benefit both academic and industrial organizations. In all, hands-on collaborative works like these exemplary chemical engineering capstone projects provide transformative learning experiences for students as they transition from academic training into their professional careers.