At Lithios, I redesigned a fluid assembly that connects three process lines to a lithium extraction stack. The previous setup allowed back flow and fluid mixing, which diluted the lithium-rich fluid leaving the stack. My goal was to keep each fluid separate while still allowing flow into and out of the stack.

I used check valves oriented in opposite directions to control flow, with three inlet lines and a separate line connected directly to the stack. Since the fluids have different densities, I placed the densest at the bottom and the least dense at the top to reduce gravity-driven mixing. The design went through four iterations: soft tubing as a proof of concept, then threaded transparent rigid tubing, then two rounds testing orientations, check valve types, and flow rates to see how turbulence affected mixing and how much pressure the valves could handle. I dyed each fluid a different color to make mixing visible. Testing revealed that laying the system flat filled the lines more efficiently, reduced trapped air, and further limited mixing.

The final design effectively limited back flow and mixing, with diaphragm check valves performing best. The assembly is now being considered for use in the company's full-scale industrial lithium extraction plant. This project strengthened my skills in iterative prototyping, experimental testing, and fluid system design.

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