Catalyst Development and Process Data Analysis Expert

Technical Consultant #1672


  • Catalyst development, (metal oxides, mixed oxides, reduced metals, zeolites, etc.), catalyst characterization and testing.
  • Troubleshooting plant production issues in catalytic processes such as inadequate activation and premature catalyst deactivation.
  • Every aspect of chemical production such as chemical process development, process implementation, process scale-up, plant data monitoring.
  • Chemical engineering and data and analysis to identify opportunities for increasing productivity and product quality, and plant production support during trials and scale-ups.
  • Unique distillation laboratory design experience.


Independent Consultant, 2009 - Present

Air Products and Chemicals, Inc., Allentown, PA, Principal Development Engineer, 2005 - 2009

  • Identified scope and methods to reduce production costs and also improve reliability for global ethyl amine plants.
  • Identified ways to eliminate or reduce catalyst deactivation and reverse some of the deactivation, thereby decreasing catalyst cost in amino propyl diethanol amine (APDEA) production.
  • Identified scope for increasing process yields and hence reduce costs for producing tertiary amine catalysts (TEDA).
  • Demonstrated TEDA viability through laboratory experiments and cost analysis.
  • Identified 2 catalyst deactivation mechanisms in APDEA process and eliminated one and reversed the other in order to get multiple catalyst use, resulting in potential annual cost savings near $1 million.
  • Initiated and led the effort to create a database to document production history at a production site acquired by Air Products.
  • Successfully implemented solutions which maximized output by analyzing process data and identifying similar reactors behaving very differently.
  • Recommended proven process changes to purify raw material to improve catalyst life as well as process reliability.
  • Identified relationship between impurities in lower cost ethanol and catalyst life for ethyl amines plants.
  • Analyzed historical plant data and laboratory studies encompassing 20-25 years of TEDA production and research to understand what process changes are most likely to improve product yield.
  • Evaluated and validated the recommendations in the laboratory.

Sunoco, Inc., Marcus Hook, PA, 1995 - 2002

Process Development Engineer, 1998 - 2002

  • Identified scopes for improving existing phenol process technology licensed jointly by Sunoco and UOP with primary focus on distillation.
  • Evaluated commercial benefit of proposed improvements using a combination of bench scale experiments, pilot scale engineering studies, process modeling and in-plant testing and identified avenues to increase reliability and reduce cost of all chemicals' operations.
  • Identified relationship between lower feed temperature and levels of acetol in product phenol resulting in a purer phenol product.
  • Designed and directed multi-craft group in building of "state of the art" pilot distillation laboratory utilized to facilitate research and development projects supporting newly acquired 100 million pound/year phenol plant.
  • Developed a monitoring routine in ASPEN data acquisition system for all heat exchangers in the cumene plant.
  • Enabled operators to detect heat exchanger fouling at an early stage and hence avoid sudden disruption in operation.
  • Enabled Marcus Hook refinery to reduce the cost of Udex unit's extractor acid wash by approximately $100,000 annually by conducting laboratory analysis of the extractor deposit.
  • Completed study to determine vapor pressure of mineral spirits enabling compliance with a pending EPA regulation.
  • Developed effective working relationships with plant operations staff which allowed access to otherwise inaccessible data on phenol plant operations.

Research Engineer, 1995 - 1998

  • Developed heterogeneous catalyst analogs of Sunoco's patented homogeneous catalyst system.
  • Provided physical and chemical characterizations of catalysts to identify key properties governing catalyst activity and selectivity.
  • Screened catalysts using gas phase plug flow reactors with on-line analysis.
  • Performed reactor data analysis by incorporating lotus macros for detailed calculation of conversion, selectivity, yield, turnover number and generated data summary table.
  • Performed preliminary engineering economic calculations for determining process viability and profitability.
  • Invented a novel technique to synthesize stable supported polyoxometallate catalysts and received a patent.
  • Identified pore structure to be a major determinant in catalyst activity and selectivity and invented methods to optimize that.
  • Successfully troubleshot a major reactor and catalyst.

Honors & Publications


  • Six-Sigma certification

Academic and Professional Affiliations

  • North American Catalysis Society
  • Philadelphia Catalysis Club

Publications and Patents

  • 5 publications
  • 8 presentations
  • 7 patents


  • Ph.D. Chemical Engineering, The University of Akron, OH
  • M.S. Chemical Engineering, Indian Institute of Technology (IIT), Kanpur, India
  • B.S. Chemical Engineering, Jadavpur University, Calcutta, India
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