Expert Details

Expert in Chemical Process Analysis, Chemical Process Design, Development, Troubleshooting, Improvement

Expert ID: 727947 New York, USA

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Expert has 30 years experience in the chemical process industries including polymerization process R&D, process troubleshooting, operations, technology transfer, and management of projects of up to $15 million. He has worked in the polyolefins, electronic materials, fuel ethanol, and in polymer finishing operations. He received his PhD in Chemical Engineering from Rensselaer Polytechnic Institute in 1986 in the field of numerical analysis of low Reynolds number flow.

Expert has extensive experience in the Innovene (gas phase polypropylene), Spheripol (loop and gas phase polypropyllene) and Unipol (gas phase polyethylene) processes, with approximately 15 years combined experience with these processes. He has developed polymerization reaction models to predict polypropylene MWD for the spheripol loop reactors and has done significant experimental work in the gas phase for PP-PE copolymers and metallocence gas phase PE, as well as bimetallic (ziegler-Natta/metallocene) catalyst development in the gas phase.

During his time in the electronics materials industry, Expert drove significant process improvements in the extrusion compounding of reactive thermosets, saving his emplyer an average of $250,000 in direct costs per year over a four year period in a down market. The improvements were focused on waste reduction, process efficiency, and quality improvements. He led a number of problem solving teams that identified root causes for chronic quality problems, developed and implemented solutions within a short time frame. In one instance a quality issue that cost the company $180,000 over 6 months was resolved in one week. His abilities as a team leader and project manager led him to the position of Lead Engineer for a transition of the electronic molding powders business to China, where he was responsible for validating manufacturing formulas with Chinese-sourced raw materials and similar, but different manufacturing equipment.

Upon the successful transition of the business, Expert worked in the fuel ethanol industry as a project manager, in charge of two concurrent projects for the Distillation, Dehydration, and Evaporation section of the plants; these projects were in the $10-15 million range. He also acted as lead process engineer on 2 projects of similar scope, and was involved in the training of plant operations personnel.

After the retrenchment of the fuel ethanol market, Expert acted as a Sr. Process Engineer working for an extruder OEM in support of sales and design engineering of packaged systems for polymer devolatilizing.

His recent experience as a Process Implementation Manager for INEOS Technologies included all phases of polypropylene projects including basic design, detailed design reviews, SHE reviews, operator training, field installation checks, precommissioning, commissioning, startup, and performance testing. He has successfully started up 3 Innovene PP plants.

He now is President of Aurora Analytics Engineering Consulting, PC.

Assisted in designing small scale equipment for MonoMethylHydrazine purification, including heat transfer equipment, FMEA, and equipment specification

Expert may consult nationally and internationally, and is also local to the following cities: Buffalo, New York - Rochester, New York - Niagara Falls, New York - Erie, Pennsylvania

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Education

Year Degree Subject Institution
Year: 1986 Degree: PhD Subject: Chemical Engineering Institution: Rensselaer Polytechnic Institute
Year: 1983 Degree: MS Subject: Chemical Engineering Institution: Rensselaer Polytechnic Institute
Year: 1982 Degree: BS Subject: Chemical Engineering Institution: Rensselaer Polytechnic Institute

Work History

Years Employer Title Department Responsibilities
Years: 2006 to Present Employer: Undisclosed Title: President Department: Responsibilities: He is responsible for all aspects of the business, from lead development to performing project work.
Years: 2008 to 2010 Employer: NFM Welding Engineers Title: Sr. Process Engineer Department: Process Engineering Responsibilities: Expert was responsible for sales support in the extrusion pilot plant, process engineering design and ancilliary equipment specification, comissioning and startup activities.
Years: 2007 to 2008 Employer: Thermal Kinetics Engineering Title: Sr. Project Manager/Sr. Process Engineer Department: Responsibilities: Expert was project manager for two projects in the Distillation, Dehydration, and Evaporation section. These projects were in the $10-15 million range. He also acted as a lead designer on two other projects of similar scope.
Years: 2005 to 2006 Employer: Henkel Technologies Title: Sr. Project Engineer Department: Electronic Materials Responsibilities: Expert was resonsible for the validation of product formulations using Chinese-sourced raw materials on similar (but different) extrusion equipment. The products were used to qualify the new operating plant for existing Henkel customers. He resided in China during the project.
Years: 2000 to 2005 Employer: Henkel Technologies Title: Engineering Scientist Department: Electronic Materials Responsibilities: Expert investigated and implemented process and yield improvements in support of molding powder and filled liquids production in manufacturing facility. He identified, proposed, and managed manufacturing improvement capital projects in range of $20,000 to $200,000. Served on international teams for product commercialization and technology development
Years: 1997 to 2000 Employer: Mobil Chemical Title: Sr. Research Engineer Department: Low Pressure Polyethylene Pilot Plant Responsibilities: Expert planned and executed pilot plant programs in support of new polyethylene catalyst development projects and production plant support. He also collaborated with outside consultants in development of process models and technology strategy.
Years: 1989 to 1997 Employer: Montell Polyolefins Title: Research Engineer/Scientist Department: Research and Development Responsibilities: Expert acted as internal consultant for Design of Experiments and Statistical analysis. He worked closely with operating plants to address polymer production quality issues and process troubleshooting. He also developed mathematical models describing polymerization reactor performance and developed novel experimental methods for Ziegler-Natta catalyst evaluation. He supported plant operations for commissioning of new equipment and commercialization of new catalyst systems.
Years: 1987 to 1989 Employer: Sterling Research Group Title: Sr. Research Engineer Department: Pharmaceutical Sciences Responsibilities: Mathematical modeling of drug absorption studies
Years: 2013 to Present Employer: Undisclosed Title: Process Implementation Manager Department: Polypropylene Project Delivery Responsibilities: Responsible for all phases of polypropylene projects including basic design, detailed design reviews, SHE reviews, operator training, field installation checks, precommissioning, commissioning, startup, and performance testing. He has successfully started up 3 Innovene PP plants.

International Experience

Years Country / Region Summary
Years: 2005 to 2006 Country / Region: China Summary: He was Lead Engineer responsible for transfer of process and engineering technology of a $50 million business to Henkel – Hua Wei Electronics Joint Venture. He coordinated production trials for more than 70 existing and new products. He was responsible for relocation of capital equipment valued at $5 million from US to China. Resident of China for 1 year; can speak survival Mandarin.
Years: 2008 to 2009 Country / Region: China Summary: Assisted in startup and troubleshooting of a extrusion devolatilization line to produce EPDM rubber.
Years: 2012 to Present Country / Region: China Summary: Multiple projects including technical meetings, technical service, precommissioning/commissioning and startup activities

Career Accomplishments

Associations / Societies
AIChE
Licenses / Certifications
Registered Professional Engineer NYS (2004).
Publications and Patents Summary
Expert has one patent regarding the preparation of polyolefins.

Additional Experience

Expert Witness Experience
Respondent's expert on a fluidized bed dryer for fuel ethanol dispute (2011)
Training / Seminars
Process Operator training for Innovene PP Process (2014, 2015, 2016)
Successful Process Startup (Doha, 2011)
Vendor Selection
Initial screening of vendors for process equipment for inclusion on Recommended Vendors List.

Fields of Expertise

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