Expert in Chemical Process Analysis, Chemical Process Design, Development, Troubleshooting, Improvement
Expert ID: 727947 New York, USA
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
|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|
|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.|
|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|
|Associations / Societies|
|Licenses / Certifications|
|Registered Professional Engineer NYS (2004).|
|Publications and Patents Summary|
|Expert has one patent regarding the preparation of polyolefins.|
|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)
|Initial screening of vendors for process equipment for inclusion on Recommended Vendors List.|
Fields of Expertise
precommissioning, project commissioning, Hazard and Operability study, causation analysis, chemical process, chemical process analysis, chemical process design, chemical process safety engineering, chemical process troubleshooting, continuous mixing, continuous polymerization, continuous process, continuous process analysis, data analysis, numerical analysis, process hazard analysis, analysis of experiments, analysis of covariance, process simulation, mathematical analysis, continuous fluidized bed thermal processing, chemical process equipment designing, chemical research and development, chemical process safety analysis, factor analysis, continuous drying, continuous distillation