Phosphorus Chemical Operations: Manufacturing Management Consultant

Technical Consultant #1219

Manufacturing of organic, inorganic and phosphorus chemicals, (organophosphorus, phosphonate, phosphite, phosphononic, and phosphinic).
Capital project process development, new process development and scale-up.
Technical writing, SOP, operating instructions, manuals and feasibility studies.
Production rate improvement and process optimization.
Process integration and strategic planning.
Energy efficiency improvement.
Accident investigation prevention.

Independent Consultant, 2005 - Present

Undisclosed Company, Consultant, 2006 - 2011

National and International Projects in China, India, United Kingdom and U.S.A.

Improved efficiency of rare earth metal recovery research and development process.
Modified technology for manufacture of high-value phosphorus-based surfactant to simplify workup and improve efficiency.
Reformulated phosphorus-based flame-retardant for cellulosic textiles.
Commissioning of organophosphine chemicals plant.
Optimized wet phosphoric acid plants reactor operation at two locations generating annualized savings of raw materials and energy worth more than $4million.
Commercialization of phosphorus-based flame retardants.
Improved product quality and increased capacity of semi-continuous chemical process by 30%.
Relocation of toll manufacturing for range of organophosphorus chemicals.
Process design for energy reduction in elemental phosphorus manufacturing.
Process design of calcium phosphates factory.
Process design of sodium phosphates factory.
Study to improve raw material utilization and increase capacity of batch process. Project payback less than 1 month.
Study to improve product quality and increase capacity of batch chemical process by 40%
Solved a longstanding problem of off-spec production, developing a novel analytical test to locate the source of trace contamination undetectable by spectroscopic means.

Rhodia Inc, Charleston, SC, 1984 - 2005

Manufacturing Development Manager, 1999 - 2005

Technical Manager for Toll Manufacturing and new product development.
Achieved multimillion dollar savings leading technical team to change supply chain of main raw material (elemental phosphorus) to use overseas (China) source.
Developed new industrial processes utilizing novel chemistry to make high value specialty chemicals to produce industrial and pharmaceutical intermediates by leading cross-functional research and development and engineering teams.
Achieved $400k savings and reduced cycle times 15% to 75% by reformulating long-established batch processes.

Technical Manager, 1996 - 1999

Managed up to 8 process engineers and 5 control engineers at site making organophosphorus chemicals.
Reduced raw material supply costs by over $500k annually by undertaking a comprehensive review of theoretical efficiencies and directing projects to reduce consumption and losses.
Expanded capacities of several units, both batch and continuous, (typically spending 5% of replacement cost to achieve 30% to 50% capacity increase).
Improved process safety systems by directing engineering and process control projects resulting in several site awards.

Credentials

Academic and Professional Affiliations