Reaction Kinetics and Catalytic Process Development Chemical Consultant

Technical Consultant #1740

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.

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.

Credentials

Publications and Patents