Expert Details

Expert in Chemical Process Engineering

Expert ID: 107745 Georgia, USA

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Expert has over 40 years of experience as a process engineer and project manager on new facilities for food, flavors, fragrances, fine chemicals, resins, and tall oils. He has taken the lead in driving R&D and manufacturing groups toward efficiency in capital and operating costs; operability, reliability, and maintainability; schedule; process safety and permitting; available technical and other resources. He is also experienced with conceptual engineering, preliminary capital and operating cost estimates and economic evaluations, process optimization with process flow diagrams (including material balances and batch cycles), equipment lists, utilities and environmental efforts, preliminary layouts, and definitive capital estimates. During and following Management approval, this information would be further refined and supplemented, and assembled as a "process" or "front end package" and transmitted (and explained) to an engineering company for detail design. Acting in a consulting/liaison role during construction, Expert would later be active in chemical plant troubleshooting during and after startup.

In any project, Expert selects, optimizes, designs/calculates and specifies standard and special chemical process equipment. This is usually done in two phases--first, in the preliminary design, where equipment is selected, optimized and "sized" in a preliminary fashion, to go with the development of the preliminary flow sketch, equipment list and estimate; then, during the detail design phase, I do (or, in a large project, supervise) the final design, specification and procurement of the equipment. This generally involves vendor input. He has designed many successfully operating reactors and agitators, pumps, heat exchangers of all kind (heaters/coolers, condensers, vaporizers/reboilers), separation equipment (fractionators, extractors, scrubbers etc.), and electrolytic equipment, etc.

Expert has done or supervised all kinds of plant cost (or, capital cost) estimates, from the "back of the envelope" type, through the preliminary, factored estimates to detailed estimates of varying degrees of precision. Due to his experience with many estimates over the years, Expert has developed a feel for all these kinds of estimates once he is familiar with the project, the plant site and the organization(s) involved. He is also good at reviewing estimates generated by others.

Expert has worked on fine chemicals projects for most of his career. Typically, he has worked in batch, multiple-use (as contrasted with dedicated use), retrofit facilities. The design of such facilities requires special flexibility, judgment and experience to arrive at a reliable, safe design while avoiding an excessive number of calculations (peak maxima and minima etc.). There were also typical special needs, like jacketing equipment and piping with steam or hot oil, chilled (refrigerated) condensers, steam tracing, automated reactor cleaning systems, metered liquid and solid reactor feed (some designed to handle sticky solids), or evolution of reactor vapors while feeding solids, etc.

Process safety and process safety management have been one of Expert's ongoing interests. On nearly every project, he has dealt with such issues as upper and lower explosive limits, reactor rupture disk sizing, testing and application of thermal stability and dust explosion parameters, design of rupture disk collection systems, etc. In recent years, he has dealt with HAZOP reviews, process safety management, and OSHA requirements.

Expert has in-depth knowledge of the process and mechanical design and specification of heat exchangers. He has designed numerous heat exchangers that are now operating successfully. In other cases, he provided process data to heat exchanger vendors who did the final specs.


On-site Consulting Over the past two decades Expert was, in effect, an "internal consultant". One example involved a situation in a plant that could not recover most of the solvent from a solution that typically barely covered the bottom dish of a large tank. The plant had proposed a new, expensive distillation system. Expert proposed the installation of a steam-heated exchanger in a line between an (existing) pump at the bottom of the tank to circulate the tank contents from that pump through the exchanger.In a large environmental project, He designed a unique, large 3-pass exchanger in a fouling process, with a 5 F approach. The exchanger has been operating successfully for over 20 years.He selected, designed and installed a glass system for a corrosive process on the Gulf Coast. This consisted of a glass distillation column and condenser, teflon lined pumps and piping.Based on discussions with plant operators and engineers and literature surveys, he eliminated one of two major reactors in the H2O2 process.Based on site studies, he demonstrated that it cost less to manufacture a specialty chemical in Kentucky than in France.

Expert may consult nationally and internationally, and is also local to the following cities: Savannah, Georgia - Charleston, South Carolina - North Charleston, South Carolina

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Education

Year Degree Subject Institution
Year: 1971 Degree: MBA Subject: Corporate Finance Institution: New York University
Year: 1953 Degree: MS Subject: Chemical Engineering Institution: Columbia University
Year: 1952 Degree: BS Subject: Chemical Engineering Institution: Columbia University

Work History

Years Employer Title Department Responsibilities
Years: 1999 to Present Employer: Undisclosed Title: Independent Consultant Department: Responsibilities: Teltech consulting on technical design problems; preliminary & detail estimates; air pollution problem; economic study.
Years: 1977 to 1999 Employer: Union Camp Corporation Title: Project manager Department: Responsibilities: Manage study/estimates, design,construction & startup of tall oil distillation, resins, foods, nutraceuticals, environmental, process safety projects in the US and the UK.
Years: 1974 to 1977 Employer: Rhone Poulenc/Rhodia Title: Process-Project Engineer Department: Responsibilities: Manage: Study, estimate, design, build, control cost & schedule of specialty organics plants in Texas and NJ. Transfer process technology from France to the US.
Years: 1968 to 1974 Employer: FMC Corporation Title: Senior Process Engineer Department: Responsibilities: In the International Div., estimate and design hydrogen peroxide plant in Mexico City. In the Process Eng. Dept., study and improve H2O2 process, process design of CS2 and pool chemicals facilities, coke and gas from coal.
Years: 1963 to 1968 Employer: The Lummus Company Title: Process Engineer/Project Engineer Department: Responsibilities: As a process engineer, work with client on numerous estimates and detail process design. As a project engineer, work on acetylene chemicals project, and on a cooperative study in Italy on a caprolactam precursor.

International Experience

Years Country / Region Summary
Years: 1993 to 1995 Country / Region: United Kingdom (Cheshire) Summary: Process improvement, design and startup of fine chemicals facility.
Years: 1965 to 1966 Country / Region: Italy (Adriatic, nr. Venice) Summary: Spent 1 1/2 years on cooperative program to increase the yield and purity of a caprolactam precursor.
Years: 1974 to 1977 Country / Region: France (Southeast and Southwest). Summary: Made serveral visits to Southeastern (Rhone Alpes) and Southwestern (La Rochelle) France to transfer French technologies to the US.
Years: 1969 to 1969 Country / Region: Mexico Summary: Visited site near Mexico City to prepare preliminary and detailed cost estimates, layout etc for fine chemicals facility.

Career Accomplishments

Associations / Societies
Expert is a member of the American Institute of Chemical Engineers (AIChE) and the Tau Beta Pi honorary engineering society.
Licenses / Certifications
He is a Registered Professional Engineer in New Jersey.
Awards / Recognition
He has several patents and technical publications.

Additional Experience

Vendor Selection
Experience in sourcing and locating vendors of process equipment (incl. high alloy, plastic and lined)piping etc. Also familiar with major and Southeastern engineering and construction contractors.
Marketing Experience
Marketing for engineering companies (both sides of the table - seller and buyer).
Other Relevant Experience
As process engineer and project manager, Expert worked closely with regulatory specialists to provide them with data for their permit applications and to review their application. In early stages of process and project development, he worked to minimize liquid and air and solids wastes and to select and/or design facilities - often processes in themselves - to handle such emissions. He has done considerable development and design work on odor abatement systems. Expert have designed several vent collection systems with incinerators and dust collectors.

Language Skills

Language Proficiency
German Native language
French Speak with an accent.
Italian Read fluently. Speak and write with mistakes.
Czech Speak and write a little

Fields of Expertise

chemical plant design, chemical plant layout, chemical process analysis, chemical process design, chemical process development, process engineering, chemical engineering, chemical process equipment, process engineering equipment, chemical plant cost estimation, batch process, fine chemical, fine chemical production, oil hydrogenation, chemical plant explosion, chemical plant troubleshooting, chemical process safety, chemical process safety engineering, chemical process safety management, process safety, process-engineering safety, chemical process heat exchanger, stickies, oil pump, chemical explosion, batch process design, competitive chemical production analysis, static mixer, vacuum crystallizer, abietic acid, fractionating column design, geraniol, chemical plant operation, tall oil fatty acid, oleic acid, chemical reactor control, flash-drying, fractionating column, distillation equipment, chemical plant start-up, tall oil, chemical industry emergency shutdown procedure, continuous process, fine chemical intermediate, chemical process equipment selection, chemical process equipment optimization, chemical process equipment corrosion failure, air pollution control system, heat exchanger design, batch mixing, environmental regulation, flavoring material, chemical plant corrosion, chemical process economics, chemical reactor engineering, chemical plant accident, process-engineering sedimentation, process-engineering filtration, process-engineering extraction, process-engineering distillation, process-engineered separation, air pollution control, chemical reactor design, sterol, synthetic resin, heat exchanger, heat exchanger application, fatty acid, continuous process analysis, chemical reactor

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