A clean energy company developing direct air capture technology using limestone-based CO2 removal required structural components capable of supporting heavy mineral loads in their carbon capture systems. The existing ABS plastic shelving and tray components bowed under the weight of limestone powder, compromising system performance. The ABS components also exceeded budget targets for scaled deployment. The client needed cost-effective, structurally robust alternatives that could withstand continuous loading while meeting aggressive price reduction targets.
The Details
Industry
Energy & Environment
CAPABILITIES APPLIED
The original ABS plastic shelving and tray system presented multiple interconnected structural and economic challenges that threatened the viability of scaled deployment. The shelving could not support its own structural weight combined with limestone powder loads, resulting in mid-span deflection that disrupted material flow and compromised system efficiency. The high material and manufacturing costs of ABS components exceeded budget parameters for volume production, limiting the economic feasibility of scaling the technology to commercial deployment levels.
Following initial engagement to address the shelf failures, the client expanded requirements to include a replacement tray for limestone processing operations. The combined shelf and tray components needed to achieve a 50% cost reduction compared to existing ABS versions while maintaining structural performance and operational functionality. Both the shelf redesign and the integrated shelf-tray system operated under compressed development schedules requiring rapid design iteration, prototype validation, and transition to volume production.
Re:Build developed a thermoplastic composite shelf design replacing the failing ABS components. The solution provided sufficient structural rigidity to support limestone powder loads without deflection while reducing material costs. The client ordered 5,000 units, with final deliveries completed in November 2023 for installation at the California demonstration facility.
To achieve the mandated 50% cost reduction for the expanded system requirements, Re:Build consolidated the separate shelf and tray functions into a single integrated component. Through a paid design study involving close collaboration with the client, the engineering team optimized part geometry, material usage, and manufacturing processes to meet revised price targets while maintaining structural integrity. Prototype components were fabricated at Re:Build’s advanced development facility. The client conducted first article inspection in May 2024. All 80 prototype parts were delivered in late June 2024 and entered testing and validation protocols.
