Expert Details

Expert in Aluminum Reduction, Alumina Feed Control, Bath Chemistry, Process Control Strategies

Expert ID: 727584 New York, USA

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Expert has 26 years of experience in aluminun reduction specializing in increased current effeciency and reductions in power consumption. He has developed alumina feed control, resistance control, ratio control, liquid level control, potline process improvement plans and current distribution strategies. He also has expertise in new cell start up and "superheat" based control philosophies. He has expertise in statistical process control and routinely utilizes this discipline in many aspects of process improvement plans. He has also developed and provided technical training for multiple layers of smelting employees ranging from entry level production workers up to and including potline managers. He has worked with staff in multiple aluminum companies resulting in improved effeciency and potline stabilzation. He has the ability and experience to effectively communicate to and work with all levels of expertise in this field.

Worked with Century Aluminum in 2008 to successfully identify and correct effeciency decreases in the four potlines in Ravenswood, WVWorked with Century Aluminum in 2007-2008 to develop basic technical training for new employees at the Ravenswood plant. Was contracted and successfully worked with the four primary technical supervisors at Ravenswood on potline management and setpoint philosophy and control.Worked with Columbia Falls Aluminum on a monthly bases from 1999-2008 to provide technical training and support for their potlines and staff. Also provided expertise during mutiple potline shutdowns and restarts.Worked with the Kubal Smelter in Sweden to identify performance improvement opportunities and process audits in 2005 and 2006

Expert may consult nationally and internationally, and is also local to the following cities: Utica, New York

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Year Degree Subject Institution
Year: 1984 Degree: Certificate Subject: Chemical Engineering, minoring in quality and statistical control. Institution: General Motors Institute, Flint Michigan 1981-1984

Work History

Years Employer Title Department Responsibilities
Years: 1999 to 2009 Employer: RSAC Title: Principal Department: Consulting Responsibilities: He is the owner of RSAC.
Years: 1997 to 1999 Employer: ALCOA Massena, NY Title: Technical Coordinator Department: Smelting / Primary Metals Responsibilities: Oversee the reduction process including management of process engineering staff, Chemlab staff, and specific production staff. He was responsible for establishing and implementing process improvement plans for achieving and surpassing both financial and non-financial smelting objectives. He represented ALCOA Massena in divisional "Like Technology Teams" charged with improving and standardizing operating procedures and philosophies throughout the division.
Years: 1996 to 1997 Employer: ALCOA Massena NY Title: Technical Supervisor Department: Smelting / Primary Metals Responsibilities: He was responsible for new cell start up procedures and operations. Represented Massena for ALCOA's "New Cell Start Team"
Years: 1992 to 1996 Employer: ALCOA Massena NY Title: Process Engineering Department: Smelting / Primary Metals Responsibilities: He was part of a technical staff which worked on all aspects of aluminum reduction.
Years: 1984 to 1992 Employer: ALCOA Massena NY Title: Potline Supervisor Department: Smelting / Primary Metals Responsibilities: He was one of the four supervisors responsible for the production employees routine work performed in the potlines.
Years: 1981 to 1984 Employer: General Motors Title: Student Engineer Department: Central Foundry Responsibilities: He was coop engineering student at General Motors Institute through the Central Foundry Division.

International Experience

Years Country / Region Summary
Years: 2005 to 2006 Country / Region: Sweden Summary: Worked with technical staff to identify and correct process ineffeciencies. Also provided process audits for Smelting and Plant management.
Years: 1999 to 1999 Country / Region: Australia Summary: Worked with the Alcoa smelter in Portland regarding new cell starts and general pot operation improvements.

Additional Experience

Training / Seminars
He has developed and delivered aluminum reduction technical training for both bargaining and non-bargaining empoyees at Columbia Falls Aluminum and Century Aluminum, Ravenswood. He has also developed and delivered basic statistical training for production and management employees at Columbia Falls Aluminum
Other Relevant Experience
He has a background in both technical and operating strategies with regards to aluminum reduction. He has the ability to "bridge the gaps" which often occur between engineering and production employees. By having hands-on experience in both fields, he can improve communication and align strategies between the two sets of backgrounds. Unlike some consultants, he can actually say YES when asked, "Have you ever actually done this", when suggesting changes for improvement.

Fields of Expertise

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