Chemical Plant Design and Process Economics Consultant
Technical Consultant #1133
- Senior Consultant with ten years of research and design experience in the Process Economics Program of SRI Consulting.
- Experience includes 8 PEP Reports and becoming a winner of the 1996 Monsanto "Million Dollar Research Challenge" (Competition was International).
- Preceded experience of over 33 years of diversified research, development, and design work with Dow Chemical, a Fortune 20 company.
- During this time expertise was demonstrated in creative problem solving in basic and applied research, new product and process development, improving existing production plants, and managing design, construction and start-up of new production plants.
- Focus has been in the polymer area, organic chemicals, and pharmaceuticals, including 27 technical publications and 47 U.S. patents.
- Awarded Monsanto's second $1 million challenge for our innovative research proposal in waste recovery technology.
- Monsanto challenged the worldwide scientific community to find a practical, cost-effective technology that would recover high-purity amino acids and phosphoric and phosphorous acids from a particular waste stream, leaving clean sodium chloride.
Independent Consultant, 2001 - Present
- Major participant in a project to develop new uses for an existing foreign world scale chemical plant.
SRI Consulting, Senior Consultant, Process Economics Program, 1994 - 2001
Process Economic Reports
- Researched all available literature involving each technology.
- Collecting information from industrial sources.
- Evaluating this existing technology.
- Researching and developing solutions to design problems; completing a process design and capital estimate based on best technology.
- Combining an analysis of the entire field of technology with an economic analysis into the final PEP Report.
- Polyethernitrile Heat Resistant Polymer from 2,6-dichlorobenzonitrile and Resorcinol.
- 1-4 Butanediol from maleic Anhydride via Dimethyl Maleate
- Dendrimer Polymer from Diaminobutane and Acrylonitrile
- Supercritical Loop Reactor Slurry Process for Producing Polyethylene and Polypropylene
- Polybutylene Terephthalate and Butanediol
- Phthalic Anhydride
- 1,3-Propanediol and Polytrimethylene Terephthalate
- Polyethylene Terephthalate
- Non-metallocene Single Site Catalysts
Dow Chemical Company, Midland, MI, 1956 - 1993
- Process Engineering Associate, Michigan Engineering, 1990 - 1993
- Research Associate, Designed Thermoplastic Research, 1971 - 1990
- Senior Research Specialist, Manufacturing Rep. Process Development, 1973 - 1979
- Research Specialist, Styrene Molding Products Lab, 1970 - 1973
- Senior Research Engineer, Nuclear and Basic Research Lab, 1961 - 1970
- Research Engineer, Plastics Production Lab, 1956 - 1958
- Directed the team which found an environmentally acceptable process for salicylic acid (aspirin precursor), which had not been uncovered in 50 years of research and development. A world-scale plant was constructed using technology protected by two of my U.S. patents.
- Discovered a simple method for removal of vinyl chloride from saran emulsions which allowed conformance with new environmental regulations which threatened to close the $50 million per year business.
- Insight gained was applied to other related products. Two U.S. patents.
- Devised a practical process for producing heat resistant copolymers from alpha-methyl styrene/ acrylonitrille, where over 30 previous studies had not found this heat resistance.
- Related gelation theory to condensation polymerization in a new, practical way.
- This led to a new understanding of paints, a national ACS award, and doctorate degree.
Facility Design and Development
- Managed design and construction of a "fast-track" 3 million pound/year plant for producing t-butyl styrene. This "most complex process in the Michigan Division" was completed on time and on budget, and saved $4 million by using most of an existing facility.
- Designed, constructed, and operated the company's first unattended pilot plant for producing high impact polystyrene copolymers. Several clones are still in operation, saving over $90,000/year each.
- Provided complete process engineering design of all equipment in the polymerization and stripping section of an operating world scale ABS latex plant.
- Assembled process design for the first fully integrated polybenzoxazole fiber plant, and estimated capital. Suggested changes caused research which saves $15 million capital.
New Products Development
- Received Dow's Technology Center award for development of two commercial polystyrene products, one with extremely low monomer content, the other for a products with an improved balance of strength and processability.
- Developed a tough heat resistant copolymer of styrene/maleic anhydride and butadiene rubber. This product was fully commercialized at Dow, patented, and was also licensed to Arco.
- Completed development of a styrene/maleic anhydride resin to replace casein as a pigment binder for paper coating. If commercialized would have resulted in more than $5 million profit/year.
- Developed three polystyrene products based on anionic polymerization. First with unique balance of properties, second a utility grade from impure monomer (1/2 monomer cost), and third a conventional product with 25% less capital.
- Published 27 technical articles most with oral presentation. General Editor of the 250 page Styrene Polymers section of Wiley's Encyclopedia of Polymer Science and Engineering.
- Patented 47 new inventions in the U.S. (most also patented in several foreign countries). Successfully defended a key patent from infringement.
- Over 60 internal research reports at Dow that document carefully collected and interpreted data for others to build on.
- Chaired several internal Dow technology teams, including process engineering guidelines team and Styron specifications task force.
- Chaired Sessions at national meetings for both the American Institute of Chemical Engineers and the American Chemical Society.
Case Western Reserve University, OH, 1958 - 1962
- Graduate Fellow (Glycerin Producers Association)
Honors & Publications
- Professional Engineer, State of Michigan
- Veteran U.S. Marine Corps
Academic and Professional Affiliations
- American Chemical Society - ACS
Publications and Patents
- 27 Technical Publications
- 47 U.S. patents
- Ph.D. Chemical Engineering, Case Western Reserve University, Cleveland, OH
- B.S. Chemical Engineering, Michigan Technological University, Houghton, MI
- B.S. Chemistry, Michigan Technological University, Houghton, MI