Expert in Chemical Process Engineering
Expert ID: 722779
Expert developed expertise in liquid and solid handling while involved in hydraulic and lube oil compounding and processing, in the manufacture of powdered detergent additives, and in pulp processing. She specified, sized, and selected pumps for special applications (high viscosity, high flow, low available NPSH, abrasive and corrosive medium, shear sensitive liquid). She troubleshot existing pumping systems and recommended installation guidelines for trouble-free operation. She specified and selected a novel agitating system for special application in a reactor, where initial mixing requirements were governed by heat transfer in high viscosity environment, followed by low viscosity mixing for rapid reaction. Expert is experienced in the natural growth agglomeration of powders with binders (Schugi, O’Brien, ribbon blender, paddle mixer, pan agglomerator, and Pellegrini). She solved several solids flow problems (hang up, arching, ratholing, and segregation) and recommended remedies. She is familiar with the Johanson Indicizers for testing the flow properties and cohesiveness of solids. In addition, she developed and delivered training sessions on pumping, pipes, tanks, solids handling, and liquid mixing to process developers.
She developed expertise in batch chlorination and continuous chlorination (Powell chlorinator) in the hypochlorite (bleach) manufacturing process. She analyzed process parameters and recommended operational and equipment changes for significant raw material savings (yield improvement) for consistent product quality and for increased safety. She developed expertise in the dry neutralization process of anionic surfactants with soda ash in high shear environment. Expert is experienced in the manufacturing of viscosity index improver for multi grade motor oils, using neutral oil and synthetic rubber. With a simple grafting reaction, the viscosity index improver could be turned into a dispersant viscosity index improver by adding diallyl formamide. The process involved the application of high-pressure homogenizers, high shear mixers, high viscosity fluid handling, and heat transfer in a high viscosity medium. In addition, she is experienced in the manufacture of polyalphaolefins (base oil for synthetic motor oils). The three-step process included polymerization of decene with boron trifluoride catalyst and a cocatalyst, distillation (atmospheric and vacuum) to separate different molecular weight components, and final hydrogenation.
Expert has 25 years of experience in process development, process design, and chemical plant design in the petrochemical, paper, and consumer product industries. She developed a conceptual design for a continuous blending operation for a household cleaning product involving at least ten components, set addition order, and non-Newtonian mixing. She designed the pilot plant to verify technology, and scaled up to plant production (10x scale-up factor). She designed, built, and operated a scaled-down pilot plant for solids processing to verify different process technologies (100x scale-down factor). She designed, built, and operated a pilot plant for modified viscosity index improver processing. She developed processes for the manufacture of a viscosity index improver and a dispersant viscosity index improver. She provided P&ID, plant layout, and specified, selected, procured, and commissioned equipment; in addition, she started up the plant. Expert developed the conceptual design for a methyl methacrylate manufacturing process based on the technology of a major supplier. She specified equipment, provided the flow diagram and plant layout to accommodate the process in an existing facility. She estimated the capital and operational costs to bid on tolling it for a European customer. Expert provided the conceptual design for automating a batch polymerization and hydrogenation plant operating in conjunction with a continuous distillation process for polyalphaolefins. She designed and built a vacuum distillation unit for polyalphaolefins. She integrated the design into an existing atmospheric distillation process. Expert developed a patented granulation process to convert a liquid component into solid for a powdered laundry detergent additive. The process involved a chemical reaction (conversion of methylsulfate salt of methyl morpholinium acetonitrile into bisulfate salt) followed by liquid loading on a carrier with particle size control. She provided the conceptual design (process flow diagram, material balances, and equipment specification) for the chemical reaction to request proposals from prospective toll manufacturers.
Expert managed every aspect of projects from pilot plant-to-plant start up, ranging from $400M to $2.5MM in magnitude. Based on pilot plant experimental results, she developed the project scope, P&IDs, the project timeline, specified and selected equipment, secured permits, provided cost estimates, and submitted for approval. After approval, she procured equipment and services. She scheduled and supervised field construction, and trained operators, commissioned equipment, and turned the plant over to operation. Expert redesigned a piping system for raw material delivery in a polyalphaolefin plant for a polymerization reactor. She designed a spray head for better gas absorption; the design changes improved raw material utilization, resulting in $120M/year savings in boron trifluoride. Expert redesigned a piping system for an oil compounding operation; by doing so she eliminated cross-contamination, and dramatically reduced potential for human error. She sized centrifugal pumps, gear pump agitators, and heating coils for high and low viscosity Newtonian and non-Newtonian fluids. She specified a process control concept and individual instrumentation (flow meters, temperature sensors, analytical instruments, pressure and level measurement devices) for numerous processes. Expert also designed pipe inserts for merging streams to eliminate hydraulic imbalance in a continuous hypochlorite process.
Expert developed expertise in the application of a thermal activity monitor, which is a microcalorimetry instrument capable of detecting heat effects of chemical, physical, and biological changes on the micro- and nanowatt scale. The instrument was a very valuable tool for shortening lengthy stability and materials-of-compatibility testing.
Expert developed manufacturing standards (material balances and standard operating instructions, including testing) for hypochlorite and hypochlorite containing products. She authored numerous standard operating procedures (SOPs) for pilot plant and plant equipment operation, as well as for administrative processes. The SOPs were for a variety of things, for different equipment, processes, both chemical and administrative, and not limited to hypochlorite.
Expert acted as a consulting engineer for duplicating a manufacturing process for viscosity index improver/dispersant viscosity index improver in a Louisiana site, based on the process she developed originally for a California site.She decreased the segregation potential of a two-component solids system by testing flow characteristics of the solid mixture, and recommending equipment changes (hopper bottoms). Expert helped several business units by developing a test method for significantly shortening long term stability testing of packaging materials and unstable products.As an independent consultant, she assessed the capabilities and technology of a used oil reprocessor in Utah. She provided a recommendation to the costumer concerning the future potential of the technology. Expert consulted at several plants on improving overall yield of continuous bleach production. She analyzed production data and identified impactful process parameters, and recommended an implementation plan.