ALKYLATION
AMINE UNITS
ATMOSPHERIC DISTILLATION
COKE CALCINING
DEASPHALTING
DELAYED COKING
DEWAXING
FLUID CATALYTIC CRACKING
FLUID COKING
GASIFICATION PETROLEUM COKE / COAL
HYDROCRACKING/HYDROTREATING
LIGHT ENDS SYSTEMS
LUBES MANUFACTURING
REFORMING
SULFUR PLANT
SOUR WATER STRIPPER
VAC. DISTILLATION
VISBREAKING
ACIDS
Sulfuric Acid: planning, process design, debottlenecking and troubleshooting
ALCOHOLS
Process design manager for large multi-unit oxo-alcohols plant in Contractor’s offices
AROMATICS
Design of catalytic reformer specifically to produce aromatics
Design, troubleshooting and debottlenecking of complete aromatics complex
OLEFINS
Design of pyrolysis furnaces
Design, troubleshooting, debottlenecking and startup of all sections in olefins plant
Studies on reboiler improvements for olefins towers
Safety studies of olefins plants
Process design group leader on major ethylene facility
Process designs of several revamp/expansion projects for existing ethylene facilities
Start-up leader on propylene super-fractionator utilizing heat pump compression
Process design of butylene super-fractionator utilizing heat pump compression
Operations Supervisor of propylene and butylene fractionation units
Process design of butane isomerization unit using IFP technology
PHENOLS
Nonyl-phenol (high & low chlorine) manufacturing: planning, process engineering & design, troubleshooting, startup, unit optimization
POLYMERS
Poly-isobutylene manufacture. Process design, start-up, troubleshooting, debottlenecking Butyl and Halo-butyl Polymers: Process design, troubleshooting, debottlenecking, start-up, new product development
Air emissions quantification and permitting
Debottlenecking studies and revamp designs for large Unipol polyethylene plant, areas included were polymerization and finishing
POLYMER DEVOLATILIZATION
Direct devolatilization of LLDPE, LDPE, high ethylene EP and EPDM. Conventional devolatilization extrusion equipment and LIST kneader technology
Air emissions quantification and permitting; emissions control technology evaluations
SPECIALTY CHEMICALS
Oxo alcohol manufacture. Planning, process design & engineering, troubleshooting, kinetic modeling; debottlenecking; environmental control
Plasticizer manufacture. Planning, process design & engineering; assessment of product grade slate change impact on plant throughput and environmental control facilities
Lube oil additives manufacture. (ZDDP, Ca-sulfonate, Mg-sulfonate, Polyisobutylene, Nonyl-phenol (Cl and low-Cl), Salicylic Acid, etc.) Planning, process design & engineering, troubleshooting, batch reactor optimization, batch cycle time improvement, MEI improvement; air pollution and odor control. Raw material utilization optimization and waste minimization studies
Air emissions quantification and permitting; emissions control technology evaluations
Toluene diisocyanate: process design / start-up / and operations (Supv)
Vitamin C: planning and process design
Animal anti-virus medicine: planning studies and process design
Tall Oil Distillation Units: planning, process design and start-up
Fat Splitters: planning, process design and start-up Vegetable Oil: planning, process design and start-up
Soap manufacturing: revamp studies and process design including environmental efficiency improvement projects
Process design leader for new developmental motor oil additives unit
SYNTHESIS GASES
Process design manager for a partial oxidation unit to produce syngas in Contractor’s offices. Process utilized Texaco technology
COMBUSTION
ENERGY CONSERVATION
ENVIRONMENTAL CONTROL
FLUID MECHANICS
FLUID SOLIDS
FRACTIONATION
HEAT TRANSFER
REACTION SYSTEMS
RHEOLOGY
SEPARATIONS
WASTE WATER TREATMENT
WATER TREATMENT
NOX CONTROL
SOX CONTROL
PARTICULATE EMISSIONS CONTROL
WASTE WATER
EMISSIONS QUANTIFICATION
PERMITTING
CONTROL TECHNOLOGY EVALUATIONS
COMPLIANCE TESTING
REGULATORY NEGOTIATIONS
RISK ASSESSMENT
ACCIDENTAL RELEASE
ADVANCED PROCESS CONTROL (DMCPLUS)
BASIC AND SUPERVISORY CONTROL
SAFETY INSTRUMENTED SYSTEMS
TURNAROUND PLANNING – PROCESS
Identification of Limits: Hydraulic, Heat Transfer, Distillation
Unit and Equipment Capability Assessments
Design for: Replacement, Expansion, Performance Improvement, Operations Improvement
TURNAROUND PLANNING – MECHANICAL CONDITION ASSESSMENT
Mechanical Integrity Assessments
Rationalization of historical work list, RBI recommendations and Operations Needs
Identification and prioritization of critical needs
Development of Condition Assessment Plan
Effective utilization of turnaround inspection resources
Maximum use of noninvasive global screening methodologies to reduce turnaround time and costs (Maximize Preturnaround Work, Minimize Discovery during Turnaround)
Application of Proprietary Unit Specific Acceptance Criteria to Streamline Turnaround Decision Making Process
Proprietary Repair Technologies to Address Anticipated Deficiencies Allowing Clients to more Effectively Plan their Turnaround
TURNAROUND SUPPORT – MECHANICAL
Onsite Technical Expertise: Metallurgical, Mechanical, Fitness for Service, NDE Inspection
Rapid Response Metallurgical Evaluation
Development and Assessment of Repair and Reconditioning Methods (QA/QC)
All Refining, Petrochemical, Utility, and Environmental Processes and Equipment
TURNAROUND SUPPORT – PROCESS
Identification of Critical Repair/Reconditioning Needs
Development and Assessment of Repair and Reconditioning Designs
Focus turnaround efforts on what needs to get done All Refining, Petrochemical, Utility, and Environmental Processes and Equipment
BLENDING
Just-in-time multi component blending facilities: wax, lubricants and fuel oil. Process design, operations, troubleshooting
BOILERS
Rebuild of water walled industrial boilers including new combustion systems, controls, water treatment, etc. Process design, detailed design, equipment evaluation, project management, preparation of operating guidelines, development of remote monitoring control systems, performance testing, start-up
Fabricator evaluation & selection, expediting, compliance with project specifications (TQA)
Rebuild of 1920’s firebox style industrial boiler, including retubing and updating combustion systems including controls
CAUSTIC UTILIZATION
Refinery spent caustic reduction/reuse assessments. Identification of opportunities for cascaded reuse of partially spent caustic; reduced caustic consumption by modifying operating conditions
Evaluation of technologies for treating sulfidic spent caustics. Wet Air Oxidation; bio-treatment; 3rd Party Recycle Use of alternative alkali/neutralization agents
COMPRESSION SYSTEMS
Sour gas recovery
Refrigeration: ammonia, propylene, ethylene. Process Design, troubleshooting, debottlenecking, start-up.
Troubleshooting and solutions of axial flow fan erosion problems
CONDENSATE SYSTEMS
Steam: debottlenecking / revamp of steam condensate systems in refining and chemical manufacturing facilities to accommodate plant expansions / contractions / additions and changes in onsite facilities
Emissions quantification of steam condensate from process heating applications.
COOLING WATER SYSTEMS
Revamp of 200,000 gpm system including new cooling towers – New Jersey
FLARE SYSTEMS
DRE evaluations, emissions quantification
Contingency analysis and pressure balance studies on existing and to be modified plant flare systems
FUEL GAS SYSTEMS
Refinery fuel gas systems – collection, distribution, drying, treating, automated analysis, control systems. Process design, debottlenecking, troubleshooting
Low Btu gas systems – collection distribution, drying, automated analysis, control systems and industrial boiler and fired heater revamps. Process design, troubleshooting
STEAM SYSTEMS
Revamp of 600# industrial steam system including extraction turbines, process and building heating. Process design, detailed design, project engineering and management, and operations
Steam generator design: FCCU regenerator WHBs; fired heater steam generation coils, industrial water and fire tube boilers. Process design, troubleshooting, debottlenecking
PRODUCT & RAW MATERIAL STORAGE
LPG storage facilities – process design
Hydrocarbon storage facilities – onsite and offsite tankage, transfer facilities (including marine facilities), metering, fugitive emissions control, oil loss, tank gauging systems. Process design, project development, project management & engineering, operations, troubleshooting
Hazardous waste storage facilities: planning, process design, project engineering, start-up, regulatory reporting.
P2S5: bulk solids handling systems including metering and environmental control facilities: planning, process design, project engineering, start-up
PACKAGING & SHIPPING
Bulk polymer pelletizing, drying and packaging facilities, polyethylene, EP, EPDM, Butyl rubber
Lubricating oil bottling facilities: oil blending, raw material receiving (bottles, boxes, etc.), high speed filling lines, labeling, packaging, palletizing and warehousing. Process design, operations, troubleshooting, debottlenecking, project management & engineering
Polyethylene pelletization, storage, packaging and shipping facilities: planning, process design, EPC follow-up, startup, troubleshooting and debottlenecking
Polypropylene pelletization, storage, packaging and shipping facilities: planning, process design, EPC follow-up, start-up, troubleshooting and debottlenecking
High temperature liquid polymer packaging: planning, process design, EPC follow-up, start-up, troubleshooting and debottlenecking
HOT OIL SYSTEMS
Part of Low-sulfur MOGAS facilities – Benicia CA
Part of Lubricant Additive Plant – Marseilles, France
Part of Devolatilization facilities for polymer plants – various locations
Screening and design of hot oil system for the Oxo Alcohols unit at Baton Rouge Refinery
Operation supervisor for downstream fired heater vapor generation unit for plant reboiling and heating services
REFRIGERATION SYSTEMS
Ammonia, Propylene, Ethylene. Process design, troubleshooting, debottlenecking, start-up. Various locations
POWER GENERATION
Grassroots plants, added capacity, revamps. Cogeneration, combined cycle, simple cycle, CHP. Technical and Financial Screening Studies. Project Management, construction, performance evaluation, testing, start-up. Planning studies. O&M cost planning and optimization
DUE DILIGENCE
Refinery Evaluations for major units and other chemical manufacturing and utilities components
EQUIPMENT ASSESSMENT
From new construction, re-rating, reconfiguration, condition assessment and fire damage restoration of Hydrotreater Reactors, Towers, drums, rotating equipment, piping, pipelines and terminal facilities
TURNAROUND PLANNING AND EXECUTION
Experience with turnarounds on planned and unplanned basis for all types of refining, petrochemical and utility plants from 9 months to days. Coordinated mobilization, assessment, repair strategy development, implementation and return to service of various equipment such as vessels, heat exchangers, piping and other components
CORROSION/MATERIALS ENGINEERING
Provided latest in diagnosis and latest application of corrective actions in a wide spectrum of damage mechanisms and corrective actions
REGULATORY AND SPECIFICATION COMPLIANCE
Working knowledge of applicable API RP’s and standards in addition to various corporate specifications (TEP’s, REP’s, EGG’s and others)
RISK BASED INSPECTION
Subject matter expert for all refining, utility and most petrochemical systems and components in a variety of leading RBI Methodologies
FAILURE ANALYSIS
Local laboratory capability for rapid analytical turnaround and providing terse and insightful replacement/repair direction in a timely fashion
PROPOSAL REVIEW
Commercial and technical evaluations
Contractor recommendations
Proposal preparation
Source testing protocol document preparation
PROJECT SCHEDULING
Project planning, engineering design, procurement, equipment fabrication and delivery
Start-up scheduling
Project size: 0.5 – 50 M$
Tools: Primavera, Microsoft Project
PERMITTING
Environmental permitting to support both operations and project execution
FCCU operating permits and environmental control facilities permitting
FCU operating and construction permits
Negotiations with regulatory authorities for environmental permit approval
CONTRACT MANAGEMENT
Engineering, Procurement, Construction, Start-up phases
Cost Control and Contract Change Management
CONSTRUCTION SUPERVISION
Technical Advisor
Performance Testing, Start-up
FABRICATION
Supplier evaluations and selection
Contract Negotiations
Fabrication cycle management
Deliveries sequencing and logistics
Process Specific Quality Assurance/Control
OWNER’S ENGINEER
FEL design leader in Contractor’s offices
Post FEL project follow-up. Process and equipment specific
Detailed design follow-up
HAZOP reviews
“Cold Eyes” reviews
PROJECT REVIEWS/FACILITATION
GAP Analysis
Value Engineering (Cost Reduction)
PROJECT ENGINEER
FCCU scrubber from planning (FEL-1) through detailed design
Pulse Jet and Reverse Air Fabric Filters – planning (FEL-1) through start-up
ESP – planning (FEL-1) through start-up
COLD EYES REVIEWS
FCCU technology package (ExxonMobil); FCCU revamp designs, yield estimates, operations test plans
Hydrotreating, Hydrocracking, EPR, Alkylation, FCCU emissions control, Coke Calciner, Visbreaking, Reactive Extrusion Processes, Atm & Vac Distillation Debottlenecks, etc.
Project cold eyes reviews from screening to start-up
New technologies for heavy oil recovery
Technical readiness assessments for new technologies (SATCON, NOx control, Alkylation, FCC SCT, etc.) HAZOPS
Reactive extrusion systems, pilot plant and commercial (Castrol, Dow Corning, ExxonMobil) Wet Gas Scrubbing system (ExxonMobil)
Hydrotreaters, Hydrocrackers and FCC units
Flue Gas Desulfurization Systems (ExxonMobil, Syncrude)
Toluene diisocyanate (TDI) manufacturing
Ethylene, aromatics and polymer plants
HAZOP leader on many refining and chemicals projects
VALUE ENGINEERING
Wet Gas Scrubbing System (ExxonMobil)
Lubricant Additive Plant (Infineum France, SA)
Fired Heaters and Boilers
Selective Catalytic Reduction systems for NOx control
Proprietary Solution Polymerization Plants
Automatic Lube Oil Blending Facilities
Bulk Hazardous Materials Storage Facilities
Hydrocracker
Various chemical processes
Butyl plant expansion, new polymer processes evaluations
ENERGY CONSERVATION
Fired heaters: performance assessment, debottlenecking, revamping, T/A assistance, troubleshooting, operations and reliability improvement
Boilers: performance assessment, debottlenecking, revamping, T/A assistance, troubleshooting, operations and reliability improvement
Heat exchanger network evaluations and optimization
Unit heat integration optimization
Refinery wide steam system optimization
Inter-unit heat integration optimization
High efficiency heat exchanger systems
Vacuum system energy optimization
Heat exchanger fouling assessment, cleaning and fouling mitigation
Steam turbine/electric motor alternative selection
Waste water treatment unit energy minimization
Cooling water system optimization
Refrigeration system optimization and refrigerant change evaluations
DESIGN GUIDELINES
Developed standardized design methodologies for: fired heaters and boilers; FCCU Scrubbers facilities; FCCU scrubber water treating facilities; ESP facilities; and FCCU Cyclones
Authored Process Design Manuals for central engineering groups including: heat transfer equipment, vapor/liquid separation equipment and systems, fluid mechanics, environmental control facilities, plant utility systems, fluid solids facilities (FCCU & FCU), solids handling systems (coke and chemicals), devolitalizing and drying extrusion equipment, piping design, safety instrumented systems, etc.
PROPRIETARY TECHNOLOGY DEVELOPMENT
Reactive extrusion process for organo-silane polymers
FCCU scrubber and purge treatment technology
Hydro-visbreaking process
FCCU deNOx technology
Shale oil recovery processes
DOE sponsored Advanced Fired Heater Development
Scanfiner, dealkylation, pressure swing reforming and Flexcor T
Ethylene, aromatic and polymer plants
Ethylene Propylene Rubber (EP, EPDM) Commercialization (Sinopec) OPERATING GUIDES FCCU, Wet Gas Scrubbers
Hydrotreaters, Hydrocrackers, Atmospheric and Vacuum Distillation, light ends systems, Amine and Sour Water Units, Alkylation units, Dimersol units, CCR units, Steam Reformers, PSA units for hydrogen recovery
Electrostatic Precipitators
Third stage separators and FCCU flue gas expanders
Various chemical plants and units
Heat pump compression fractionation units
Heaters and boilers
TECHNOLOGY ASSESSMENT PROCEDURES
Technology evaluation / assessment protocols for integration with project FEL / staged gate cycles
Systems / procedures for technical and process development and commercial readiness assessments PRODUCT DEVELOPMENT
Application and or process specific product development for cost reduction, process improvement, or energy savings by integration of engineering technologies. Wet Gas Scrubbers, Fluid Solids Equipment, Pneumatic Conveying Equipment, Heat Transfer Equipment
Environmental issues/control assessment from concept to commercialization for specialty chemicals START-UP SUPPORT
Visbreaker
Delayed Coker
Polymer devolatilization & finishing facilities
Fuel oil blending facilities
FCCU ExxonMobil affiliates and licensees
Hot oil systems
Startup leader for grass roots FCC units
Hydrotreater, hydrocracker and light ends units
FCCU Wet Gas Scrubbers ExxonMobil affiliates and licensees
Electrostatic Precipitators ExxonMobil affiliates and licensees
Cyclone Systems ExxonMobil affiliates and licensees
Ethylene, aromatics and polymer plants
Toluene Diisocyanate plants
Olefin super-fractionation units
Tall Oil fatty acid distillation units
TRAINING
Operators/Operations
Processes
Equipment Specific Operations
Technologies o Refining Processes & Integration
Chemical Processes
Separations Technologies
Environmental Control Technologies
Combustion Systems
Advances Controls