Expertise

• Emulsion polymerization.
• Vinyl acetate polymerization technologies.
• Vinyl acetate copolymer polymerization technologies.
• Production of sorbitan esters and derived alkoxylates.
• Batch process design, scale-up and process implementation.
• Process modeling.
• Mixing, agitation and dispersion.
• Safety hazard analyses.
• Continuous improvement processes and process quality.
• Epoxy resins.
• Polyurethane resins.
• Hydrogenation.
• Expert witness.

Experience

Independent Consultant, 2008 - Present

Croda Chemical PLC., Wilmington, DE, Technical Manager, 2005 - 2008

• Technical Manager of manufacturing plant producing:
  • Sorbitan esters made with the reaction of sorbitol with acid and dehydration and made with varying levels of hydroxyl functionality;
  • Alkoxylates made with the reaction of etylene oxide and/or propylene oxide with different substrates, including the sorbitan esters;
  • Amides, made with the reaction of organic amines with alcohol or acid materials in singe or multi-step reactions; and,
  • Phosphate esters by the reaction of anhydrous phosphoric acid with different substrates.
• Familiar with manufactured products in applications such as cosmetic, pharmaceuticals, lubricants, agricultural chemical adjuvants and industrial surfactants.
• Directed technology professionals to develop and introduce new specialty chemical products and production facilities.
• Increased product and process quality and safety through review of processes with interdisciplinary teams of engineers and chemists; used Six Sigma methodologies.
• Improved safety and environmental performance through implementation of root cause analyses, hazard studies and emissions evaluation systems.
• Implemented multiple safety improvements, including dust explosion protection in oranic powder systems.
• Key participant in the development and implementation of capital programs totaling $10 million.
• Commissioned and started-up of a new multi-purpose unit for the manufacture of specialty chemical products with multiple unit operations and processes.
• Led teams to improve First Pass Quality (FPQ) and Operational Equipment Effectiveness (OEE) by using Root Cause analysis (RCA), Statistical Process Control (SPC) and Statistical Quality Control (SQC).
• Decreased manufacturing costs through reduction in wastewater generation and water and steam usage, leveraging monitoring systems to identify waste and system inefficiencies.
• Introduced products new to manufacturing site through pilot plant development and transfer to commercial manufacturing.

Air Products and Chemicals, 1974 - 2004

Positions:

Principal Research Associate - Chemicals Group, 1997 - 2004

Principal Research Associate - Corporate Science and Technology Center, 1993 - 1997

Manager - New Process Research, Polymer Chemicals Technology, 1983 - 1993

Manager - Process Development, Polymer Chemicals Technology ,1977 - 1983

Senior Research Engineer - Corporate Engineering and Chemical Technology, 1974 - 1977

Selected Highlights at Air Products

Technology Research and Development

• Developed and supported technology across the Chemicals Group, ($1.5 billion in sales) in specialty chemical products including performance polymers, epoxy products and hydrogenation processes.
• Drove programs with high potential application value in process and chemistry fundamentals, process monitoring and controls.
• Provided internal consultation to technical and business functions.

Process Technology Development and Optimization

• Conceived, developed and implemented processes with step changes in process conditions globally. Achieved greater than 20% improvement in throughput and 25% reduction in potential capital while maintaining performance.
• Developed patented continuous processes for vinyl-acetate ethylene polymers.
• Designed and implemented on a commercial scale, a high pressure (1500 psia) reactor system for batch production of emulsion polymers 30% larger than existing. This system has optimized heat transfer and mixing and a resulting high throughput.
• Worked with pressure vessel designers and suppliers to realize the design concepts.
• Provided consultation and guidance as a mixing system expert, especially in stirred vessels. Introduced the use of CFD tools (Fluent) for agitation evaluation.
• Developed process design and analysis tools for application in batch process system designs and process and product development based on the use of engineering science.

Polymerization and Dispersion Technology

• Led a group of up to 10 technologists, including senior chemists, responsible for new product vinyl acetate polymerization development and optimization, resulting in differentiated higher margin products with high solids content and high ethylene content. These products constitute 20% of the 500 million pounds per year sales of vinyl acetate ethylene copolymers at Air Products.
• Identified, developed and implemented technology for the production of chemical and physical hybrid systems with unique properties and high margins.
• Investigated mini-emulsion technology and polymerization in supercritical media.
• Investigated dispersion technology, especially for emulsions.
• Improved product and process development speed and efficiency through the development and utilization of fundamental and statistical models of emulsion polymerization systems. These models, including population balance models that were developed within the corporation and in collaboration with external researchers.

Business and Technology Processes

• As a manager and technical contributor, established and implemented work processes for work groups and teams. Led and participated in programs supporting the $300 million Global Performance Polymers business.
• Led a multi-functional high-level global team, to develop work processes and systems in production, product development and commercialization, for sustainable quality and reliability, resulting in step changes in the improvement of prime material and on-stream. Utilized six-sigma methodology.
• As the corporate expert in emulsion polymer technology, provided technology leadership globally in U.S., Asian and European regions.
• Worked with the business leadership to plan and set direction for product portfolios, market strategy and potential ventures in a $500 million business. As a key member of the Asian entry team, developed and evaluated product and process technologies to provide value to strategic options.

Honors & Publications

Education

• Ph.D. Chemical Engineering, University of Notre Dame
• M. S. Chemical Engineering, University of Notre Dame
• B. Tech. Chemical Engineering, Indian Institute of Technology, Bombay, India