Expert Details

Expert in Chemical Process Engineering

Expert ID: 722779 California, USA

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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.

Expert may consult nationally and internationally, and is also local to the following cities: San Jose, California - San Francisco, California - Sacramento, California - Oakland, California - Stockton, California - Fremont, California - Modesto, California - Salinas, California - Santa Rosa, California - Hayward, California

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Year Degree Subject Institution
Year: 1971 Degree: M.S. Subject: Chemical Engineering Institution: University of Technical Sciences, Budapest, Hungary

Work History

Years Employer Title Department Responsibilities
Years: 2014 to 2016 Employer: Self Employed Title: Principal Engineer Department: Responsibilities: Consultant on process design, manufacturing troubleshooting
Years: 2013 to 2014 Employer: Resin Designs LLC Title: Site manager Department: Responsibilities: Led the team of 15 through a difficult integration period to ensure that the changes have no significant effect on customer satisfaction. Maintained exemplary safety records and continuous improvement programs. Mentored the team through the ISO recertification project.
Years: 2007 to 2013 Employer: Dow Corning Corporation Title: Engineering Mgr, Site Mgr Department: Responsibilities: Led the team of 35 through 15 months of acquisition process to achieve seamless transition. In the preceding years initiated numerous Six Sigma projects to drive continuous improvement and cost reduction. Implemented Lean Six Sigma, resulting in $260K savings. Initiated marketing efforts to find new markets and new applications for the Newark made silicone sealants and heat sink materials. Actively participated in new product development (Patent on silicone gel manufacturing), mentored fast formulation to shorten development time and increase sales of new products.
Years: 2005 to 2007 Employer: MBA Polymers Inc. Title: Project Manager Department: Engineering Responsibilities: Was instrumental in the commissioning and start up process for plastics recycling plants in Guangzhou (China) and Kematen a. d. Ybbs (Austria). These joint ventures were using the patented technology developed by MBA Polymers (Richmond, CA). The assignment required excellent organizational, communication and technical skills to overcome cultural and communication barriers, and to solve equipment and process problems.
As an Engineering Manager Established a coherent engineering group consisting of engineers, technicians, designers and maintenance technicians, empowered and enabled them to handle improvement and capital projects from inception to implementation. Stepped up the capabilities of the group members by providing extensive training.
Years: 1997 to 2005 Employer: Clorox Services Company Title: Research Associate/Project Leader; Senior Scientist Department: Laundry Home Care Department Responsibilities: As a Research Associate/Project Leader from 2000 to 2005, Expert was responsible for developing and scaling up processes for solid and liquid laundry and home cleaning products. She also led the commercialization efforts of the same products. As a Senior Scientist from 1997 to 2000, she was responsible for the development of granulating technology for a detergent additive component in collaboration with a German business partner. She was also responsible for the process development aspect of its commercialization.
Years: 1996 to 1997 Employer: KAO Infosystems Title: Production Manager Department: CD Packaging Responsibilities: She was responsible for the efficient operation of the in-house CD packaging department.
Years: 1995 to 1996 Employer: Evergreen Oil Inc. Title: Process/Plant Engineer Department: Responsibilities: Was responsible for improving overall plant operation by identifying and executing several major (waste water treatment system, tank farm revamp) projects.
Years: 1989 to 1995 Employer: Castrol North America Title: Plant Manager Department: Specialty Lubricants Division Responsibilities: She was responsible for overall operation of production facility with compounding, packaging, grease manufacturing and chemical processes, for maintaining mil spec quality level of products and for overall compliance with environmental regulations.

Years: 1981 to 1989 Employer: Castrol North America Title: Process/Project Engineer Department: Specialty Lubricants Division Responsibilities: Expert managed every aspect of expansion projects, (vacuum distillation, viscosity index improver manufacturing process) ranging from $400,000 to $2,500,000 in magnitude.
Years: 1975 to 1979 Employer: Beilstein Institute Germany Title: Chemical Engineer Department: Responsibilities: She was responsible for excerpting and reviewing materials submitted for inclusion in Beilstein Handbuch, the most important reference book for chemists besides Chemical Abstract.
Years: 1971 to 1974 Employer: Csepel Paper Mill Hungary Title: Plant Engineer Department: Sulfite and Semicellulose Plant Responsibilities: Was responsible for coordinating the sulfite pulp and semicellulose plant operation.

International Experience

Years Country / Region Summary
Years: 1970 to 1974 Country / Region: Hungary Summary: Expert was a plant engineer for a semicellulose plant in a vertically integrated cardboard manufacturing plant.
Years: 1975 to 1978 Country / Region: Germany Summary: She excerpted articles from periodicals to be included in the Beilstein Handbuch. She created names for chemical compounds according to IUPAC and Beilstein conventions.
Years: 1988 to 1988 Country / Region: Germany Summary: Assessed a methyl methacrylate production process in order to design a similar domestic plant.
Years: 1996 to 2000 Country / Region: Germany Summary: She assisted in developing and commercializing an activator for laundry additives containing non-chlorine bleach.
Years: 2005 to 2006 Country / Region: China, Austria Summary: She was responsible for the commissioning and start up process for plastics recycling plants in Guangzhou (China) and Kematen a. d. Ybbs (Austria).

Career Accomplishments

Associations / Societies
Licenses / Certifications
She holds a P.E. license from the State of California.
Publications and Patents Summary
Expert has three patents in granulation in nonwoven products, and in silicone gel manufacturing, and two publications.

Additional Experience

Training / Seminars
Expert developed and delivered the following training topics annually: Pumps (application, troubleshooting, set-up); Tanks, Piping, and Valves (atmospheric tanks, pressure vessels, piping and tubing, fittings); Solids Handling (characterization, conveying, blending, storage, flow, drying, size enlargement and reduction, and dust control); Liquid Mixing (mixing of Newtonian and non-Newtonian liquids, agitators, applications, and scale-up); Process Control Basics (control loops, instrumentation, and tuning); How to Write Manufacturing Standards.
Vendor Selection
She has extensive experience in locating and selecting equipment vendors (specialty process equipment, hot oil heaters, fluid and solids moving equipment, storage equipment, and agitators).
Other Relevant Experience
She created spreadsheets for quick estimation of waste and associated cost of web utilization for nonwoven products. Included different shape arrangements, shape sizes, edge wastes and cutting wastes. This analytical tool became very useful for technical and business decisions.

Language Skills

Language Proficiency
Hungarian Hungarian is Expert' mother tongue.
German She is fluent in German, able to speak, read, and write it.
Russian Can read and translate from written Russian.

Fields of Expertise

chemical compounding, liquid handling, liquid mixing, liquid pumping, pump, solid material handling, solid mixing, chemical engineering, chemical plant operation, bleach, bleaching agent, chlorine bleach, Clorox, chemical plant layout, chemical plant design, chemical process design, chemical processing plant design, chemical process development, chemical-process flow chart, pilot plant construction, pilot plant scale-up, pilot plant process development, scale-up, process assessment, chemical pilot plant development, bleach activator, chemical process equipment, chemical process equipment designing, chemical process equipment selection, construction cost, construction project management, construction schedule, micro-calorimetry, standard operating procedure, manufacturing procedure, manufacturing plant layout, tank farm, oil pump, household chemical product, agglomeration, solid property, liquid container, particle-size reduction, liquid cooling, plant operations management, slurry mixing, powder blending, chemical plant start-up, composite recycled plastic, chemical process control instrumentation, chemical plant management, chemical processing plant, particle-size analysis, waste control, process development, chemical process analysis, chemical plant cost estimation, chemical process safety, chemical processing, operations, liquid density measurement, construction, chemical process, unit operations, liquid storage, sparging, powder mixing, petroleum engineering, gas handling, chemical process heat exchanger, chemical process control, liquid cavitation, calorimetry, agitation

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