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Reaction Kinetics and Catalytic Process Development Chemical Consultant

Technical Consultant #1740


Expertise

  • Kinetic modeling and reaction engineering analysis for process development and scale-up.
  • Chemical process and catalyst patent review and analysis.
  • Catalyst development and scale up.
  • Development of green process technologies.
  • Productivity and yield improvements in commercial technologies.
  • Oxidation and epoxidation process technologies.
  • Hydrogen peroxide production technologies.
  • Amines production technologies.
  • Production and reactions of organic hydroperoxides.
  • Applications of zeolite and supported metal catalysts.
  • Research and development project management from exploratory through pilot plant demonstration.

Experience

Independent Consultant, Present

Arco Chemical, Lyondell, LyondellBasell, Newtown Square, PA, 1981 - 2010

  • A $50 billion manufacturer of chemicals, fuels, and polymers. World's leading producer of propylene oxide and derivatives.

Manager New Propylene Oxide Technology

  • Initiated and recruited team with long term mission of inventing a direct oxidation process for propylene oxide with no co-products or toxic wastes, and less than 50% the capital cost of the existing commercial processes.
  • Led group to invent and demonstrate at lab scale a new process replacing 5 reaction steps of the existing process with a single reaction step.
  • Developed program with leading catalyst manufacturer to scale-up catalyst production for the single step process.
  • Upgraded LyondellBasell's catalyst research and development capabilities by adding automated reactor equipment, advanced analytical tools, and training technical staff.
  • Established new culture of collaborative inter-disciplinary innovation teams within research and development organization.
  • Formed productive research interactions with catalysis and reactor engineering experts at major research universities.
  • Led design, construction, startup and operation of a $7 million pilot plant to develop and demonstrate the integrated reaction and separations of the new PO process.
  • Over 60 U.S. patents filed based on inventions of project team.

Manager/Principal Researcher PO and Derivatives Research and Development

  • Managed group to support and improve company's proprietary propylene oxide and derivatives processes.
  • Achieved 30% reduction of yield losses and upgraded safety and environmental performance of the commercial PO processes.
  • Developed quantitative reaction models based on reaction kinetics and pilot plant studies, and implemented findings in commercial plants.
  • Invented a new proprietary technology to produce hydrogen peroxide using a propylene oxide process intermediate.

Air Products and Chemical, Allentown, PA, 1977 - 1981

  • Group Leader and Senior Research Chemist in Alkylamines Research and Development Department.
  • Developed kinetics and reaction models for company's proprietary alkylamines processes.
  • Led development of new process to produce alkylamines from olefins feedstocks'.
  • Co-invented first application of a zeolite catalyst for shape-selective control of mono-di-tri alklylamines product distributions.

Honors & Publications


Credentials

  • Adjunct Associate Professor of Chemical Engineering, Widener University.

Publications and Patents

  • 4 Publications
  • 28 U.S. Patents

Education

  • Ph.D. Physical Chemistry, Michigan State University, East Lansing, MI
  • B.S. Chemistry, Magna Cum Laude, Westminster College, New Wilmington, PA
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